FORWARD overview 6.0L PO ER TROK TROK avai availa labl bl serv servic ic lite litera ratu ture re
le
in
:::I
WARNINGS
OFF posi posi ion, ion, un es by he proc proced edur ure. e.
PARK REVERSE NEUTRAL
:s
::I
monoxide.
othe otherw rwis is
requ requir ired ed
FORWARD overview 6.0L PO ER TROK TROK avai availa labl bl serv servic ic lite litera ratu ture re
le
in
:::I
WARNINGS
OFF posi posi ion, ion, un es by he proc proced edur ure. e.
PARK REVERSE NEUTRAL
:s
::I
monoxide.
othe otherw rwis is
requ requir ired ed
6.0L ::21
::II ::II Horsepower
Torque
Specifications Identification
:!II 14
Features
:!II System
lo
17
Wate Pu
19
::!I ::II
Y System
R
lo
S 27
M
:!II ::!I
:B
.79 APPENDIX
.8
::!I
:s !I
:!I
::!I :II :!II ::II
21
:!I ::!I
:II ::!I :II
6.0L
:s
:!I
Engine
6.0l
OVERVIEW
6.0L
ow
Powe
Stroke engine.
Overview
trok
Engine Features Powe
Stroke ha
Powe
Stroke
been
esig ed
Va iabl
om tr
Turb
harg
range.
standard
se by th
go ernmen
in
600
Powe
Stroke
reates
25 500
iIiiiii
400
300
~~
===:I
200
P:iII
100
P!:iIi 00
1000
1500
3000 engine spee
Torque [ft-Ib]
[rpm
3500
4000
6.0L
OVERVIEW
4 O
4 i
Peak Torque
. ( @ 3
@ R @ R
5 g
@ 3
Specifications
Front
Powe
Stroke
in Imnrn\l~'t1
pe fo ma ce
an
cleane
emission Powe
2,4,6,8.
Stroke are
6.0L Engine
OVERVIEW eria Number
le
in equentia
Injectio
lo io nu be
buil
Contro
Module).
eng.ine..
Emission
abel
module (PCM).
emission standards. in
1) Thermosta
3) Fuel
re su
Regula or
Fu Th
10
1) FICM
4) Crankcas
Ventilatio
11
12 10
1)
xh us
xpan io
2)
ea
hi ld
::!I
3) Li in
"E e"
:!
4)
eria Nu
er
:!II
:!II
:!II :i!I
:!II Bl ck
::!I
ea er
2) Tu bine Outlet
oint
I:
1) Heater Re ur 2) EG
12
Th ot le Actuator
:::II
4) Injector Connectors
:::I :::I :=I 17
:s 3) Tu bo ha ge
ompr ssor
Ou le
::I
::!I :::!I
:=I
:::I
::I
18 13
G.Ol
FEATURES
Rocker Carrie
fulcrums.
I:
Cy inde
ea OW
ai
lo
an
ST OK
ef icienc
ll
20
Rear Geartrai
geartrai
14
noise.
6.0L
FEATURES ly heel heel
or he
F-25 F-250/ 0/35 35
engi engine ne
he
SPRINGS
anua anua
Supe Superd rdut ut
rans ransmi mi sion sion
ru k.
id
ta te
ing. ing.
22
Sing Sing
as
F-45 F-450/ 0/55 55
lywh lywhee ee
Supe Superd rdut ut
ru ks
part.
23
Norm Normal al Heat Heat indu induct ctio io
reat reat en
Disc Discol olor orat at on
hard harden ened ed
lo it
15
oo in it ou
le ve
stem stem di on ec in
re
eatu eatu es adia adia or ho es
ainl ainl ss stee steel. l.
17
th
oi cool cooler er
is lo fron fron cove cover. r.
II
Cover
r:
cyli cylind nder er head heads. s.
engine.
th
engi engine ne
is dama damage ged. d.
29 18
::
if
:::I
Fron Cove
:II outward.
::I
::I object.
Injector Sleeve 6.0l Powe
:ell
=:II
Stroke us
stainles
teel
he co lant
anua fo
or
de ails
::!I :!II
19
combustion
chamber.
ic
le
Ie
20
ubricati Powe
yste
Feat re
Stroke
cooler.
oi pa
during
ervici g.
OI PRESSURE REGULATOR
36 21
Lu
he oi pressu
egulator
Pr
sure Oi Sy te
Sc
mati
elieving exce si
Turbo
line. Oil Reservoi fo Hi Pressure Pu
0 .9 5 Q t
T o H ig h Pressure
coolin
Oil
System
jets
Ri
Ba
Left Ba
T=Tappet
crankshaft
main bearings
CB
Ca
MB
Main Be ri
CR
Co
Be ctin
Ro
37 Be Powe
Plat Stroke
ig
22
ck-u
ae atio
Tube
Oi Aeration
nd poor pe fo mance.
poor idle
caus
oi aeration
Oi Pressure Re ulator
closed belo
that
re su e.
POWER STROKE.
gasket.
ig
Fr
Cove
il
et l,
ne pi ce gasket
Oi Co le
oi cooler
No th il le is ma it caus contaminatio of th lubricatio an cooling systems.
Oi Co le
Ho
the crankcase
24
in
Filt
Ba
ld
Valves
c::J urboch rger
oi ee
FI 20 psi.
change.
Oi Filter POWE
ILTE
::
LE
NT
TR KE
se
ar ri ge
engine.
lid.
:=II
Oi Reservoi
Screen
in
25
crankcase.
th
crankcas
fo lubrication.
oi pan.
48 Turbocha ge Control
valve.
cover.
26
il
pply
VGT
:::I
Ho izon al Fuel
onditionin
during
ondition
odul
:::I oo
ue
ower Stroke fuel filter
:::I
:::I. FU
FILT
lI
UE
RETURN
52 27
ELECTRIC TRANSFER PRIMING PUMP
1
FUE REGULATIO VALVE 60 +/- PS CRACKING PRESSURE
-
-,
CYLINDER HEAD
RB
.020" DIESEL THERMO RECIRCULATIO VALVE (DTRM) FUEL TANK PRIMARY FILTER/WATE SEPARATOR 10 MICRON (WI HEATER WIF PROBE)
53 lv
Horizontal Fuel Conditioning
asse
ly wh re pa ti le
la ge th
fuel.
micron fuel filter
egul te
iese ther (DTRM).
ecirculation
cylinder
fuel pressu
by elea in system.
valv
tank.
eads
HFCM (H rizontal Module)
Fuel Condit onin
:::I :::I :::I :::I
fue conditions.
:I
HFCM (H rizontal
ue Cond ti ning
::
::I
(2rC).
DTRM
:II
:-
FU
ILTE
55
la
:::I
(2rC)
56
::I
29
filter housing.
styl
filter
Fuel Pressure Regu ator
HFCM via valve.
valve or belo
valve is 60ps above this specification.
valve valve
valves
copper gaskets.
removed.
30
in
:::I ::::I tu
::
ir
ir
:J :::I
:::I :::I ::::I
GR
AL
:I ::I COMPRESSOR OUTLET
:lI
:=
::I :c:lI
GR COOL TURBIN
UTLE
31
Ai Inle
Ai Cooler
*Throttle Plate
Intake Ai Temperature 'Senso #2
Valve
Cooler
Manifold Absolute Pressure Sensor
Contro
Exhaus Pressure Sensor
Valv
Turb Outlet to Exhaus
62
engi
hr ug
he intake
anifold.
recirculatio
(EGR
cooler
il
strategy sensor (MAF).
he
ra kcas
ir ar
ve tila io
noise.
heads.
sy te
ixed
he urbo ha ge
co pr ssor
he
th
turb char er
urbine
he l.
xp nsion. Th
----------------~--
pinnin
ur in
Ai Fi te
an
Filter Minder
he radiator
filter housing.
in
Ai Filter
emen
in replacement.
