31S26T0 engine perfomance operation and diagnosis 2009

Engine
Performance
Operation and
Diagnosis

31 ­ Engine Performance

FCS21046REF

Student Guide
FCS­21046­REF

Course Code: 31S26T0
August, 2009



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 in­
dividual 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 in­
structed otherwise for a special service operation. If you
have a manual transmission, it should be in REVERSE (en­
gine OFF) or NEUTRAL (engine ON) unless instructed oth­
erwise for a specific service operation.
• Operate the engine only in a well­ventilated area to avoid the
danger of carbon monoxide.

• 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 hang­
ing 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.

• Keep yourself and your clothing away from moving parts
when the engine is running, especially the fan and belts.
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 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 © 2009 Ford Motor Company

Produced and Coordinated by
Technical Service Support Operations
Ford Customer Service Division

August, 2009



ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

INTRODUCTION

INTRODUCTION

Engine Performance Operation and Diagnosis

Intro ­ 1

August, 2009


ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

INTRODUCTION

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS
Course Description
This is a 4–day course facilitated by an instructor. This course is designed to provide you a hands­on opportunity
to apply knowledge learned in previous curriculum courses and improve your skills using various tools and
equipment. Each day you will have multiple opportunities to practice selected skills. The results of your work are
recorded on worksheets.

Worksheets
All activities and workstation worksheets are designed to complement the hands­on activities and are identified
by number and by name. Students will complete the worksheets as they perform each Vehicle, Bench or CMT
Workstation.

Course Requirements
Each technician attending this course will be required to pass a combination of hands­on and written evaluations.

These will be administered on the afternoon of the fourth day.
•

The hands­on evaluation is pass/fail type. It will be conducted with exercises in PID review/evaluation and
concern diagnosis and will cover:
— PID monitoring
— Diagnosis with DTCs
— Using a pinpoint test to diagnose an engine performance concern

In order to pass the course, you must demonstrate mastery of the skills covered at an evaluated hands­on exercise
AND you must answer at least 80% of the written post­test questions correctly.

Course Objectives
Upon successful completion of this course, you will be able to:
•

Use a scan tool to select PIDs and monitor normal system operation.

•

Identify faults and monitor changes in system operation using a scan tool.

•

Use PC/ED, wiring diagrams, and workshop manuals to diagnose an engine performance concern.

•

Use the SSCC diagnostic process to diagnose an engine performance concern.

•

Follow a pinpoint test to perform various tests on engine performance related components.

•

Identify the root cause of an electronic engine performance concern.

Engine Performance Operation and Diagnosis

Intro ­ 2

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ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

INTRODUCTION

Course Agenda
LESSON ONE:
•

Prerequisite Review

•

Workstation One: Secondary Ignition Operation and Testing

•

Workstation Two: Evaporative Emission (EVAP) Operation and Testing

•

Workstation Three: Fuel Delivery System Operation and Testing

•

Workstation Four: Electronic PC/ED and VCT

LESSON TWO:
•

Workstation One: Exhaust Gas Recirculation (EGR) System Operation

•

Workstation Two: Variable Camshaft Timing (VCT) System Operation

•

Workstation Three: Fuel Control System Operation

•

Workstation Four: Idle Air Systems Operation

LESSON THREE:
•

Workstation One: Vehicle: MIL ON, Hesitation

•

Workstation Two: MIL ON, Engine Runs Rough

•

Workstation Three: Vehicle: MIL ON

•

Workstation Four: MIL ON, Hesitation

LESSON FOUR:
•

Workstation One: Vehicle: MIL ON

•

Workstation Two: MIL ON, Engine Runs Rough

•

Workstation Three: Vehicle: MIL ON, Rough Idle

•

Workstation Four: MIL ON

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ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

INTRODUCTION

NOTES

Engine Performance Operation and Diagnosis

Intro ­ 4

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LESSON ONE

PREREQUISITE REVIEW

LESSON ONE

Engine Performance Operation and Diagnosis

1­1

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LESSON ONE

PREREQUISITE REVIEW

NOTES

Engine Performance Operation and Diagnosis

1­2

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LESSON ONE

PREREQUISITE REVIEW

PREREQUISITE
REVIEW

Engine Performance Operation and Diagnosis

1­3

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LESSON ONE

PREREQUISITE REVIEW
PREREQUISITE REVIEW

DIRECTIONS: Answer the following questions. The answers will be reviewed in class.

