31S28T0 advanced engine perfomance operation and diagnosis 2009

Advanced Engine
Performance ­
Diagnosis and
Testing

31 ­ Engine Performance

FCS21049REF

Student Guide
FCS­21049­REF

Course Code: 31S28T0
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



ADVANCED ENGINE PERFORMANCE DIAG & TESTING

INTRODUCTION

INTRODUCTION

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ADVANCED ENGINE PERFORMANCE DIAG & TESTING

INTRODUCTION

ADVANCED ENGINE PERFORMANCE DIAG & TESTING
Course Description
This is a 4 day course facilitated by an instructor. This course is designed to provide hands­on opportunities for
technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previous
curriculum courses. Each day you will have multiple opportunities to practice selected skills. The results of your
work are recorded on worksheets.

Worksheets
All activities and workstations have an accompanying worksheet 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 a pass/fail type. It will be conducted with exercises in PID review/evaluation
and intermittent concern diagnosis and will cover:
— PID monitoring.
— intermittent diagnostics.
— diagnosis without DTCs.
In order to pass the course, you must demonstrate mastery of the skills covered at the 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:
•

Identify types of DTCs (Condition and component generated).

•

Perform data analysis (Mode 6, PID) during diagnosis.

•

Perform diagnosis using the scan tool, oscilloscope, breakout box and other tools.

•

Perform intermittent concern diagnosis.

•

Perform diagnosis using the symptom chart.

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ADVANCED ENGINE PERFORMANCE DIAG & TESTING

INTRODUCTION

Course Agenda
LESSON ONE:
•

Prerequisite Review

•

Workstation One: MIL ON, Engine Misfire (On Vehicle)

•

Workstation Two: MIL ON, Wrench Light On, No Throttle Control (Bench)

•

Workstation Three: No Crank (On Vehicle)

•

Workstation Four: E85 Bench Calculation and DTC P0133 (CMT)

•

Lesson One Written Activity

LESSON TWO:
•

Workstation One: MIL On (On Vehicle)

•

Workstation Two: IDS Recordings (Bench)

•

Workstation Three: Engine Misfire (On Vehicle)

•

Workstation Four: IDS Recordings (Bench)

•

Lesson Two Written Activity

LESSON THREE:
•

Workstation One: Intermittent Stall (On Vehicle)

•

Workstation Two: Intermittent Rough Idle (CMT)

•

Workstation Three: Intermittent Buck/Jerk (On Vehicle)

•

Workstation Four: Intermittent Misfire/Skip

LESSON FOUR:
•

Workstation One: MIL ON, Hesitation (On Vehicle)

•

Workstation Two: Intermittent Misfire (Bench)

•

Workstation Three: MIL ON, Hesitation (On Vehicle)

•

Workstation Four: Intermittent Misfire (Bench)

•

Lesson Four Written Activity

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ADVANCED ENGINE PERFORMANCE DIAG & TESTING

INTRODUCTION

NOTES

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Testing

Intro ­ 4

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LESSON ONE

PREREQUISITE REVIEW

LESSON ONE

Advanced Engine Performance ­ Diagnosis and
Testing

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LESSON ONE

PREREQUISITE REVIEW

NOTES

Advanced Engine Performance ­ Diagnosis and
Testing

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LESSON ONE

PREREQUISITE REVIEW

PREREQUISITE
REVIEW

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LESSON ONE

PREREQUISITE REVIEW
PREREQUISITE REVIEW

DIRECTIONS:
1. When retrieving DTCs, which should you perform first?
A. Perform KOEO On­Demand Self Test
B. Perform KOER On­Demand Self Test
C. Retrieve CMDTCs for the module being tested
D. Retrieve all CMDTCs from all modules
2. Data that is captured at the exact time a DTC is generated is known as:

____________________________________________________________________________________________________________________________________________

3. Pinpoint test QT1 directs you to test fuel quality. How should this be done?

4. In the faults legend below the wiring diagram, circle the faults that would prevent the output device in this
circuit from operating properly.

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LESSON ONE

PREREQUISITE REVIEW

5. If you suspect high resistance in the circuit, what test could you perform?

____________________________________________________________________________________________________________________________________________
6. Which section of the PCED would you use to begin diagnosing a lack of power concern with no DTCs?
A. 0. Introduction
B. 1. Description and Operation
C. 2. Diagnostic Methods
D. 3. Symptom Charts
E. 4. Powertrain DTC Charts and Descriptions
F. 5. Pinpoint Tests
G. 6. Reference Values
7. What systems could cause a lack of power?