...
of th
radiator
intake manifold
33
VG
Features Powe
Stroke
response.
is elec roni ally actuated.
as er in ol
VG
conditions
on
on ention
Turbin
electronically
34
ambien
hydrauli ally
Compressor
comp es or
VG
co tr lled an
controlled.
urbo harger
OF OI
ISTO SUPPLY
id
is en ed
CAM
move.
VG
V al v rb
Va
OE
ll Op
70 VG
Co tr
urbo Va es Mi
Valv Po itio
71 VG rb
Co tr
Valv
Va es Full Cl se
35
ACTUATOR
ISTO NI VANES
actually is
73
AC UATO
ISTO
io partiall
driv
open
EG
74
il
le
VANES
conditions ca ne ativel ffec co po en it commande open pr ventin tu bocharge overspeed.
ac as
larg
urbo harger
75
36
GR Va ve ecircula ion)
valv
adds cooled
xhaust
emissions.
pressure
(boost).
manifold.
EG EXHAUS
COOLER CONNECTION
GR Co le
valve.
of th
engine
engine co lant
epen in
on conditions
manifold.
37
IR EG
Y5 TE
Throttle
plate.
op ra ion, bu la er wa unnecessary.
dete
ined
removed.
.1
Intake Manifold Power Stroke
GR COOLER
heads.
cover.
ompr ssed
manifold.
manifold.
38
in ak
ai
Fue Managemen System FICM Fue Inje ction Contro Module
PCM Powertrain Contro Module
CKP
Generati ue System Diagra
an ge en
MAP
lubrication
System
AP
cylinders.
EDT
BP
High Pressure Oil System
EP IAT2
MAF IAT1
Fuel Supply System
EG Position
ECT
ICP
82 Ge eratio Fuel Ma agemen System Ma or Co ponent
njec ors. lectrica
Co ponents.
Actu to s.
Ge eratio ue anagemen System Advantages
control.
in Regulator).
39
HIGH PRESSURE
CH CK VA AN FITTIN
HIGH PRESSURE HIGH PRESSURE
HIGH PRESSURE OI BRANCH
system an
on
contains approximatel
rail.
(1 ou le rail, limi hydrauli disturbance/feed ba ro injector operation.
piston.
lines.
40
High
ressur
Oi
yste
chemat
Oi Reservoi fo Hig Pressure
G)
'0 Cooler Bypass
SI
C
a v
t h O i f
+
ICP Sensor v e
Contains 4 00 0 P S Relief Valve
Drai
to Crankcas
86
Schematic
injectors. ir
:::I
high pr ss re pu p.
::
contains
:::I
he system's pressu
psi.
41
Cover th
crankcase.
HIGH PRESSURE UM COVE
train.
xter al
il le ks
IP (Injecti Co trol ress re Regulator) CP (Injection Co tr Pressure Sensor
tu bo ha ge
urbine inle
Feature
ampe
42
yd auli
nois s.
ipes
ue
je to
Feat re
illion
NT RN
econd)
njecto
O- IN
-r ng
le
ocke
ar
ar ier.
91 Injector Coil
Spoo Valv
injector.
the crankcase
.017
43
Intensifie
plunge
Piston
downward
Plunger
Barrel
is built.
IC
BARREL
pressure
UNGER scuf in
an
poor perf rmance
94 Injectio
Nozzle
ly psi.
PINTLE
95 44
tage
of njection
injection.
Fill Cycl closed position
plunger.
INTENSIFIE
PISTON combustion
FU
chamber.
IN
Oi Pressure
c::::::Jl
PINTLE CLOSED
Atmosphereic Pressure
Fuel Pressure
97 45
in
he intensifie
is on
ha be
INTENS FI
move.
STON
barrel.
Oil Pressur
Fuel Pressure
position.
IN ENSIFIER barrel.
injectio
begins
Oil Pressure
IN LE OP
EJ
A tm os ph er ei c
Fuel Pressure
46
P re ss ur e
PISTON
INTENSIFIE
PISTON
coil of th
injector
closed position
spoo valve.
Oil Pressure
IN LE OP
Fue Pressure
100
closed position
etur
to th ir initia po ition.
it
Oil Pressure
PINTLE CLOSED
Fue Pressure
101
Ge eratio Overview
II
lectrica
Co po ents
system.
Sensor Overview
peM
P ow er tr ai n
ICP
C on tr o
M od ul e
MAF&IAT1
BP
ECT
MAP EGRVP
IAT2
EP
CKP
EO
103 Sensor
Overview
magnetic field.
re eren voltag to aintai on istenc hroughou al operatin conditions
strategy.
49
FICM Fuel Injectio Contro Module
Q)
"S
"0
~c
~8 .~ t:::
a...
APS
Three-Trac
AP Coorilatio
(])
OJ ell
Malfunction Indicato Lamp ~C~lo-s-ed~----------------~FU~II~ Throttle
Throttle Position
Control Valve
Throttle
VGT
Control Valve
(A Position) la incorporates
thre
potentiometers
hree po entiometer on
he th ee
us agree.
oten io eter
il
50
lo it failur an stil maintainin performance.
IPR Injection Pressure Regulator
II
:Z
::II
Barometric Pressur
Se FICM Fue Injection Contro Module
:::I
:::I
::!I :::II :::111
::!I
Malfunction Indicator Lam
::iI :::I.
Barometri
Pressure Sensor
(Analo
Voltage)
4.5
:::eI ::!I
3.5
2.5
~~~=-~===-==~~~~~~~~~ VGT
-2500
Elevatio
(feet abov
se
level)
Control Valve
Control Valve
105 Baro (B rometric
Pr
variable capacitanc
sensor
analog oltage pressure.
is
re
igna that indi ates
lt in
51
Crankshaft Position Sensor FICM Fuel Injectio Contro Module
(J.)
"S
"0
::2; ::2;C
a_O .~ (J.)
:;
CKP
CK Ou Malfunction Indicato Lamp
106 CK
(Cra kshaft
Position
ranksh ft
signal. ly exhaust).
gap. ware strategies
52
peed an
po itio
=r
::r
Camshaft Position Sensor FICM Fuel Injectio Contro Module
::cr
::r a...()
Ql
:;:; o,
::cr :is
::r
CMP CM Ou
=r
Malfunction Indicato Lamp
:s
107 CM
(Camshaf
engine block.
osit on
ca
cycl
perfor
fuelin
calculations
with software strategies
ig
lc
engine. in
correspondingly. ig signal.
53
Engine Coolan Temperatur
Sensor FICM Fue Injection Contro Module
Cl)
"S
"0
1l.0
.~ Cl)
ECT
Engine Coolan (Analo
Malfunction Indicator Lam
Temperatur Voltage)
Electro-Viscous Fan Clutch
T em pe ra tu r ( De g F )
49 Stat
thermistor
signal voltag
sensor
voltage.
different temperatures
coolan
de reases
signal voltag
54
he resi tanc
increases.
decreases.