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LESSON ONE

PREREQUISITE REVIEW

Primary Inputs
1. Describe the function and type of signal (analog, digital etc...) of the primary inputs in the table below.
Component
Name/Acronym

Component Function

Type of Signal

Ignition Switch

Supplies power to the PCM and provides a start and run
input.

Digital DC

Temperature
Sensors
(ECT/CHT/IAT)

Two-wire thermistors that provide engine coolant, cylinder
head, and intake air temperature information to the PCM.

Analog DC

Crankshaft
Position (CKP)

Variable reluctance sensor (VRS) that sends an AC signal to Analog AC
the PCM which indicates crankshaft speed and position.

Camshaft
Position (CMP)

Variable reluctance (AC) or Hall effect (DC) sensor that
sends a signal to the PCM. Also used to determine TDC of
cylinder #1 on the compression stroke.

AC or DC

Throttle Position
(TP)

Typically a potentiometer which sends an analog DC voltage
signal to the PCM which indicates the position of the
throttle plate.

Analog DC

Accelerator
Pedal Position
(APP)

Typically a potentiometer which sends an analog DC voltage
signal to the PCM which indicates the position of the
accelerator pedal (driver demand).

Analog DC

Mass Air Flow
(MAF)

A device which sends an analog DC voltage signal to the
PCM which indicates the amount of air entering the engine.
As airflow increases the output voltage increases.

Analog DC

Fuel Level
Indicator (FLI)

A signal that indicates the level of fuel in the fuel tank.
May be either hard wired or networked.

Analog DC

Vehicle Speed
(VSS)

A signal that indicates vehicle speed. May be either hard
wired or networked. May come from ABS module (wheel
speed sensors), VSS or OSS sensor.

Analog DC or
Digital DC

Brake Pedal
Position
(BPP)/(BOO)

A signal that indicates the position of the brake pedal.

Digital DC

Power Steer­
ing, A/C
Switches/Sen­
sors

Monitors the power steering and A/C systems to determine

if there is any additional load on the engine.

Analog DC or
Digital DC

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LESSON ONE

PREREQUISITE REVIEW

2. What IDS tests would be helpful in diagnosing these inputs?

____________________________________________________________________________________________________________________________________________
3. Describe the function of the PCM Power Relay.

____________________________________________________________________________________________________________________________________________
4. Describe the function of the PCM.

____________________________________________________________________________________________________________________________________________

Ignition System
1. Describe the function of the components in the ignition system in the table below.
Component Name/Acronym

Component Function

Coil Pack

Provides high voltage to the spark plugs. Each coil within
a pack fires two spark plugs in different cylinders at the
same time.

Coil on Plug (COP)

Provides high voltage to a single spark plug.

Knock Sensor

A tuned accelerometer which converts engine vibration to
an electrical signal. The PCM uses this signal to detect
engine knock and retard ignition timing.

2. What IDS tests would be helpful in diagnosing the ignition system?

____________________________________________________________________________________________________________________________________________

Engine Performance Operation and Diagnosis

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LESSON ONE

PREREQUISITE REVIEW

Fuel Delivery System
1. Describe the function of the components in the fuel delivery system in the table below.
Component Name/Acronym

Component Function

Fuel Pump Relay

Controlled by the PCM. Sends power to the fuel pump or
fuel pump driver module.

Inertia Switch

Used to disable the fuel pump in the event of a collision.

Fuel Filter

Filters the fuel. May be in the tank or connected to the
external fuel lines.

Fuel Pump Module

Contains the fuel pump which provides pressurized fuel to
the fuel rail, and the sender assembly which provides a
fuel level signal.

