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31S10T0 engine peformance theory and operation 2006

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FCS-14569--REF

Updated January, 2006

Ford Customer Service Division
Technical Training



IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,
as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing
service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are
given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in
those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you
should follow when you work on a vehicle.










Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to
be under the vehicle.
Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you
have an automatic transmission, set it in PARK unless
instructed otherwise for a specific service operation. If you
have a manual transmission it should be in REVERSE
(engine OFF) or NEUTRAL (engine ON) unless instructed
otherwise for a specific service operation.
Operate the engine only in a well-ventilated area to avoid
the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts
when the engine is running, especially the fan and belts.







To prevent serious burns, avoid contact with hot metal
parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.
Do not smoke while working on the vehicle.
To avoid injury, always remove rings, watches, loose
hanging jewelry, and loose clothing before beginning to
work on a vehicle. Tie long hair securely behind your
head.

Keep hands and other objects clear of the radiator fan
blades. Electric cooling fans can start to operate at any
time by an increase in underhood temperatures, even
though the ignition is in the OFF position. Therefore,
care should be taken to ensure that the electric cooling
fan is completely disconnected when working under the
hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts
and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of the
Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall
govern.
The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was
approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications,
design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is
intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available,
may be used. The right is reserved to make changes at any time without notice.
WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOID
BREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.
Breathing asbestos dust is harmful to your health.
Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when
made airborne by cleaning with compressed air or by dry brushing.
Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.
Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per
OSHA instructions and the trash hauler notified as to the contents of the bag.
If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians
should wear government approved toxic dust purifying respirators.
OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians
concerned with performing brake or clutch service should be present in the area.


Copyright © 2002 Ford Motor Company

Produced and Coordinated by
Technical Support Operations
Ford Customer Service Division
March, 2002


CUSTOMER EXPECTATIONS
Customer Expectations: Service

1. Make it convenient to have my vehicle
serviced at your dealership.

2. The Service Advisor should
demonstrate a genuine concern for my
service needs.

3. Fix it right the first time.
4. Complete servicing my vehicle in a

5. Provide me with a clear and thorough
explanation of the service performed.

6. Call me within a reasonable amount of
time after my service visit to ensure that
I'm completely satisfied.

7. Be responsive to questions or concerns
I bring to your attention.


timely and professional manner.

Expectation 3
“Fix It Right The First Time, on Time.”
Both service advisors and technicians are important players when it comes to Expectation #3.
Why
Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they
would decide to return to a dealer to buy a vehicle and get their vehicles serviced.
Technician Training
It is our goal to help the technician acquire all of the skills and knowledge necessary to
“Fix It Right The First Time, on Time.” We refer to this as “competency.”
Technician’s Role
Acquire the skills and knowledge for competency in your specialty via:
STST
– Self Study
– FordStar Broadcasts
– Ford Multimedia Training (FMT)
– Instructor Led

New Model
– Self Study
– FordStar Broadcasts
– Instructor Led

The Benefits
The successful implementation of expectations means:
– Satisfied customers
– Repeat vehicle sales
– Repeat service sales

– Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”


TABLE OF CONTENTS
INTRODUCTION
Engine Performance Curriculum Goals .......................................................................................................... Intro 1
Planned Training Pathway .............................................................................................................................. Intro 1
Engine Performance Curriculum Overview .................................................................................................... Intro 1
How to Complete the Curriculum.................................................................................................................... Intro 2
Course Description .......................................................................................................................................... Intro 3
Course Length ................................................................................................................................................. Intro 3
Target Audience .............................................................................................................................................. Intro 3
Course Prerequisites ........................................................................................................................................ Intro 3
Course Structure .............................................................................................................................................. Intro 3
Course Objectives ........................................................................................................................................... Intro 4
Classroom Multimedia Training (CMT) ......................................................................................................... Intro 5
PC-Assisted Activities ..................................................................................................................................... Intro 5
Evaluation Strategy ......................................................................................................................................... Intro 5
Day One Flowchart ......................................................................................................................................... Intro 6
Day Two Flowchart ........................................................................................................................................ Intro 7
Day Three Flowchart ...................................................................................................................................... Intro 8
Day Four Flowchart ...................................................................................................................................... Intro 10

DIAGNOSTIC PROCESS REVIEW
Student Objectives ................................................................................................................................................ 1-1
SSCC Process ........................................................................................................................................................ 1-2
Diagnostic Process ................................................................................................................................................ 1-7
Diagnostic Tests .................................................................................................................................................. 1-17
Electronic PC/ED Worksheet .............................................................................................................................. 1-23
On-Vehicle Worksheet ........................................................................................................................................ 1-24