Only
Ex aust Ga
Reci culation
alve
os tion
enso FICM Fuel Injectio Contro Module
EG
P os it i n / o nt ro l
Vave Malfunction I nd ic at o L a
EGR Po itio
vs Outp
Q)
OJ
l'l
v er ag e
i nt l
0 - 10 0
P os it i D ut y C y l e
( mm )
VGT Control Valve
109 Recirculatio wi
Valv
potentio eter
Position
yp
en or
lt
EG
valve.
eans th proper valv
th
PC
continuo sl
operation.
55
g0°0 RPM
MPH
EOP
Gaug
OJ
'0
Readin
Normal
co
Q)
a: Q)
OJ :J co
C)
Q)
Actual Oi Pressure (PSI
110 Switch)
pressure reache 5-7psi.
only.
56
approximatel
Engine Oi Temperatur
Sensor ·FICM Fue Injection Contro Module
1l.0
.~ t:::
Q)
o,
EOT
Malfunction
Engine Oil (Analog
emperature Voltage)
Gl
Pl
Lamp
Temperatur
(Oeg F)
Control
ti
Pr
Valve
OT (E gine
il Te
er ture
thermistor type sensor
voltag
th
that indicate
ha ge in he operatin environment, ensuring adequate al operatin
conditions
temperature.
engine
ompensat or il is osit variations du to temperatur
57
Exhaus Pressure Sensor FICM Fue Injection Contro Module
EP
Malfunction Indicator Lam Exhaus (Analog
Pressur Voltage
tu
OJ
15
EGR Exhaus
Pressure (PSI
Control Valve
VGT
Control Valve
112 EP (Exhaust
ress re
variable capacitanc
analog olta pressure.
58
th
sensor
indica es
FICM Fuel Injectio Contro Module
Q)
"S
"0
:2 :2C 0..
.~
1:: Q)
IntakeAir Temperature Senso (Analog Voltage
Malfunction Indicato Lamp Temperatur
(deg F)
113 AT #1)
(I take Ai
is
empe at re
sions.
filter.
temperature.
im
FICM Fue Injection Contro Module
Q)
"S
"0
:2; :2;c
~8 ·iii
fl...
IAT2
I nt ak e A i T em pe ra tu r
S en so r
( An al o
Fue Quantity Timing and Contro
V ol ta ge )
Malfunction Indicator Lam Q)
EGR T em pa tu r
Contro Valve
( Oe g F )
114 AT #2)
(Intak
ther is or
differen
Ai
yp
sensor
ai temperature.
resistance of th voltag
th
60
thermistor
manifold ai temperature.
voltag
that indicate
temperature.
satisfactory.
I!
to increase
re is an
voltag
emperature
of th
to decrease
ther is or lf
la
Injectio
Contro Pressure Sensor FICM Fuel Injectio Contro Module
Q)
's ""0
.~ 1:: Q)
:;; a...
ICP
Malfunction Injectio
Contro
Pressure
I nd ic at o
am
(Analog Voltage)
Q)
IPR Injectio Pressure Regulator
Injection Contro Pressure (PSI)
115 IC (Injection Contro Pressure) variable capacitanc
load speed, an
sensor hydrauli
analog voltag pressure.
temperature.
system is satisfactory
ha in icates
dash.
om an timing.
he co re
injectio
61
FICM Fuel Injectio Contro odule :::J
(5
0...
·iii Q)
0...
Fuel Quantity Timing an Contro
MIL Mass Air Flow Si
(A
lo
Volt ge
Malfunction Indicato Lamp
Q)
Flo
Rat
(Grams/Sec)
EGR Contro Valv
EVRT Contro Valv
IPR Injection Pressure Regulator
116
Manifold Absolute Pressure Sensor FICM Fue Injection Contro Module
MAP
MAP Signa (Analog
Voltage
Malfunction Indicator Lam 36
Manifold Pressure (PSI
44
51
VGT
Control
Control
117 MA (Manifol Pressure)
Absolute
variable capacitanc
GR du
to de er in pressure.
sensor
cycle.
in ak
manifold (boost
63
Actuators to
yd auli
echa ic l,
el ctroni
work. Powe Stroke actuators: Injectio Pressure Regulator, ha st as ecir ulatio al e, Variable
(Injecti
ress re Re ulat r)
Pressure).
in re si
P.
no start.
119 GR (E ha st Ga Valve
ec rc atio OOLE
HAUS
opens.
closed state.
120 64
GTCV (Variabl Geometry Turboc arge Contro alve
turbocharger.
121 Othe
Electrical Components
FICM (Fue Injectio
X3 CONNECTO
injector star of inje tion
Contro
Module
nd dura ion.
correc time
123 65
Power Stroke.
Glow Plug System
f:
EOT
125
cylinder.
of stainles
teel
bank.
67
lo
ug
10-1
amps
yste
and/or wiring concerns
68
Diagnostic
WIRING
Oi Filter
Replacemen
appropriat
location
lid.
recomm nd
oil.
Fuel Filter
th
appropriat
starting th
Injector
carrier.
133
Replacemen
location
vehicle.
Remova
t. Power Stroke
to
bore.
injector.
interference.
or
Injector O-ring care ully re ov
Replacemen th
ex erna
o- ings
body.
ng
136 70
To
around th
ga ke
urin
in tallation.
replaced.
ly
WELL SOCKET
137 Injector Installation
ns
specifie
torque
to instal injectors.
Injector
nstallatio
cont
lu
tightene
as specified.
71
Removal
removed from he
ar ier.
five
Rocker Ar
Bridges
original position during reassembly valve mating valves origin po itio reassembly.
bridge
ar
an
orientatio
du in
no correc ly in ta led,
To remove remove
he
properly aligne geometry.
head bolt an
fo
torque
or ec
valve train
specific tions.
Injector Sleeve
sleeve.
removed.
Injector Sleeve:
Installation
combined.
th
ylin er he d.
location of sealan
GR
alve in
(tool #303-760)
Re
application.
va
Remova
system.
tabs release.
it
o-rings.
filter base
Crankcas Carryover
Ventilation:
Removal
P OW E
ST OK
on
74
Oil
Removal
Intake Manifold
engine.
coolan
reservoir.
alve
Re oval
tool #303-769 an
turn counterclockwise
75
HIGH PRESSURE
in installing th
gasket.
with dowels
cover.
plac
gasket
Fr nt Cover:
ea an
Ap lication
coul ge nt th lu~e oil system
th
ba evenly
rocker carrier.
hammer damage ma occur.
primar
lang
of he
ra ksha t.
flexplate/flywheel.
It
ype" gear
uller.
Crankshaft
the crankshaft.
ri ar
Flan
return hose will appear clear/transparent.
cause.
12 wa following components
12
Injector
1/
Test
he WDS.
weak injectors.
weak injector
connecto
the 6.0l Powe
Stroke
weak cylinder (Relativ Injector disable, actu
compression, ompr ssion,
tc.)
165
6.0l Powe
Stroke
REMOVED
results.
Mean Cranking Bf.M
r.:J:![J
166 ti
300°F.
operating temperature. in
pressure.