____________________________________________________________________________________________________________________________________________
8. When using the No Diagnostic Trouble Codes (DTCs) Present Symptom Charts you should return to the
symptom charts if the pinpoint test does not find a fault.
True

False

9. How does the fuel control system try to compensate for large intake air leaks?

10. An abnormal fuel trim on one bank could be caused by:

11. What could cause abnormal fuel trim readings on both banks?

____________________________________________________________________________________________________________________________________________

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LESSON ONE

PREREQUISITE REVIEW

12. What could cause the upstream O2 sensors to show lean?

____________________________________________________________________________________________________________________________________________

13. Short spark duration and a higher than normal KV value may indicate what condition?

____________________________________________________________________________________________________________________________________________
14. How will resistance, peak KV and duration be affected by a spark plug with a gap that is too narrow?

____________________________________________________________________________________________________________________________________________
15. What affect would a contaminated MAF sensor have on fuel trim at idle?

____________________________________________________________________________________________________________________________________________
16. Which VCT PID would best show a concern?
A. VCTADV
B. VCTERR
C. VCTDC
D. VCTSYS
17. When using the No Diagnostic Trouble Codes (DTCs) Present Symptom Charts you should perform the tests in
the order they are listed.
True

False

18. If the tests in the symptom chart do not find the concern, what other section of the PCED should you refer to:
A. 0. Introduction
B. 1. Description and Operation
C. 2. Diagnostic Methods
D. 3. Symptom Charts
E. 4. Powertrain DTC Charts and Descriptions
F. 5. Pinpoint Tests
G. 6. Reference Values
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LESSON ONE

PREREQUISITE REVIEW

19. What is the OBD drive cycle and when should it be performed?

____________________________________________________________________________________________________________________________________________
20. What is Mode 6 Data?

____________________________________________________________________________________________________________________________________________

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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
MIL ON, Engine Misfire

SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern. Use the steps in this worksheet
to determine possible causes, separate those causes into a list of systems and components, then systematically
eliminate each to come up with the root cause(s) of the concern.
DIRECTIONS: Read the information in the repair order to start your diagnosis. Diagnose the concern and
complete the necessary information on the pages that follow. *
Repair Order
Year

Model

Engine

Trans

Other

Customer Concern

Check Engine Light ON, Engine Misfire
Vehicle History/ OASIS results/ TSBs
. REPAIR HISTORY
PCM Replaced

. SPECIAL SERVICE MESSAGES
20044 SERVICE PROCEDURE UPDATE ­ PCED (GAS ENGINES) PINPOINT TEST DV ­ MIL ON P2104, P2107, P2110, P2111,
P2112 DTC
2007­2008 MULTIPLE VEHICLES WHEN DIAGNOSING/REPAIRING MIL ON P2104, P2107, P2110, P2111, P2112 DTC FOR
ELECTRONIC THROTTLE CONTROL, USE THE ONLINE VERSION OF THE PCED MANUAL (GAS ENGINES VERSION). THE
DIAGNOSTIC PROCEDURES UNDER THE "DV" PINPOINT TEST HAVE BEEN UPDATED
EFFECTIVE DATE: 11/13/07

. TECHNICAL SERVICE BULLETINS
08–07–06
SPARK PLUG REMOVAL INSTRUCTIONS 4.6L 3V / 5.4L 3V / 6.8L 3V
F­150, MARK LT, F­SUPER DUTY, EXPEDITION, AND NAVIGATOR, WITH 5.4L 3­VALVE ENGINE; MUSTANG, EXPLORER,
MOUNTAINEER, AND EXPLORER SPORT TRAC WITH 4.6L 3­VALVE ENGINE; F­SUPER DUTY, AND F­STRIPPED CHASSIS,
WITH 6.8L 3­VALVE ENGINE MAY EXPERIENCE DIFFICULTY WITH SPARK PLUG REMOVAL. THIS MAY CAUSE DAMAGE TO
THE SPARK PLUG AND LEAVE PART OF THE SPARK PLUG IN THE CYLINDER HEAD. REFER TO THE SERVICE PROCEDURE
FOR TECHNIQUES TO REMOVE THE SPARK PLUGS AND EXTRACT BROKEN SPARK PLUGS. See TSB for complete details
EFFECTIVE DATE: 04/08/2008
08–04–03
MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) ­ P0456
EXPEDITION, NAVIGATOR, E­150 THROUGH E­350, F­150 AND MARK LT MAY EXHIBIT A MIL ON WITH DTC P0456 (VERY
SMALL EVAP SYSTEM LEAK ­ 0.020 IN DIAMETER (.51 MM)). FOLLOW THE SERVICE PROCEDURE STEPS TO CORRECT THE
CONDITION.
EFFECTIVE DATE: 04/02/2008

IMPORTANT NOTES:

*

OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual
concerns.

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LESSON ONE

WORKSTATION ONE

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of
this concern. As you go through your diagnosis, indicate your results for each step by crossing off component(s) and
fault(s) that are eliminated. Then, next to the fault, write the test step that eliminated it.
1. In the SSCC Table, document the system(s) that could cause the concern.