Fuel Pump Driver Module (FPDM)

Varies the fuel pump duty cycle to control its speed
in order to regulate fuel pressure on vehicles with an
electronic returnless fuel system (ERFS).

Fuel Rail Pressure Temperature
(FRPT) Sensor

Provides a fuel rail pressure and temperature signal to
the PCM on vehicles with an electronic returnless fuel
system (ERFS).

2. How is fuel pressure controlled in electronic returnless fuel systems?

____________________________________________________________________________________________________________________________________________
3. How is fuel pressure controlled in single speed mechanical returnless fuel systems?

____________________________________________________________________________________________________________________________________________
4. What IDS tests would be helpful in diagnosing the fuel delivery system?

____________________________________________________________________________________________________________________________________________

Engine Performance Operation and Diagnosis

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LESSON ONE

PREREQUISITE REVIEW

Fuel Control System
1. Describe the function of the components in the fuel control system in the table below.
Component Name/Acronym

Component Function

Fuel Injector

Electrical solenoid that meters and atomizes fuel that is
delivered to the combustion chamber.

Heated Oxygen Sensor (HO2S)

Sensor that measures the amount of oxygen in the
exhaust.

2. How does an oxygen sensor operate?

____________________________________________________________________________________________________________________________________________
3. Explain short term fuel trim and long term fuel trim.

____________________________________________________________________________________________________________________________________________
4. What IDS tests would be helpful in diagnosing the fuel control system?

____________________________________________________________________________________________________________________________________________

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LESSON ONE

PREREQUISITE REVIEW

Evaporative Emission (EVAP) System
1. Describe the function of the components in the EVAP system in the table below.
Component Name/Acronym

Component Function

Rollover Vent Valve (RVV)

Located on top of the fuel tank. Allows vapors from the
tank to enter the EVAP system but prevents liquid fuel
from doing so.

EVAP Canister

Uses charcoal to collect and store fuel vapors to be burned
later by the engine.

Canister Vent Valve/Solenoid (CVV
or CVS)

A normally open solenoid connected to the canister vent,
it is used to seal the EVAP system from the atmosphere
during EVAP leak check monitoring.

Canister Purge Valve (CPV)/Vapor
Management Valve (VMV)

Meters the amount of fuel vapor sent to the engine from
the fuel tank and canister.

Fuel Tank Pressure (FTP)

A pressure sensor which sends an analog signal to the PCM
indicating the amount of vapor pressure or vacuum in the
EVAP system.

2. Explain the operation of the EVAP system.

____________________________________________________________________________________________________________________________________________
3. When the engine is running, how does the EVAP system detect a leak?

____________________________________________________________________________________________________________________________________________
4. What IDS tests would be helpful in diagnosing this system?

____________________________________________________________________________________________________________________________________________

Engine Performance Operation and Diagnosis

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LESSON ONE

PREREQUISITE REVIEW

NOTES

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LESSON ONE

WORKSTATIONS

LESSON ONE
WORKSTATIONS

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LESSON ONE

WORKSTATIONS

NOTES

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LESSON ONE

WORKSTATION ONE
WORKSTATION ONE
Secondary Ignition Operation and Testing

SUMMARY: In this vehicle workstation, you will investigate the operation of the secondary ignition system. You
will determine the effects of faults on both a coil pack system and a coil­on­plug system.
DIRECTIONS: Complete this VEHICLE workstation following the steps in this worksheet.

Part A: Ignition Workstation – Coil Pack Ignition System
Normal Test ­ Follow the steps below to perform a test on a properly operating ignition system.
•

Use the IDS to start a new session. If the IDS detects a previous session, select the “Cancel” button and continue.

•

Select “Toolbox”, “Powertrain”, “Ignition Tools”, and “Ignition Test”

•

Follow the IDS instructions and connect the Secondary Ignition Transducers to cylinders# 3 and #6. The
instructor has connected the others for you. Be sure to route all IDS cables away from the coil and spark
plug wires.

•

Start the vehicle and idle until the engine reaches operating temperature. View the Ignition System live display
and press the “Capture” button.

•

When recording is finished (approximately 15 seconds), shut off the engine.