81
Powe
Stroke
bar. Power Stroke
to
z/
Bu
io
PCM.
inje to
ba
(not li ely)
WDS: voltage) oltage appr xi atel voltage)
82
48 olts
:!II
::II tI
:::I ::!I ::II =til
::II :eI ::11
APPENDIX
METRIC r
i
t
d
t
c
Nm 6 I 3 I
Nm g
(
n k
Nm 3 I 12 Nm 27 8 I 6 I
bf/ft B)
bf/ft o h l
i
d
d
4
b
33 Nm
f h Nm
(M1 0)
36
bf/ft Nm
bf/ft
6 I 6 I 8 I
D)
84
96
COMPONENT
STANDARD
METRIC
18 Ibf/in 6 I
10 Nm
fl
(M6)
18 Ibf/ft 11 Ibflft
15 Nm
53 Ibflin
Nm Nm
8 I
18 Ibflft l
p
Nm
10 m r
p
p
13 Nm 31 Nm
f p
8
35-38 Nm 31 Nm
I
80 Ibf/in
l
Nm
s
8-13 Ibf/ft 38 Nm 31 Nm
Ibf/ft
Nm
Sp
ia
rq
ig Wrench
firs th
49
36
ri
13
fr
inst ll M8
2) Ap ly Hi M10x1.5
Ch rt
M6
GR
GR co le
mp rature Nick (F AZ-9
94-M
fl up
rt bolt
Anti-Seiz
to thre
lt
prio to assembly. ig tl
-rin
with
in
il
fore
installing. 10
Ap ly assembly
M10x1.5 24
5)
ig te Al
Pi 1/8" 1/4" 3/8" 1/2" 3/4"
io
bolt
cr
ce te
cr
ks
ft
vi
re
NPT NPT NPT NPT NPT
85
Intake Side 13
14
Exhaust Side
Figure A\..
ic ic ic
Note Alwa
Flyw ee
86
Bolt
lt
Inta Intake ke
anif anif ld Bolt Bolt
It
,... Ibf/ft
Q)
s::::
'6
s::::
'0
Ibf/ft
Ibf/ft
,...
F-Ser F-Serie ies/ s/Ex Excu curs rsio io
2003,25
Powe Powers rstr trok ok
6 .0 .0 L P ow ow e S tr tr ok ok e D ie ie se se l E ng ng in e D ia ia gn gn os os titi c G ui ui d
Customer
( Pl Pl ea ea s
Concerns
l is is t i n t h i
P&A CODE E S
GV
IA CHAS CHASSI SI
STYL STYL
M N
I
L N
I
NOTE:
hard start! Nostart co rn with with emp. emp. belo 60 erfo erform rm step step 10first. 10first.
I
I
I T YP YP E O F S ER ER VI VI C
TRANSMISSION
AMBIEN AMBIEN
.Pe
OT
TEMPER TEMPERATU ATURE RE
fT
.Gl w P g O
e C
d a
Retrieve Retrieve Continu Continuou Check
Us th D TC TC '
Visual
ca
Troubl
Codes Codes
r et et ri ri ev ev e
C he he c
Oi Leve
f o c on on ta ta mi mi na na nt nt s
om
Correc Correc
d ur ur in in g t hi hi s t es es t a r
h is is to to riri ca ca l f au au lt s
s in g
M ilil es es /H /H ou ou r
U s s ca ca n t oo oo l I nj nj ec ec t
o n o i , co co rr rr ec ec t l ev ev el el .
je
Method
rs
D T ' s w il l
llmo
an
1 2 s ec ec . a n
do
n o c om om e
isab
s ca ca n t oo oo l
Ifco es ar
Trouble Trouble Codes
GradeN GradeNisc iscosi osity. t y.
o n e tw tw ee ee n if
9. KOEOInjec KOEOInjector tor Electrical ctrical SelfTes (Click Test) Test)
( fu fu el el , c oo oo la nt nt )
e i
. T e G w P g C
t oo oo l
Diagnostic
2. Ch ck En in
COMMERCIAL
st
le
Method
PERSONAL
mKO
1. Visua Engin Engine/Chassis assis Inspe Inspectio ctio il
N AM AM E
b ox ox )
DEAL DEALER ER NAME NAME
V EH EH IC IC L
C US US TO TO ME ME R
-NOTEI F C O NC NC E I S O U D , S E V IC IC E A S R EQ EQ UI UI RE RE D I F T HI HI S C OR OR RE RE C HE C ON ON DI DI TI TI O IT IS OT EC SS RY TO C OM OM P E T H E R E A IN IN D OF TH DIAGNO DIAGNOSTI STI PROCED PROCEDURE URE
he
p r s en en t
e riri f
o lt a
s in g t h
ca
C on on titi nu nu ou ou s a n
i s b ei ei n to
OE
DT 's
t o P i p oi oi n T es es t A F u pp pp li e
G PC PC T
an
t o G PC PC M O T p id s
e riri f
g lo lo w p lu lu g " on on " t im im e
d i p la ye ye d a t t es es t e nd nd .
ly
ru
ta
ti
Check
Visual
Relay on
Injector
Measurement
B+
Intake/Exhaust Restrictio 3. Intake/Exha I ns ns pe pe c a i f ilil te te r a n t e C he he c
I f s e l t es es t c od od e
0. Sc
i nl nl e d uc uc ts ts .
Tool
a r r et et riri ev ev ed ed , g o t o a pp pp ro ro pr pr ia ia t
PP
t es es t
Data List List Mo itorin
t s
seconds Waitto Waitto Star Star Lamp Lamp "on" "on" ttmels ttmels inde indepe pend nden en from from g/
w 9
i f a i f ilil te te r m in in de de r i nd nd ic ic at at o
"on" "on" time time
w P g R
h a b ee ee n i llll um um in in at at e
Method
Check
Visual
Spec.
Parameter
M ea ea su su r
Measurement
e ng ng in in e h ar ar ne ne s
r es es is ta ta nc nc e t o G PC PC M
VPWR
4. Suffic Sufficie ient nt Clean Clean Fue
FICMLPWR
fth
FICMVPWR
1 to to 2 o
to
illuminated. g t s am am pl pl e f ro ro m f ue ue l c on on tr tr o m od od ul ul e #2 Method
Check
Visual PW
A-
Electri tri 5. Elec e riri f
th
Fue Pum
Press Pressure ure
t h f ue ue l p um um p
a s o lt ag ag e
a( a l s a ftft e
ke
ec atke
on
C-
and pressu pressure re
Spec.
PS
Measurement
D-
SI mi
ftpres ftpressu sure re fail fail
6. Elec Electri tri
F IC IC ML ML PW PW R
n.
ff
Instrument
0 -1 -1 6
n d g nd nd . A t k e
tk fo
lo
go tonex step step to verify verify no restric restriction tion
E-
Fue Pum Inle Inle Restr Restrict ictio io
•M
I f l o w v ol ol ta ta g
c ha ha rg rg in in gg- sy sy st st em em ,
N o/ o/ lo lo w v ol ol ta ta g
rt
Sf
F IC IC MV MV PW PW R
No or lo
i nd nd ic at at e
c ou ou l
yc v ol ol ta ta g
i nd nd ic ic at at e
c ou ou l
RP
b e c au au se se d b y s ta ta rt rt in in g/ g/ ch ch ar ar gi gi n
Lo
RP
ca
s ys ys te te m i ss ss ue ue s N o R P
i nd nd ic ic at at e
IC
m in im u
P S ( 3. 3. 5 m Pa Pa ) i s r e u ir e
th
i nj nj e t or or s t o
of50
e na na bl bl ed ed .
w hi hi l
No or lo
I ~ -
c rra a nk nk in in g c ou ou l
be
fo
il inth
'20
s te te m
EOT("F)
5s
OK chec chec fue
ar OK repla replace ce fue pump.
o lt a
re di
b el el o
(30 PSI w/o CKP signal. signal. pe
i n i ca ca te te s l o
og
7 00 00 0 f ee ee t i n a l titi tu tu de de , b u n o t o e xc xc ee ee d 1 2 s ec ec on on ds ds .