IGNITION SYSTEM DIAGNOSIS AND TESTING
Student Objective .................................................................................................................................................. 2-1
Ignition Concerns .................................................................................................................................................. 2-2
Misfire Diagnosis .................................................................................................................................................. 2-4
COP Misfire Diagnosis ......................................................................................................................................... 2-8
No Start Condition Diagnosis ............................................................................................................................. 2-13
Ignition Bench Worksheet .................................................................................................................................. 2-14
Ignition COP On-Vehicle Worksheet ................................................................................................................. 2-15
Ignition HDR On-Vehicle Worksheet ................................................................................................................. 2-16

FUEL SYSTEM DIAGNOSIS AND TESTING
Student Objective .................................................................................................................................................. 3-1
Fuel Delivery System ............................................................................................................................................ 3-2
Fuel Control .......................................................................................................................................................... 3-8
Fuel Economy Test ............................................................................................................................................. 3-22
Fuel System – Bench Worksheet ........................................................................................................................ 3-23
Fuel System – On-Vehicle Worksheet ................................................................................................................ 3-24

PCM WIRING AND CIRCUITS REVIEW
Student Objective .................................................................................................................................................. 4-1
PCM Inputs ........................................................................................................................................................... 4-2
PCM Outputs ...................................................................................................................................................... 4-11
PCM Power and Ground ..................................................................................................................................... 4-18

Diagnosis and Testing

September, 2003

TOC-1



TABLE OF CONTENTS
AIR INLET DIAGNOSIS AND TESTING
Student Objective .................................................................................................................................................. 5-1
IAC Valve ............................................................................................................................................................. 5-2
Controlled Air Inlet Systems ................................................................................................................................. 5-5

PASSIVE ANTI-THEFT SYSTEM (PATS)
Student Objective ..................................................................................................................................................
Basic PATS ...........................................................................................................................................................
Integrated PATS (IPATS) .....................................................................................................................................
Engine Performance Concerns Unrelated to PATS ..............................................................................................

6-1
6-2
6-3
6-4

EMISSIONS SYSTEM DIAGNOSIS AND TESTING
Student Objective .................................................................................................................................................. 7-1
Positive Crankcase Ventilation (PCV) ................................................................................................................. 7-2
Exhaust Gas Recirculation (EGR) ........................................................................................................................ 7-5
Thermostat Heater Control .................................................................................................................................. 7-10
Catalysts .............................................................................................................................................................. 7-13
Evaporative Emissions (EVAP) System ............................................................................................................. 7-16
EVAP Worksheet ................................................................................................................................................ 7-24
OBD Test Modes Worksheet .............................................................................................................................. 7-25
EGR / IAC Worksheet ........................................................................................................................................ 7-26


DAY THREE WORKSHEETS
Worksheet 1 (WDS EVAP Diagnosis – Hands-on) ........................................................................................
Worksheet 2 (MIL ON – PC Assisted) ............................................................................................................
Worksheet 3 (Runs Very Rough at Idle – Hands-on) .....................................................................................
Worksheet 4 (Crank/No Start CMT) ...............................................................................................................

WS3-3
WS3-4
WS3-6
WS3-8

DAY FOUR WORKSHEETS
Worksheet 1 (No Start – Hands-on) ............................................................................................................... WS4-2
Worksheet 2 (Engine Runs Rough – PC Assisted) .......................................................................................... WS4-6
Worksheet 3 (Hesitation on Acceleration – Hands-on) ................................................................................. WS4-8
Worksheet 4 (Engine Runs Rough – CMT) .................................................................................................. WS4-10

TOC-2

April, 2002

Diagnosis and Testing


INTRODUCTION
ENGINE PERFORMANCE CURRICULUM GOALS
The goal of the Engine Performance Curriculum is to provide you with the necessary training to enable you to
”Fix it right the first time – on time.” This Engine Performance Diagnosis and Testing classroom course provides
you with hands-on practice as it relates to diagnosis and testing.


Planned Training Pathway
Ford Motor Company has identified the skills and knowledge necessary to meet the Engine Performance
Curriculum goals. The Planned Training Pathway is a sequence of courses that are designed to provide students
with these skills and knowledge.

Engine Performance Curriculum Overview
The Engine Performance Curriculum consists of all of the following types of courses:
Web-based – These courses are self-paced. You are responsible for learning the material on your own time. The
courses are posted on the Internet and you are given the appropriate access codes.
Classroom – The classroom courses allow for application of the skills and knowledge learned in the prerequisite
courses through hands-on, real-world scenarios.