SSCC Table
Symptom: Misfire

System: Base engine,
Ignition, Fuel Control

Component:VPWR circuit,
control circuit, PCM, coil
and boot, spark plug

Cause:

2. In the SSCC Table, document the component(s) that could cause the concern. Then, use the wiring diagram
to identify the faults that could cause the concern.
3. What does the pinpoint test recommend as a repair for this concern?

____________________________________________________________________________________________________________________________________________
4. Prior to replacing the PCM, you should always consider other possible causes. What component(s) and fault(s)
could still be the cause of the concern?

____________________________________________________________________________________________________________________________________________
•

Call the instructor to the workstation for further directions.

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LESSON ONE

WORKSTATION TWO

WORKSTATION TWO
MIL ON, Wrench Light ON, No Throttle Control

SUMMARY: In this BENCH workstation, you will diagnose a customer concern. Use the steps in this worksheet to
determine possible causes, separate those causes into a list of systems and components, then systematically eliminate
each to come up with the root cause(s) of the concern.
DIRECTIONS: Read the information in the repair order to start your diagnosis. Verify the customer’s concern.
Diagnose the concern and complete the necessary information on the pages that follow. *
Repair Order
Year
Engine

2008
3.5L

Model

Edge

Trans

6F50

Other

Customer Concern

MIL is ON, Wrench Light is ON, lack of power, little to no throttle control, high idle.
Vehicle History/ OASIS results/ TSBs
. REPAIR HISTORY

No related history.

. SPECIAL SERVICE MESSAGES
20380 20380 FORD/LINCOLN/MERCURY VEHICLES WITH REPLACEABLE THROTTLE POSITION SENSOR: TPS REMOVAL
SERVICE PROCEDURE UPDATE.
FORD/LINCOLN/MERCURY VEHICLES HAVE A SERVICEABLE THROTTLE POSITION SENSOR (TPS). A NEW SERVICE
PROCEDURE HAS BEEN RELEASED TO REDUCE THE POSSIBILITY OF A BOLT BREAKING DURING TPS REMOVAL CAUSED
BY THE THREAD LOCKER USED. PLEASE REFER TO THE ONLINE WORKSHOP MANUAL, SECTION 303­14 FOR UPDATED
REMOVAL PROCEDURE.
EFFECTIVE DATE: 08/12/2008
20211 CROWN VICTORIA AND GRAND MARQUIS ­ AIR CLEANER ASSEMBLY (9600) IDENTIFICATION.
CROWN VICTORIA AND GRAND MARQUIS MAY HAVE INCORRECT AIR CLEANER ASSEMBLY (9600) INSTALLED THAT CAN
RESULT IN POOR ENGINE PERFORMANCE, HARD STARTING AND/OR MULTIPLE DIAGNOSTIC TROUBLE CODES (DTC’S). A
UNIQUE AIR CLEANER ASSEMBLY IS USED ON ALL POLICE (P71) VEHICLES AND IT CAN BE QUICKLY IDENTIFIED BY RIBS
THAT ARE VISIBLE ON THE TOP COVER OF THE AIR CLEANER ASSEMBLY, ALL OTHER VEHICLES HAVE A SMOOTH AIR
CLEANER TOP COVER. VERIFY THE CORRECT AIR CLEANER ASSEMBLY HAS BEEN INSTALLED, ESPECIALLY IF A VEHICLE
HAS RECENTLY BEEN REPAIRED SUCH AS AFTER AN ACCIDENT, AND IT IS EXPERIENCING SOME OF THE SYMPTOMS
LISTED ABOVE. IF THE INCORRECT AIR CLEANER WAS INSTALLED, INSTALL THE CORRECT AIR CLEANER ASSEMBLY,
COMPLETE A PCM RE­SET AND REEVALUATE THE VEHICLE.
EFFECTIVE DATE: 04/10/2008

. TECHNICAL SERVICE BULLETINS
No related TSBs

IMPORTANT NOTES:
MIL ON, Wrench Light ON. DTCs P0123 –Throttle/Pedal Position Sensor A Circuit High, P0223 – Throttle/Pedal Position Sensor
B Circuit High. Results for PPT DV3 – TP1=5.0V, TP2=5.0V.

*

OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual
concerns.

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LESSON ONE

WORKSTATION TWO

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of
this concern. As you go through your diagnosis, indicate your results for each step by crossing off component(s) and
fault(s) that are eliminated. Then, next to the fault, write the test step that eliminated it.
1. In the SSCC Table, document the system(s) that could cause the concern.

SSCC Table
Symptom: MIL ON, wrench
light ON, no throttle control

System: Air delivery
(Electronic Throttle
Control)
Component:Throttle body,
ETC, PCM, wiring, TP
Sensor

Cause: Open TPRTN circuit

2. In the SSCC Table, document the component(s) that could cause the concern. Then, use the wiring diagram
to identify the faults that could cause the concern.
3. Could an obstructed throttle body cause this concern? Why or why not?