IC
during during crank. crank.
lines lines betw betweenpump eenpump andfuel tank tank
filter filter
d ef ef au au lt s t o 1 4
G-
F UE UE L P W
H-
F IC IC MS MS Y C - N o y n c ou ou l
P ul ul s
w id t
Refer to PC/EDsection PC/EDsection
e f u lt s t o
w/
CK
c au au se se d C M
ig al or
K P f au au lt s
for detailed detailed tes procedu procedures res
HardSta HardStart/ rt/No No Star Star or Perf Perfor orma manc nc conc concer ern, n, this this form form must must befilled befilled ou to th poin poin of repa repair ir an retu return rned ed to rece receiv iv warr warran anty ty cred credit it an diag diagno nost stic ic tim fo th follo followi wing ng parts parts
Fue Inject Injectors ors (9E527 (9E527), ), regula regulator tor-in -injec jectio tio
L is t P ar ar t N a e ,
:=j'---:-L 60
Measurement
Hg,inspec both both fuel fuel filter filters. If filte filters rs ar 6" Hg,inspec
r ob ob le m
b e c au au se se d
issu issues es
IC If> 6/1 Hg rest restri rict ction ion chec chec
Whentro Whentroub uble lesh shoo ooti ting ng
b e c au au se se d
#8
rh Spec.
regu regulat lator or If regu regulat lator or an
b at at te te ry ry ,
P CM CM .
by 12-w 12-way ay conn connec ecto to
I P d ut ut y c yc yc l
W ha ha t
i s p re re se se nt nt , c he he c c irir cu cu it s t o t h
tf Instrument
If
c on on di di titi o
o r p ow ow er er /g /g n
contro contro pressu pressure( re(9C9 9C968) 68)
pum assemb assembly ly hig pressu pressure re oil (9A543 (9A543), ), turbo turbo charge charge assemb assembly/ ly/ped pedest estal al (6K684 (6K684), ), fue pum (9350) (9350)
Labo Labo oper operat atio ions ns list listed ed more more than than once once ar w er er e f o n d a n w ha ha t r e a ir s w er er e e rf rf or or me me d
um er an
S er er i
um er
a rt rt s r e l a e d
cont contin inua uatio tio
of th
FIC~·(l FIC~·(l,2B59~ , 2B59~
and PCM(EEC PCM(EEC)(1 )(12A6 2A650 50
diag diagno nost stic ic proc proced edur ur an shou should ld be cfai cfaime me only only once once
II
-S
xc
io
P ow e
2003.25
ke
6 .0 .0 L P ow ow e S tr tr ok ok e D ie ie se se l E ng ng in in e D ia ia gn gn os os titi c G ui ui d
Cust Custom omer er
( Pl Pl ea ea s
Conc Concern ern
I
I
En in /Cha /Chassis
y t
t t
STYL STYL
TEMPER TEMPERATU ATURE RE
2a
Posi Positio tio
• P
h k y o , e
Idle Idle St
Method
Hoses
fo leak leaks. s.
M on on itit o E G
p os os it io io n s en en so so r P I
Spec. Percent
Instrument
Leaks
Check
Sca
a n c al al cu cu la la t
t ra ra ve ve l. .
Actu Actual al Perc Percen en
Chec Chec D ra ra i
90
N F
if
optimu optimu
4 00- 5
Tak
Closed If RP
-100%
•M
Repair Repair issue issue causin causin
9. Exhaus
Visual
Chec Chec
fo cont contam amin inan ants ts
ve
proced procedur ur
s ca ca n t oo oo l w itit h t h
( 17 17 0 F )m )m in im im u
a t 3 ,8 ,8 0
@ 3
le
M ea ea su su r
On
i n p a rk rk ln eu eu lrlr al al .
(1 Spec.
c on on ne ne ct ct io io ns ns ,
0 R
• P o ni ni t
f ue ue l p re re ss ss ur ur e a t e ng ng in in e f ilil te te r h ou ou si si n
an
MA
t t
t at at 3
MG
R oa oa d T es es t
t es es t p or or t
an
Spec.
Instrument
C'
If fuel fuel pres pressu sure re fails fails low Ifpress Ifpressur ur
s e t h s ca ca n t oo oo l d ur ur in in g t hi hi s t es es t a r
h is is to to riri ca ca l f au au lt s
is abov abov
lectri ctri
Fu
e r
Spec_ Spec_ PSI
El ctri ctrica ca
Self Self-T -T st
n a
l p
Re tric tricti ti
kc
M ea ea su su r pi
p i
Spec.
Instrument
Cr
fue pressu pressure re regula regulator tor valve. valve.
Pr
re
a t o i f ilil l t ub ub e w it h 6 .0 .0 L C ra ra nk nk ca ca s
njector
If
Code Code
6" Hg,inspect bot
fue filters filters If filter filter
P PT PT .
Restrictio tio 7. Intake Restric
. F
Ifmor
l A
Measurement
8" H20MAX H20MAX
than than 8" H2O,refe refe to base base engi engine ne in Shop Shop Manual nual
l A un en in
I ns ns ta ta l c le a h os os e o n f ue ue l r et et ur ur n l in in e a t f u e c on on tr tr o m od od ul ul e
00
RP
T ak ak e o i s am am pl pl e f ro ro m t h
Refe Refe to shop shop manu manual al fo appr approv oved ed proc proced edur ure. e.
Check Check filter filter minder minder switch/in t ch/indic dicato ator. r.
R PM PM .
Magnehelic
areOK,check fue
regulator. If regulator ulator and filters filters areOK,replace areOK,replace fue pump.
a r r et et ri ri ev ev ed ed , g o t o a pp pp ro ro pr pr ia ia t
c ov ov er er .
at3,0
Spec.
(0-60" H'O)
If> 6" Hgrestr Hgrestric ictio tion, n, chec chec lines lines betw betwee ee pump pump an fuel fuel tank tank
P re re ss ss ur ur e T es es te te r
( 17 17 0 F ) m i ni ni mu mu m
b re re at at he he r t ub ub e o n l ef ef t v al al v
e as as ur ur e a t W O T w it h n o l o Instrument
I ho ho ua ua h 8 .
blade blade fo dama damage ge
3 03 03 -7 -7 58 58 , w itit h e ng ng in in e a t 7 0
B lo c
Measurement
" Hg Hg M
w ilil l c lili c i n s eq eq ue ue nc nc e
Measurement
2 2 P SI SI G M I
Iftest fails fails low inspect pect turb turb
lm
I f s e l t es es t c od od e
k.
Measurement
step10b.
Pump Pump Inle Inle
s e t h s ca ca n t oo oo l
Trou Troubl bl
e ng ng in in e
l or or l
spec spec chec chec fuel fuel retu return rn lines lines fo rest restri rict ctio ion. n.
If no restri restricti ction on is present, sent, replac replac
lOb. lOb.
Diagnostic
i nj nj ec ec to to r
t oo oo l
g ea ea r t o o bt bt ai ai n d es es irir e
c ur ur re re n f au au ltlt s
5. Retr Retrie ieve ve Co ti uous
li
turb turboc ocha harg rger er
o f d am am ag ag e o r l ea ea ks ks .
