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Technical Bulletin

November 2010

Power Stroke 6.0L Diagnostics

Submitted by: Tony Salas

This bulletin is intended to aid technicians in the correct procedure of performing


diagnostics on a Power Stroke 6.0L.

ADS SERVICE INFORMATION COMMITTEE


Association of Diesel Specialists (ADS)
P.O. Box 26487 - Overland Park, Kansas 66225-6487 USA
Telephone: 913.345.0288 - Fax: 913.345.0299 - E-mail: tech@diesel.org

The Association of Diesel Specialists publishes this Technical Bulletin with the belief that all the
information set forth is true and accurate, but the Association disclaims any liability to the reader or third
persons for any injury or damages which result from any inaccuracies. The information is for use of ADS
members. Any distribution, reproduction or sale of this material or the contents hereof without the consent
of ADS is expressly prohibited.

Powerstroke6.0LDiagnostics PerformanceTrainingTechniquesLLC

www.performancetrainingtechniques.com AntonioTonySalas
ToolsNeeded:IDSScanTool,misctools,servicemanual 7022354504

PreliminaryChecks

1. Ensureyouhaveadequatefuelplusnocontamination
2. EngineOilLevel
3. CheckAirFilterANDFUELfilter(Primary(inHFCM)andSecondary(Ontopofenginein
front)Ensureoringsealsareroundandnotpinchedordistortedduetoovertightening
caps.
4. StateofChargeoftheBatteries(Checkseparately)Performloadtest
5. MeasureFuelPressure(45PSIMinimum)
6. Checkcoolantlevelandforcontamination(EGRCoolerleak)
7. Smoke:Whatdoescolorindicate?
a. Blackoverfueling
b. BlueOil
c. Whiteunburntfuel
d. WaterormoistureHeadgasketorEGRCoolerleak
8. InstallIDSScanTool
9. IfnostartconditioncheckthefollowingunderDataLoggerwhilecranking

ScanData Reading

a. ICP ICPDesired(Greaterthan510PSI)
b. ICPDesired ICPDesired(Greaterthan510PSI)
c. SYNC YES(Readingshouldstayfixed)
d. FICMSYNC YES(Readingshouldstayfixed)
e. FICMV BatteryVoltage
f. FICMMain Greaterthan46Vnolessthan44V
g. BAT BatteryVoltage

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10. Ifvehiclerunsorrunsrough,checkthefollowingunderDataLogger(engine)while
idling:

ScanData Reading

a. ICP ICPDesired(Greaterthan510PSI)
b. ICPDesired ICPDesired(Greaterthan510PSI)
c. SYNC YES(Readingshouldstayfixed)
d. FICMSYNC YES(Readingshouldstayfixed)
e. FICMV BatteryVoltage
f. FICMINJV Greaterthan46Vnolessthan44V
g. BAT BatteryChargingSystemVoltage
h. EGRVP 0%
i. EGRDC# 0%
j. APP 0%(readingtakenwithnoeffortonpedal)

Ifvehiclehasnoscantoolcommunicationandrunsroughorhardstart,disconnectthe
following:

a. DisconnecttheEBPSensor(thissensorifshortedwillcausenostart)
b. DisconnecttheGlowPlugController(ThisunitshortedwillcauseGlowPluglighton
andnotstart)orintermittentstalling.

(ReplaceEBPsensororGlowPlugControllerifenginerunsupondisconnecting
them)

PerformCylinderBalanceGraphTest

1. Checktheperformanceofeachcylinder.Ensurethatallcylindersareevenandare
contributingenginepower.
2. Performthecylinderkillportionofthegraphandcomparethesignaturesofeach
RPMdropofeachcylinder.Theyshouldbeeven.Thiscanbeseenbyobservingthe
signaturethegraphleavesforeachcylinderfiringevent.
3. Note:Ifyouhaveacylindergraphwhereacylinderisrisingitisoverfuelingduetoa
leakyinjectororanoilsaturatedintercooler.
4. Stictionisatermwherewehaveseeninjectorspoolvalvesstickintermittently.
Mostlyseenwithacoldengine.Symptomisyouwillobservebalancegraphshowing
amissonacylinderbutastheengineiswarmedupitwillthenfirecorrectly.This
canalsobearandommiss.Injectorwillrequirereplacement.