____________________________________________________________________________________________________________________________________________
4. Review the wiring diagram, what circuit(s)/fault(s) have not been tested?

____________________________________________________________________________________________________________________________________________
5. What is the cause of the concern?

____________________________________________________________________________________________________________________________________________

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LESSON ONE

WORKSTATION THREE
WORKSTATION THREE
No Crank

SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern. Use the steps in this worksheet

to determine possible causes, separate those causes into a list of systems and components, then systematically
eliminate each to come up with the root cause(s) of the concern.
DIRECTIONS: Read the information in the repair order to start your diagnosis. Diagnose the concern and
complete the necessary information on the pages that follow. *
Repair Order
Year

Model

Engine

Trans

Other

Customer Concern

No Crank
Vehicle History/ OASIS results/ TSBs
. REPAIR HISTORY
No related history.

. SPECIAL SERVICE MESSAGES
20144 MULTIPLE VEHICLE LINES – INTERMITTENT PCM, FUEL PUMP, IGN. COIL, OR FOG LAMP RELAY
FOCUS, CROWN VICTORIA, GRAND MARQUIS AND TOWN CAR VEHICLES MAY EXHIBIT AN INTERMITTENT NO CRANK,
NO START, NO FUEL PRESSURE ON STARTUP, NO SPARK ON STARTUP OR NO A/C OPERATION. ESCAPE, MARINER,
TAURUS, SABLE, EXPLORER, SPORT TRAC, MOUNTAINEER, AND RANGER VEHICLES MAY EXHIBIT A HARD TO DIAGNOSE
INTERMITTENT ABS OPERATION WITH MIL ON, INTERMITTENT FOG LAMPS OR NO A/C OPERATION, DUE TO INTERMITTENT
RELAY OPERATION. CHECK FOR PROPER INSTALLATION AND FUNCTION OF THE RELATED RELAYS (ENGINEERING PART
# 4F1T­14B192­AA (4­PIN)). IF NORMAL DIAGNOSTICS INDICATE RELAY REPLACEMENT IS NECESSARY, REPLACE WITH

SERVICE PART # F5TZ­14N089­B (5­PIN, EXTRA PIN IS NOT UTILIZED
EFFECTIVE DATE: 02/20/07
20001 SOME VEHICLES MAY EXPERIENCE A NO CRANK, NO START OR NO COMMUNICATION CONCERN AFTER
PROGRAMMING THE ECM, TCM OR IC.
REPROGRAMMING CONCERNS MAY BE CAUSED BY THE DLC OR VCM BECOMING DISCONNECTED, LOW BATTERIES
ON THE IDS, OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE. IF THERE WAS AN INTERRUPTION DURING
REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT
DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY
REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO
LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE.
TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE
ORIGINAL SESSION ONCE THE IDS IS RE­BOOTED.
EFFECTIVE DATE: 10/10/2007

. TECHNICAL SERVICE BULLETINS
No related TSBs

IMPORTANT NOTES:

*

OASIS Messages and TSBs provided on this repair order are for training purposes only and may not be actual
concerns.

Advanced Engine Performance ­ Diagnosis and
Testing

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August, 2009

LESSON ONE

WORKSTATION THREE

DIRECTIONS: When directed, use the “SSCC Table” to identify the type of fault(s) that COULD be the cause of
this concern. As you go through your diagnosis, indicate your results for each step by crossing off component(s) and
fault(s) that are eliminated. Then, next to the fault, write the test step that eliminated it.
1. In the SSCC Table, document the system(s) that could cause the concern.

SSCC Table
Symptom: No crank

System: Primary Inputs and
PCM, Networks, Starting,
PATS, Base Engine
Component:PCM, Wiring,
Ignition Switch, BJB,
Battery, Instrument
Cluster, PATS Key

Cause:

2. In the SSCC Table, document the component(s) that could cause the concern. Then, use the wiring diagram
to identify the faults that could cause the concern.
3. Navigate to the service information and view the wiring diagram for this vehicle. What modules are on the
network with the PCM?

____________________________________________________________________________________________________________________________________________

4. View the wiring diagram. What pins provide power to the PCM Power Relay?

____________________________________________________________________________________________________________________________________________
5. What component is the root cause according to the Pinpoint Test?

•

Once you have identified the root cause of the concern, call the instructor to the workstation.

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LESSON ONE

WORKSTATION THREE

6. What else could cause this concern?

•

Use the DMM and wiring diagrams and prove that the answer to the previous question is the root cause of
the concern.

•

Delete the IDS session.

7. Which option did you choose to delete the session?
A. hold
B. complete
C. delete
D. abort

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