0 R w it h c a
s el el ec ec t a pp pp ro ro pr pr ia ia t
Parameter
Inje Inject ctor or
tube tubes/ s/co conn nnec ecti tion ons, s,
h os os e f o s ig ig n
RP
MGP
6. KOE
Measurement
ne
Diagnostic
O TC TC s r et et riri ev ev e
RP
ur
insp inspec ec inte interc rcoo oole le
tf
s e t h s ca ca n t oo oo l
67
in Har Start/ Start/No No Start sectio section. n. Tes 10c
Pr
Care Carefu full ll
Measurement
P um um p P r
ma
O TC TC s s e d ur ur in in g t hi hi s t es es t a r
RP
13. Bo
4 k a ( 4 P
Oa
KO
e ng ng in e t em em pe pe ra ra tu tu r
Spec.
Parameter
on oil, oil, corr correc ec leve level. l.
fault.
Re ul to
to n ex t s te te p
M on on itit o
th
default).
IPR
V is is ua ua llll y i ns ns pe pe c e xh xh au au s s ys ys te te m f o d am am ag ag e
a 17 17 0
(fue (fuel, l, cool coolan ant) t)
Visual
Pe fo
at
Pse
ur
Parameter
out of spec. spec. values values before before contin continuin uing. g.
If
Correc Correc GradeN GradeNisc iscosi osity. t y. Mile Miles/ s/ho hour ur
Pr
will
r ee- co co nn nn ec ec t s en en so so r a n g o t o 1 2b 2b .
Restric Restrictio tio
EPwit
lep
Rw hs
Travel
Oi
45 PSI) PSI)
le 90
Measurement
before before discon disconnec nectin tin
ns ta ta bl bl e is still still u ns
2b Inje Injectio ctio
Open
Check
in
RP
is unst unstab able le disc discon onne nect ct IC sens sensor or (ICP (ICP
fo
perfor performan mance ce
Ch
readin readin
t, th
i s r ec ec om om me me nd nd e
Method
67 a+
s b
s am am pl pl e f ro ro m f ue ue l c on on tr tr o m od od ul ul e h ou ou si si ng ng .
C et et an an e r at at in in g b et et we we e
w itit h s ca ca n t oo oo l
Spec.
ICP
If engi engine ne RP
Cl
ur
C (
(650 (650-8 -800 00 PS
Closed
S uf fi fi c
RP
Parameter
0 % ( 0. 0. 66- 1. 1. 2 V )
tool tool
Visual
(ICP (ICP Pr
T a lep a n
hose hose,a ,and nd mani manifo fold ld
E le ct ct ri ri ca ca l
ilit ilit
• C
f o d am am ag ag e
hose hose,i ,int nter erco cool oler er
F ue ue l O i C oo oo la la n
IDATE
T YP YP E O F S ER ER VI VI C
B. EG
r p
I ns ns pe pe c a l w irir e c on on ne ne ct ct io io n
NUMB NUMBER ER
I
IAMBIE IAMBIENT NT
Insp Inspecti ecti
e no no f
Insp Inspec ec MA
CHAS CHASSI SI
L N
TRANSMISSION
GV
Visua
.(
1863 1863 CLAI CLAI
IP&A CODE E S
• V
N AM AM E
l is is t i n t hi hi s b ox ox )
DEAL DEALER ER NAME NAME
V EH EH IC IC L
C US US TO TO ME ME R
-NOTEI F C O NC NC E I S F OU OU N S ER ER VI VI C R E U IR IR ED ED . I F T HI HI S C O R EC EC T TH C O D IT IT IO IO N I T I S N O N EC EC E S AR AR Y T O C OM OM P E T H E E M I ND ND E HE DIAGNO DIAGNOSTI STI PROCED PROCEDURE URE
fo
m i u te te .
O i P re re ss ss ur ur e S wi wi tc tc h p or or t a t i dl dl e
I ns ns pe pe c s am am pl pl e f o p re re se se nc nc e o f a i b ub ub bl bl es es . at WO
Method
w itit h m ag ag ne ne he he li c g au au ge ge . Check
Spec.
Instrument
If ai is pres presen en in retu return rn fuel fuel insp inspec ec fuel fuel syst system em fo leaks
fo
H'O
xcessi xcessive ve oil aeratio
KO
T hi hi s w ilil l t es es t t h
I CP CP , E G
KOER DTC
Hard Hard Star Start/ t/No No Star Star or Perfo Perform rman ance ce conc concer ern, n, this this form form must must be fille fille ou to th
an VG
p er er fo fo rm rm an an ce ce .
r o l em em s
L is t P ar ar t N am am e
w er er e f o n d a n
N um um be be r a n
wh
S er er i
r ep ep ai ai r
Nu be
er
o f p ar ar t
p er er f r me me d
re la ed
can be caused caused by deplea depleated ted oil additiv additives, es,
pick-up k-up tube tube leak leak fron fron cove cove seal seal leak leak or uppe uppe pa
Note Note If perf perfor orma manc nc Diag Diagno nost stic ic
poin poin of repa repair ir an retu return rned ed to rece receiv iv warra warrant nt
conc concer er
stil stil exis exists ts
sea/ sea/le leak ak
refe refe to Enha Enhanc nced ed Inje Inject ctor or
in this this sect sectio ion. n.
cred credit it an diag diagno nost stic ic tim fo th foll follow owin in
Fue Inject Injectors ors (9E527 (9E527), ), regula regulator tor-in -injec jectio tio contro contro pressu pressure( re(9C9 9C968) 68) pum assemb assembly ly hig press pressure ure oil (9A543 (9A543), ), turbo turbo charge charge assemb assembly/ ly/ped pedes estal tal (6K684 (6K684), ), fue pum (9350) (9350) Labo Labo oper operat atio ions ns liste liste more more than than once once ar cont contin inua uati tion on of th diac diacno nost stic ic proc proced edur ur an shou should ld be clai claime me only only once once W ha ha t
Check
Visual
Visual
Magnehelic/
Whentro Whentroub uble lesh shoo ooti ting ng
Method
Check
FICM(128 FICM(128599 599
parts parts
andPCM(EEC)(1 andPCM(EEC)(12A6 2A650 50
Engine Mounte
Components
SENSORS Reguator Sense
II!!:
ICP CRANK
SITION
OSITION RC~-NCD
£J I!!:
-A
"""!
ACTUATORS
®1iQ
KEYPW R
V / / / /
(Orientation;;; Lookin int terminals on connector P UR PL E t . B LU E G RE E
r e ( 5 V OL TS ) S IG NA L C IR CU )
D k B lu e
B LA C RE
i n ( 4 V OL TS )
D at a C om m n ic at io n
L in k
G RO UN D C IR CU I 1 2 V O T S tv Batt)
FUEL INJECTORS
-""~"-
.lri~'2n'''~!!3.I;!.~"l~~=~=======::; 1---..;1
#1
#3
#5
n C l P
:~::g~::
O pe n C oi l Ground
-+-~_-=--~--fnl]~~1
--------tJ
90
Module / /
it"
Swi!ch
eu
Vehicl
Mounted Components
B ac k U P L am p
rffi--s+ R el ay Co nl ro l
V PW R
H B K
91
Engine Moynted Components
v_
'GRVe
K'YPWR
PO
:,~,,___J -"C;;;;",
:X2~7=
-:.~~
(Orientation Looking int terminals on connector
= ':,4,: Qie'=
jnj (48 VOLTS) ref ( S Y O IS
NA
pk Bill 1AC
_'~2:
RC
pata Cooom"ojcatjoQ
:,~,:
ink
ClRClJJJ
G AO II N
IV
RaW
I NJ E
-,~,=
_...l:'~
OR
;~~=
Q!