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PerformSelftestsandretrieveDTCs

1. PerformSelftests
a. KOEOSelfTestsInjector
b. KOERSelftests
2. RetrieveCMDContinuousMemoryCodes
3. Followdiagnosticchartsandchecktherearenoflashupdatesaddressingtheissue.

PerformtheAirBubbleTest

1. Airinthefuelsystemwillbecheckedbyfirstremovingthesecondaryfuelfilter
a. DisconnecttheFuelPumpattheHFCMinthechassis.
b. DisabletheFICMbydisconnectingtheFICMRelay
c. Ensurefuelispresentinsecondaryfuelfilterhousingwithfilterremoved.
d. Haveatechniciancranktheenginewhileyouanalyzethefuelinthefilter
housing.Iftherearebubbles,youhaveairinthesystem.
e. Iftherearebubbles,youneedtofindifleakisonPassengersideordriver
side.PerformtheBalloonorairtest.(Cause?Possibleinjectorovertightening
and/orcoppersealfailure.

BalloonTest

1. Removefuellinesfromthesecondaryfuelfiltertothecylinderheads(Twolines)
2. Uponremovingeachlineyoucaneitherfastenaballoonorahose.
3. Ifyoudecideonusingthehose,insertotherendofhosesintoaglassorwater.
4. DisablefuelpumpanddisconnectFICMRelay.Crankengine
5. Whilecrankingobserveballoonstoinflationorforbubblesifyouusedhose.
6. Ifonelineshasevidenceofairbyeitherinflatingtheballoonorblowingbubbles,
youhaveisolatedthebankthathasanairleak.Removethefourinjectorsonthat
banktofindleak.

(Note:IfairisnotpresentensurethereisnoairinthefuelsystemattheHFCM.This
islocatedinthechassisattheprimaryfilter.Hookupaclearlineonthereturnto
tankline.Ifthereisairpresent,youneedtocheckoringsealsontheprimaryfilter
cap.)




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ICPPressure

BEFOREYOUDIAGNOSEICPPRESSUREISSUES,ENSUREOILLEVEL.REMOVEIPRANDINSPECT
FORCONTAMINATION.Itisassumedafteryoumeasureandconfirmengineoilpressure.(You
canmeasureengineoilpressureattheengineoiltemperaturesensor.)

1. Contaminated?
a. HPOilpumpneedstobereplaced
b. Checkscreenatthebottomoftheoilreservoirwhichisunderneaththeoil
cooler.
c. Snubervalvesneedtobecheckedformetal.(locatedontheinletoftheoil
railona2003model.Locatedintheendofthestandpipesina2004andlater
model.)
2. CheckIPRDutycycle.Verifythatduringagivenenginespeed,dutycycleshouldnotbe
fluctuatingdramatically.
3. IfnoICPPressure,findleak.ON2004models,makesureyouperformaleaktest.Use
shopairthroughtheICPsensorholeandlistenforanairleak.(Noteitisnormaltohear
asmallhissofairthroughtheinjectors.Youwillbeabletodistinguishthedifference
betweenafailureleakandaninjectorhiss.
4. Certainengineswillhaveintermittentfishbitedriveabilityissue.Amissbutwitha
snapaswithafishbiteonaline.ICPsensorshouldbedisconnectedandtest.
5. Oringsarenowbecomingmoreapparenttofail,theycauseleaksontheoutletofthe
pump.Iforingisblownorripped,donotjustreplaceoring,replaceHPpumpandflat
fitting.
6. TherehavebeenleaksfoundonthesideoftheHPoilpump.Therearebearingsthat
werepressedintoseal.Thesehavebeenknowntopopout.Checkforleaksontheside
oftheHPoilpump.(03and04models)
7. 2003engineswiththeICPsensorinthebackunderneaththeturbochargernexttothe
IPRvalve,theyareknowntocauseoilleaks.Careintouchingsincetheyarebrittle.
8. Itisnormaltofindasmallhissingsoundfromtheinjectorsthroughtheirexhaustports.