30 kV Test ­ Follow the steps below to simulate an open secondary wire or very wide spark plug gap.
•

Set the Spark Tester to 30 kV.

•

Remove the secondary wire from cylinder #5 spark plug, install the spark tester in the secondary wire, and attach
the spark tester to a ground. (DO NOT USE BATTERY NEGATIVE AS THE GROUND)

•

Start engine, restart ignition test, and capture ignition system values.

•

When recording is finished (approximately 15 seconds), shut off the engine.

3 kV Test ­ Follow the steps below to simulate a shorted secondary wire or a closed spark plug gap.
•

Set the Spark Tester to 0, then back the adjustment off one half of a turn. Start engine, restart ignition test, and
capture ignition system values.

•

When recording is finished (approximately 15 seconds), shut off the engine.Select “Playback Viewer” to view
the recordings you made. Play each recording from beginning to end. (To switch between recordings, use the
forward and back buttons below the menu button.)

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LESSON ONE

WORKSTATION ONE

For each cylinder, draw a line showing the min and max of each recording in the appropriate IDS screen.

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LESSON ONE

WORKSTATION ONE

1. In the normal recording, what is the average firing voltage of all cylinders?

____________________________________________________________________________________________________________________________________________
2. In the normal recording, what is the average spark duration of all cylinders?

____________________________________________________________________________________________________________________________________________
3. How are spark duration and peak KV related?

____________________________________________________________________________________________________________________________________________
4. Which cylinder is paired to the cylinder with the Spark Tester installed?

Cylinder #1

5. With the Spark Tester set to 30 kV, why is the duration so short on that cylinder?

6. With the Spark Tester set close to 0, why is the duration so long on that cylinder?

7. What type of fault might cause low peak kV?

____________________________________________________________________________________________________________________________________________
8. What type of fault might cause high peak kV?

____________________________________________________________________________________________________________________________________________
9. If the firing voltage for a cylinder remains constant, what type of concern may be present?

•

Disconnect the Secondary Ignition Transducers from cylinders #3 and #6. Reconnect the spark plug for
cylinder #5.

•

Reset the Keep Alive Memory (KAM). (“Toolbox” > “Powertrain” > “Reset KAM” > “PCM”)

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LESSON ONE

WORKSTATION ONE

10. What happens when KAM is reset?

•

Delete the IDS vehicle session. Return vehicle to normal operating condition.

Part B: Ignition Workstation – COP Ignition System
Review the results of power balance and ignition tests on a COP vehicle
•

Prior to using the Ignition Test, the suspect cylinder must be identified using the Power Balance test. Perform
the following steps to view the results of this test.
•

Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Grand Marquis 4.6L IGNITION)

•

Access the Power Balance test. (“Toolbox” > “Powertrain” > “Power Balance”)

•

Select playback display (Recordings Group COP_ALL_PIDS, Recording 1). Play the recording from
beginning to end.

1. Which cylinder indicates a concern?
•

Cylinder #4

After the suspect cylinder was identified, the Ignition Test was performed. The red clip was placed on the
suspect cylinder’s coil. The blue clip was placed on the coil from a good cylinder. Perform the following steps
to view the results of this test.

•

Access the Ignition Test. (“Toolbox” > “Powertrain” > “Ignition Tools” > “Ignition Test”).

•

Select playback display (Recordings Group COP, Recording 1).

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LESSON ONE
•

WORKSTATION ONE

Draw a copy of the recording on the IDS screen.

2. What is the average spark duration of the two cylinders? DUR1
3. What is the average firing voltage of the two cylinders? PKV1

1.2 ms
15 KV

DUR2
PKV2

1.6 ms
12 KV

4. What type of fault might cause the concern in this recording?

____________________________________________________________________________________________________________________________________________
5. At idle, the spark plug is fired in repetitive mode as indicated by the REP display. According to the General
Information tab, what affect might this have on Spark Duration?

____________________________________________________________________________________________________________________________________________
•

Exit and save the session by selecting the Vehicle tab, then the Close Session tab, then Hold.

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