-=,~
lL
-X2~1=
~X2~_S=
_,U;;~=
r;;'-;:;;;,-I-"~''"-Injector Pinoyt
1 - O pe n O pe n C lo s C lo s
92
C oi l C oi l C oi l C oi l
P ow e G ro un d P ow e G ro un d
NOTE: F o c l r it y
th prin al t hr e F IC M c o e ct or s ar
shown together as
~:~b:~: b lu e f o X I an blac fo '---_X_3,_-'
12WayOniOff
Engne Connecto
5RIlO Transmission WiringAssembly
93
C o nt in u ou s
O p er a ti o n
S el f
es
ey On En in
S el f
es
Ke
On
t) f f( K E O
n gi n
R un ni n ( KO ER ) Condition
Description
T ow /H au l
U gh t f ia sh e
A ss i n e
bu no
se P ro ba bl e
Fault Trigger/Comments I nt er na l t o
CM
G T A ct u t o
in
C ir c i t c he c
D i g no s
cicu
,
as oc
ed
wi
C au se s Am
ve
c he c
a
t i
- S
Ranqe/Performance
ri
rm
g re at e
th
K OE O MA
ri
is
50
r pm ,
e l T es t o r d ur i
c on ti n o u
v ol t o e l es s t h
,3
i a n os ti c
m on it or in g
it Bi se
K OE O
n -D em an d
m on it or in g
S el f
MA
o lt a
inVR
rc
o lt s
es
u ri n
i s g re at er h
o nt i u ou s
th
4,
en or
C M- MA F
ir it
o rt e
to
RE
i a n os ti c
o lt s
re th te
re
0,
v ol t
e fa ul t 1 0
/B
kp te
r es su r
x pe ct e lt
fo
( 1 . 6 P SI ) th
o rm a
fi
o pe ra ti o
ro
he
tr
rt
is re te
fa
P0112
ava r ob ab l volts
t e p er at ur e
Defaul
he
IA
v ol t g e
i s l es s t h
v ol t g e
i s r ea t
.1
77°F/25°C.
P0113
ava r ob ab l
t e p er at ur e
v ol ts , D ef au l
IA
th
,9
7 7 F /2 5° C
t em pe ra t r e ta
he
e x e ct e
f o n or m
p er at io n
re
he
CT
he
CT
lt O pe n i n c ir cu it , s ho r
t em pe r t ur e
e x e ct e
V Ol t g e i s r ea t
f o n or m
th
,7
p er at io n
o lt s
D ef a l t
8 00 F/ 8 0 C
t o p ow er ,
no
fast idle E ng in e O i T em pe ra tu r
a ul t
S en so r C ir cu i
i a e d s en so r
c ir c i t f au lt ,
CM
a s ti h an g
in
OT an
t em pe r t ur e
e x e ct e
1 2° F/ 10 0° C
(i ra
ff
M FD ES ) f o n or m
p er at io n
W HE N e a
f as t i dl e Op
OR t em pe r t ur e
x pe ct e
f o n or m
isgr
p er at io n
lt
he
cu
s ho r
o we r
OT
lt
fast idle &C rp
fo
or
th
e co nd s r P fo I nd ic at e
OT P0236
ee
c om m n de d
" on " f o
or
th
s ho r
t o p ow er ,s ti ck in g
r el ay .
e co nd .
C' t l w i MA
P0238
v ol t
i s l es s t ha n
v ol t
is re te
. 03 9
ir ui
h or t t o g ro un d o r o pe n
d ef e t i
o lt s
C' t ha n 4 .9 1
lt
as
OR
C yl i d e
# 2 l nl ec t
C ir cu i
ow
C yl i d e
# 2 I ni ec t
C ir cu i
ig
IC
e te ct e
P0267
pe
i ni ec t
ir it
I n "e ct o
c ir cu i
l ni e t o
ir ui
o pe n
d ef ec ti v
co
as Cylinder Cylinder
#4 #4
IC
d et e t e
h or t i n a n i ni ec t
i rc ui t t o a r u nd .
h or t t o r ou nd ,
d ef e t i
as 5 h
n o
c ir cu i
o pe n
d e e ct iv e
c oi l
as as
I n ie c to r c ir c ui t o o e n d e f ec t iv e c o il .
94
o il .
e ns or ,
o r o pe n c i c u
P oo r c on ne ct io n
R an ge /P er fo rm an c
( Ba n
d ef ec t v e
s en so r
e le ct r c a
nose
o r s in gl e s en so r
P0381 pe
P0402
C*
E xh au s
Ga
R ec ir cu la ti o
F lo w E xc es si v
or
e ng in e s pe e
/ Io ad .
e ng in e s pe e
/ Io ad .
EG
c ir cu i
ui
he
mp
ns on
Sensor bias
D et ec te d
P0403
a ct ua to r
th
S en so r c he ck .
D ia gn os ti c
c ir cu i
b ia s ro
a ss oc ia te d
rt to
te
P0404 P0405
E xh au s
OR
Ga
R ec ir c l at io n
e ns o
C ir c i t
ow
GR
Fuel Leve Sensor Circui
ir ui
s ho r
to gr un
In
o r p en , d ef ec ti v
s en so r
ri
."
driver checks fo open circuit, or shor circuit. E xh au s
P re ss ur e
S en so r
PSI absolute. P0471
C* d if fe re nc e
of
/-
P a ( 1. 5 P SI ) f ro m d es ir e
P0472
EP ci ui
v ol t g e P0473
is le
ho
t o g ro un d
or op n,
d e c tv e
s en so r
t ha n 0 .0 3 v ol t
C* OR v ol t g e i s g r a te r t ha n 4 . E xh au s
r es s r e
C on tr o
V al v
ig
o lt s
In ut n 30 s
Fa
C on tr o C ir cu i w t
P0562
C* OR
v - c
f no s
Lo
V ba t
o os e
o nn e
o ns / s i a nc e
cu
Vr
e ng in e
concerns.
C ru i
C on tr o
ES ME
S ia na l
K OE R s wi t
t es t c od e
K OE R s wi t
t es t c od e
tc A C
f c e t i f r ui s
o t p re se nt .
O pe n o r s ho r
e t if cruise no f c ifcr
i r u it , s wi t
in
f ai l r e
tc
A c
f ai lu r
o r f ai l
ll
e s e qu ip pe d
PC
te
t o a ct i a t
ru
n e
n v
w it h c ru is e c on tr o
Error e
P
R OM ) E rr o G en er at o
C on tr o
G en er at o
NC C lu tc h R el a C ru i
C ir cu i
L am p C on tr o
C on tr o
C ir cu i
C on tr o am
C ir cu i
o nt r
C ir c i t 1 f
:II :Il
P0672
C* OR
2 G
2 f
P0673
C* OR
3 G
g #3 f
P0674
C* OR
4 G
P0675
C*
P0676
C* OR
P0677
C* OR
P0678
C* OR
P0683
C* OR
p en /s ho rt e
i r u it , f au lt y g l
p l g , f ai l
GP
#4
g C
5 f 6 G
o #6 f
7 G C yl i d e
g #7 f
lo
lu
8 f
ir ui
ro
ti
ro
fa
rc
il
il
Circuit Circuit
Range/Performance
T ra ns mi s i o
C on tr o
S ys t
MI
e qu es t o a test. o a test.