Diagnosis and Testing

January, 2006

Intro 1


INTRODUCTION
How to Complete the Curriculum
To successfully complete the Engine Performance Curriculum, you must take the following sequence of courses:

Ignition Theory and Operation –
Code
Ignition SystemCourse
Theory
and31S01W0
Operation Fuel and Air Theory and Operation –
Course Code 31S02W0

Exhaust/Emission Theory and Operation – Course
Code 31S03W0
Fuel, Air, Ignition and Emission Relationships –
Course Code 31S04W0
OBD II Monitors –
Course Code 31S05W0
Engine Performance Theory and Operation –
Course Code 31S07T0
Driveability Diagnostic Process –
Course Code 31S06W0
Driveability Diagnostic Routines –
Course Code 31S08W0
Engine Performance Diagnosis and Testing –
Course Code 31S10T0
Diagnosis and Testing of OBD II Vehicles –
Course Code 31S12W0
Advanced Engine Performance
Diagnosis and Testing – Course Code 31S15T0

Intro 2

January, 2006

Diagnosis and Testing


INTRODUCTION
Course Description
This course is designed to provide you with hands-on application of guided diagnosis and testing of driveability
concerns. The course emphasizes the SSCC process as well as critical thinking skills. Although you work

together in groups, each technician is responsible for completing their own worksheets. The course includes
instructor lecture, instructor-led group discussion, student activities, and student hands-on workstations.

Course Length
This is a four-day, hands-on classroom course.

Course Structure
The Engine Performance Diagnosis and Testing classroom course includes the following:


Instructor-led Discussion – You are asked to complete review questions that address content previously
covered in the WBT courses. Instructor-led group discussions focus on critical thinking skills and specific
concepts that are critical when following a diagnostic process to identify a faulty component or circuit.



Instructor Lecture – The instructor presents new information as it relates to guided diagnosis and testing.



Student Activities – The student activities are designed to reinforce concepts presented during the instructor
lecture.



Workstations – The instructor presents the concepts that are critical to successfully completing the
workstations. You participate in four on-vehicle hands-on exercises, two classroom media training (CMT)
activities delivered on CD-ROM, and two PC-assisted activities during the workstation portion of the course.




Worksheets – All activities and workstations have an accompanying worksheet designed to complement the
hands-on activities. Day One and Day Two student activity worksheets are identified by name. Day Three
and Day Four worksheets are identified by number.



Evaluation – At the end of the four-day course, the instructor asks you to complete a final written test, a final
hands-on workstation, and a course evaluation.

Diagnosis and Testing

January, 2006

Intro 3


INTRODUCTION
Course Objectives
Upon completion of the Engine Performance Diagnosis and Testing classroom course, you will be able to:


Use the SSCC diagnostic process to diagnose engine performance concerns.



Explain how to perform diagnostic tests.


Quick Tests

KOEO on-demand self-tests, KOER on-demand self tests, Continuous memory self-tests



PID Monitor



Explain PCM circuits and wiring.



Use critical thinking skills and available resources to diagnose and test specific engine performance systems,
including:


Ignition system
Identify the types of misfires.
Explain the relationship of ignition patterns to diagnosis.
Explain how to diagnose misfire concerns.
Explain how to diagnose no start concerns.



Fuel System
Fuel delivery
⇒ Identify the types of fuel delivery systems.
⇒ Describe conditions related to fuel delivery concerns.
⇒ Describe the testing related to fuel delivery concerns.
Fuel control

⇒ Describe how to diagnose a contaminated MAF sensor.
⇒ Identify open/closed loop conditions.
⇒ Explain conditions related to abnormal fuel trims.
⇒ Describe the testing related to fuel control concerns.

− Air Inlet System
Explain the conditions and tests related to diagnosing and testing the IAC valve.
Explain the conditions and tests related to diagnosing and testing Controlled Air Inlet Systems.


Exhaust/Emissions System
Explain the conditions and tests related to diagnosing specific emission systems, including PCV,
EGR, CAT, and EVAP.



Explain the basic operation of the Passive Anti-Theft System (PATS).



Using available resources, perform hands-on diagnosis and testing of specific engine performance systems
including, Ignition, Fuel, Air Inlet, and Emissions.

Intro 4

April, 2002

Diagnosis and Testing



INTRODUCTION
Classroom Multimedia Training (CMT)
The CMTs are workstation activities delivered via CD and include video and audio elements. These are
simulated hands-on practice in diagnosis and testing of driveability concerns. The PCED information is included
in each activity. The CMTs include:


Scenarios – These are DTC driven routines that address driveability concerns.