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VGTTurbocharger

1. PerformKOERSelfTest.
2. Checkvisuallyturbovanesfordamageorbinding
3. Ensuretherearenointakesleaksintheplumbingandtheintercooler.
4. AsyouobserveinDatalogger,viewthefollowingPIDS:
a. VGT
b. RPM
c. MGPManifoldGaugePressure
d. EBPA
e. EBPG
5. AsyouselectVGT#,raiseenginespeedandobserveMGPasyoucommandtheVGT
opentoclosed.080%.
6. MGPshouldriseandEBPAaswell.
7. PerformtheVGTtestinthepowertraintestsinIDS.
8. Note,stickyVGTturboscanbemisleading,carbonorcoakingcanexistinthevanes
buttheVGTsolenoidandtherackandpinionwithintheVGTcanalsobesticky.
Inspectthesolenoidforstickingandensurethepinionisnotbinding.

EGRExhaustGasRecirculation

1. AnEGRvalvethatisstuckopenover60%cancauseanostartconditiondepending
ontheamountofcarbonbuildupintheintakemanifold.
2. PerformtheEGRTestinthePowertrainsectionofIDS.
3. UsingDataloggerselecttheEGRPIDSandMAFPIDifavailable.
4. CheckforEGRVPnotopenabove0%
5. UsingIDS,opentheEGR#andobserveEGRVP.
6. Fordriveabilityissues,testdrivevehicleandensurethedesiredEGRposition
matchestheactualposition(EGRVP)
7. Note2004modelsuseaEGRthrottleplate(EGRTP)ensurethatisnotstuckclosed.
8. Observecarbonbuildupinintakeandserviceifneeded.
9. CleanEGRandreseal.
10. WithEGRremovedandelectricallyconnected,checkEGRmovementbyopeningand
closingthevalveusingtheEGR#commandinIDSdatalogger.Checkforbindingand
stickingwithKEYonengineoff.
11. Note:BGOffersakittocleantheintakeandEGRforexcessivecarbonintheintake.
WehaveuseditsuccessfullytocleanintakesandEGR.

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CrankshaftandCamshaftPositionSensors(CKPandCMP)

1. YouhaveconfirmedCKPandCMPOperationwhenyouchecktheSYNCPIDandthe
FICMSYNCPID.
2. YoumayhaveanintermittentsituationwhereyouarelosingtheSYNCsignal.Thisis
observedwhenyoufindaYESmessagechangetoNOandbacktoYESandengine
stallingandperhapsanintermittentnostartcondition.
3. FirstifyouhaveanostartconditionandyouconfirmeditisaNOmessageSYNC
condition,checkwiringandconnectionsatthesensorsandthePCM(atleftfendernext
tobattery)
4. AccordingtoFordServiceInformationifyouhavealossofCKPsensor,yourICPPressure
willdefaultto14%andICPPressurewillbe300PSI(Youneed500PSI510PSItostart)
5. IfyouhavenoCKPreading,youwillmeasuretheresistanceofthesensor.Notalways
conclusivewithboththeCKPandCMPsensors.Thebestwaytocheckiswitha
labscope.Ifnotmanyrepairfacilitieshavebeenknowntohaveasparetoreplacewith
andtest.
6. RecentlywehavefoundnoSYNCduetonoCKPinput.Sensorhasbeencheckedand
circuitsfine.WehaveneededtouseaBorescopetocheckthroughtheCKPholefor
reluctorwheelpresence.Thiscancauseanintermittentnostartduetocrankshaftend
playandwear.
7. CareinremovingtheCMPsensoritcanbebrittle.Trynottotwistbutpullthesensor
whenremoving.

Thankstoallfacilitiesthathaveworkedwithmeinmakingthissheet(andthosetrucksI
haverepairedanddiagnosed!).Thereismoretofollow.Thisistypedtoaidyouinyour
diagnostics.Anyinputwouldbeappreciatedtohelpusandtechniciansinourlineof
work.

AntonioTonySalas
PerformanceTrainingTechniquesLLC
www.performancetrainingtechniques.com
7022354504

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