OE W at e
ot
bl
t o o mp le t
i n F u e I nd ic at o
G en er at o
o nt r
OE
b or t
C ir cu i
C on d t io n I nd ic at e
NC,
n o m et .
ar in
F au lt y s en so r
f ai t i n c ir cu it .
B ra ke , C l t ch , P RN D pe
S ho r
( EO T
E TC .
i n c ir c i t
C ir c i t H ig h En in
P1184
o t w ar m e no ug h
l ea ki n
t h m os ta t
ir ui
f ai lu re .
Range
:J
7v
t O
Lo
f T t R
Exhaust G;;IS Rectronlatinn Flow
Out Of Sel Test
b at te r e s
o os e c on ne ct io ns /r es is ta nc e
o h h o FGRr.
outmr circuit chec
ermin
off test onI
FGR
c ir cu it , d ef ec t v e
reay
w p g m
Co trol circui onen shor to Vrp-f. Vhat. rtround rlp.fp.ctivp
95
coil.
P1703 P1705
Transmission P ar k/ Ne ut ra l In ul i en
Rang
Circui No Indicating
np
D ur in o S el f T es t n qi n
s pe e
Insufficent engine spee h ro tt le /P ed a
P os it io n
i nc re as e
u ri n
decrease
during self test
s el f t e t .
S en so r/ Sw it c
C ir cu i
P os it io n
S en so r/ Sw it c
C ir c i t L o
P os it io n
S en so r/ Sw it c
C ir c i t H ig h
P os it io n
S en so r/ Sw it c
C ir c i t
P os it io n
S en so r/ Sw it c
ir ui
S en so r/ Sw it c
C ir cu i
Range/Performance h ro tt le /P ed a Input P2123
h ro tt le /P ed a Input h ro tt le /P ed a Intermittent h ro tt le /P ed a
Ranqe/Performance P2127
OR
h ro tt le /P ed a
P os it io n
Lo
Input /S
rc
Input h ro tt le /P ed a
P os it io n
S en so r/ Sw it c
C ir cu i
S en so r/ Sw it c
ir ui
ow
rc
ig
Intermittent Ranqe/Performance h ro tt le /P ed a
P os it io n
Input Input T hr ot tl e/ P d a
P os it io n
e n o r/ Sw it c
C ir cu i
Intermittent P2138
l u e S
codes
Correlation / F
l u e S
Correlation l u e S
codes
Correlation
/S
re
te
values N o b o os t p re ss ur e i nc re as e w a s d et ec te d
te P s exhaus
n F
n f
C s
restriction, exhaus
n w
P s
leak
l s
t i
f 3 OR
Injector Contro Pressure Sensor Circui Lo
ro
rr
rep
ro
rr
IC
c ir cu i s ho r t o g ro un d o r o pe n d ef ec ti v
s en so r
0.04 volts. to
rt
fe
t ha n 4 .9 1 v ol ts . I nj ec to r C on tr o P re ss ur e T o
H ig h
f er r
IC
Se
is re
d ia gn os ti c m an ua l
rep
system.
3675psi/25mpa. I nj e t o
Co tr
P re ss ur e
oo Hi
I nj ec to r C on tr o P re ss ur e T o P2552
Lo
E ng in e E ng in e C ra nk in g
f er r N o s ta r
IC
te
signal ground Se
d ia gn os ti c m an ua l
IC
s ys te m
i s l es s t ha n 7 25 ps i/ 5m pa .
Se
d ia gn os ti c m an ua l
IC
s ys te m
C ir cu i
-Th
P2614
p en /s ho rt ,
Poor connection, Poor connection, l ni ec to r
C on tr o
P re ss ur e
R eq ul at o
C ir cu i
IP
circui
circui open defectiv
,b
failur
O pe n/ qr ou nd e
F IC M
sensor
PC
electrical noise. electrical noise. c ir cu it , s tu c
I PR , l oo s
c on ne ct io n
GLOSSARY Actuator signal.
signal to contro fuel injector
Analog continuously variable voltage. de er in
po en io eter styl peda position
AW
sensor th
indi at
do
ic
si nal, an
peed an
rota iona
po itio
he op ra or's
Fe tu
lo
engine
th
egulator
circui bein
measured
inpu conditioners
an
ou pu
rive s.
ref.
in temperature.
befo
th
it nter
he engine
housing. intake manifold
CAN trol modules.
in oil pressure.
th
la inta
ai system
he mi to
ee
exhaust).
GTCV
EVRT Se VG
yp
en or whic
ariabl
indica es en in
Geometry Turbocha ge
empe at re
Co tr
Valve.
Variable Geometry Turbocharger
Pump is uppl
or th
injectors.
97
GLOSSARY coolant.
color.
le
correspondin
le
pressu
oi
powere
module
ys em pressu e. in io
fi lo
in su pl
te cont ibutin
cylinder
or he injector
Impedance
1/
contributing
injector
ic
iv tion contro pressure
is
i nj e
PO
Pote tiom te
iv
ip io
in th
idle po ition.
ground.
energized.
during ea
ompres io
stro e.
GLOSSARY ::!I
ounted to
Thermistor it's resi tanc valu in elatio empera ur hange. Increasing temperatur result in decreasing resistance ecreasin te pe atur re ults in increasing re is ance Th in it is
:B return an
:II
ground
la capaci ance
hu
in in reasin
re ur
oltage
VBAT Batter voltage.
::II
:II
iz trolle
hydraulics.
turbin
housing.
::II :II
:II :8 :II
::fI
:II
VPWR Batter voltage.
le
ecre sing lo
INDEX f:
Actuators, 64
il la
EGR Cooler 37 Installation 74 Removal,74 Flow 37 Th ot le 38 Valve, 37-3 Removal,73 io
ir manage en sy te ea ures 31 flow 31-3
Electrical Components
49,6
Barrel,44
in ridges
72
in
II
io
Co ponent
Loca ions
9-13
Feat res,
Fu Coolin
system Features Flow 17-1 Fron
rankca
le
ov r, 24 owel lo ations Installation 77 Removal,76
entila ion, 74 Fuel filter eplacement
Crankshaft Heat reat en
discoloration,
15
Fuel injector 43 Coil,47 Features Fi
Removal,72
100
43
69
76
INDEX Injector
Fuel pr ssur
regula or 30
Installation 71 O-ring replacement, 70-7 Removal, 69-7 le ve 19 Installation 73 Re val, 73
Fuel supply sy te Features 27 Flow 27-2
Generati
ue anagem nt yste advantages 39 diagra 39 aj ompone ts 39
nten ifie
is on
(Injecti Valv Re ov l, 77 removal, 77 le emoval 73 yste Diagnostics, 68
Lubricatio
ressur Re ulator re oval 75
2,64
system Features 21 flow 21-2
iz
Oil
l, ig
ig cover, 42 emoval 76
aera ion, 23 Test 81 Carryover, 74 oole 24 housing, 24 Filter 25 Base 24-2 Re lace en Pan, 22 Pressure Re ulator
69
Re val, 77 Reservoir, 25-2 cree 25 Ov rview,
lo Injectio
80
no le 44
Plunger, 44
101
INDEX
Rela iv
om ressio
Ro ke
arrier 14 Removal,72
est, 81
Ro ke fulcru s, 72
ensors ov rvie
49
ly
Specifications
in
Turbocharger Removal,75 Removal,74
VG
(Variabl Geometry Turbocharger Co presso 34 Fl w, 35 Features 34 Turbine, 34
ia
102
Tu