Interactive Exercises – These exercises allow you the opportunity to apply the information presented during
instruction.

PC-Assisted Activities
The PC-assisted activities are workstation activities delivered via CD. They do not include the use of video and
audio elements. These are simulated hands-on practice in diagnosis and testing of driveability concerns with
heavy emphasis in using the actual PCED (hard copy or electronic). The PC-assisted activities include:


Scenarios – These are DTC driven routines that address driveability concerns.



Interactive Exercises – These exercises allow the technicians the opportunity to apply the information
presented.

Evaluation Strategy
Your evaluation is based on the score of a final written test and a hands-on workstation. These are completed on
the afternoon of the last day. A non-passing grade in either of these two evaluation areas constitutes a failing

grade for the course. There are no make-up tests or "do-overs" available. Any technician that fails this course
must sign up to take the course for a second time.
Final Written Test
You complete the final written test at your seat. The written test consists of 30 multiple-choice questions. The
questions focus on diagnostic concerns and processes identified during the classroom session and require critical
thinking skills to solve problems. You must correctly answer 80% of these questions (24 of 30 questions) to pass.
Final Hands-on Workstation
You must diagnose the final hands-on workstation and correctly answer all of the accompanying worksheet
questions with 100% accuracy. The hands-on activity is done without instructor assistance and the worksheet
must be completed individually. You may use all of the reference material available to you in the classroom,
including workshop manuals and the student reference book.

Diagnosis and Testing

April, 2002

Intro 5


INTRODUCTION
Day One Flowchart

Instructor
Introduction

Review
Questions

Lunch


Diagnostic
Process
Activities

Review Diagnostic
Process Worksheets

Instructor Lecture
• Fuel System Diagnosis
and Testing

Instructor Lecture
• Ignition System
Diagnosis and Testing

Review Ignition System
Worksheets

Instructor Introduces
Homework
• PCM Wiring and
Circuits Review

Intro 6

April, 2002

Instructor-Led Discussion
• Diagnostic Process
Review


Break

Ignition
System
Activities

Break

End of Day One

Diagnosis and Testing


INTRODUCTION
Day Two Flowchart

Fuel
System
Activities

Review Fuel System
Worksheets

Instructor Lecture

Instructor Lecture

• Passive Anti-Theft
System (PATS)


• Air Inlet Diagnosis and
Testing

Review Homework
Assignment

Break

Instructor Lecture
Lunch

End of Day Two

Diagnosis and Testing

• Emissions System
Diagnosis and Testing

Review Emissions
System Worksheets

April, 2002

Break

Emissions
System
Activities


Intro 7


INTRODUCTION
Day Three Flowchart

Review of Day One
and Day Two

Day Three
Workstations
• Rotation 3
• Rotation 4

Break

Intro 8

Introduction of Day
Three Workstations

Lunch

Review of Day Three
Worksheets

April, 2002

Break


Day Three
Workstations
• Rotation 1
• Rotation 2

End of Day Three

Diagnosis and Testing


INTRODUCTION
DAY THREE WORKSTATION ROTATIONS

Team 1 –
Worksheet 1
EVAP Smoke Tester
(Hands-on)

Team 1 –
Worksheet 2
MIL ON (PCassisted)

Team 1 –
Worksheet 3
Runs Very
Rough at Idle
(Hands-on)

Team 1 –
Worksheet 4

Crank/No
Start (CMT)

Team 2 –
Worksheet 2
MIL On (PCassisted)

Team 2 –
Worksheet 3
Runs Very
Rough at Idle
(Hands-on)

Team 2 –
Worksheet 4
Crank/No
Start (CMT)

Team 2 –
Worksheet 1
EVAP Smoke Tester
(Hands-on)

Team 3 –
Worksheet 3
Runs Very
Rough at Idle
(Hands-on)

Team 3 –

Worksheet 4
Crank/No
Start (CMT)

Team 3 –
Worksheet 1
EVAP Smoke Tester
(Hands-on)

Team 3 Worksheet 2
MIL On (PCassisted)

Team 4 –
Worksheet 4
Crank/No
Start (CMT)

Team 4 –
Worksheet 1
EVAP Smoke Tester
(Hands-on)

Team 4 –
Worksheet 2
MIL On (PCassisted)

Team 4 –
Worksheet 3
Runs Very
Rough at Idle

(Hands-on)

Diagnosis and Testing

April, 2002

Intro 9


INTRODUCTION
Day Four Flowchart

Introduction of Day
Four Workstations

Day Four
Workstations

Day Four
Workstations
• Rotation 1

Lunch

Day Four
Workstations

Break

Final Exam


• Rotation 4

Review of Day Four
Worksheets

Break

• Rotation 2
• Rotation 3

End of Day Four

Intro 10

April, 2002

Diagnosis and Testing


INTRODUCTION
DAY FOUR WORKSTATION ROTATIONS

Team 1 –
Worksheet 1
No Start
(Hands-on)

Team 1 –
Worksheet 2

Engine Runs
Rough (PCassisted)

Team 1 –
Worksheet 3
Hesitation on
Acceleration
(Hands-on)

Team 1 –
Worksheet 4
Engine Runs
Rough (CMT)

Team 2 –
Worksheet 2
Engine Runs
Rough (PCassisted)

Team 2 –
Worksheet 3
Hesitation on
Acceleration
(Hands-on)

Team 2 –
Worksheet 4
Engine Runs
Rough (CMT)


Team 2 –
Worksheet 1
No Start
(Hands-on)

Team 3 –
Worksheet 3
Hesitation on
Acceleration
(Hands-on)

Team 3 –
Worksheet 4
Engine Runs
Rough (CMT)

Team 3 –
Worksheet 1
No Start
(Hands-on)

Team 3 Worksheet 2
Engine Runs
Rough (PCassisted)

Team 4 –
Worksheet 4
Engine Runs
Rough (CMT)


Team 4 –
Worksheet 1
No Start
(Hands-on)

Team 4 –
Worksheet 2
Engine Runs
Rough (PCassisted)

Team 4 –
Worksheet 3
Hesitation on
Acceleration
(Hands-on)

Diagnosis and Testing

April, 2002

Intro 11


INTRODUCTION

NOTES

Intro 12

April, 2002


Diagnosis and Testing


DAY ONE

DIAGNOSTIC PROCESS REVIEW

Student Objectives


Review the Diagnostic Process



Explain how to perform diagnostic tests


Quick Tests


KOEO on-demand self-tests



KOER on-demand self-tests



Continuous memory self-tests




PID Monitor



WDS Guided Diagnostics

Content




SSCC Process


Symptom Verification



System Identification



Component Identification



Cause Determination


Diagnostic Process


Verify the symptom(s)



Identify the conditions necessary to recreate the symptom

− Identify any related symptoms


Identify the system(s)



Perform all diagnostic tests necessary to isolate the failure



Interpret the test results



Isolate the root cause of the failure

− Make the repair




Verify the repair

Diagnostic Tests


Quick Test



Parameter Identification (PID) Monitor



WDS Guided Diagnostics

Diagnosis and Testing

September, 2003

1-1


DIAGNOSTIC PROCESS REVIEW

DAY ONE

SSCC Process

SSCC Process

Following the Symptom to System, Component to Cause (SSCC) process leads you to the failed component and
the root cause of that failure.

1-2

September, 2003

Diagnosis and Testing


DAY ONE

DIAGNOSTIC PROCESS REVIEW

SSCC Process
Symptom Verification

C

CHECK
ENGINE

CHECK
FUEL
CAP

F

EP2102-A/VF


Symptom Verification - MIL “ON”
Customers bring their vehicles into the dealership because they have experienced something out of the ordinary.
Your first step in the diagnostic process must be to verify the symptom or concern.

Diagnosis and Testing

September, 2003

1-3


DIAGNOSTIC PROCESS REVIEW

DAY ONE

SSCC Process
System Identification

System Elimination
Once the symptom has been verified, the next step is to determine the system that could be causing the customer's
concern. You begin by eliminating systems that could not cause the concern.

1-4

September, 2003

Diagnosis and Testing


DAY ONE


DIAGNOSTIC PROCESS REVIEW

SSCC Process
Component Identification

Testing Components
NOTE: Always use the proper flex probes when testing with the DVOM.
Once the system has been identified, you must determine the component that has failed. Perform the necessary
tests on the suspect system to identify the failed circuit or component.

Diagnosis and Testing

September, 2003

1-5


DIAGNOSTIC PROCESS REVIEW

DAY ONE

SSCC Process
Cause Determination

EP2105-A/VF
EPII001-A/VF

Repairing and Determining Root Cause
At this point, the symptom has been verified, the system has been identified, and the failed component/circuit has

been identified. Now, the root cause must be determined to ensure that the failure does not recur.

1-6

September, 2003

Diagnosis and Testing


DAY ONE

DIAGNOSTIC PROCESS REVIEW

Diagnostic Process
The individual tasks incorporated within the SSCC process include the following:

Diagnostic Steps

Diagnosis and Testing

September, 2003

1-7


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