31EnginePerformance StudentGuide FCS21413REF...LESSONONE PREREQUISITEREVIEW PREREQUISITEREVIEW DIRECTIONS:Answerthefollowingquestions.Theanswerswillbereviewedinclass. PrimaryInputs

Engine PerformanceOperation and

Diagnosis

31 Engine Performance

Student Guide

FCS21413REFFCS21413REFFCS21413REFFCS21413REF

Course Code: 31S26T0

Version 8

IMPORTANT SAFETY NOTICE

NOTE: Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design withoutnotice and without incurring any obligation.

REPAIR TECHNIQUESAppropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as thepersonal safety of the individual doing the work. This manual provides general directions for performing service with tested,effective techniques. Following them will help assure reliability.

There are numerous variations in procedure, techniques, tools and parts for servicing vehicles, as well as in the skill of theindividual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as toeach. Accordingly, anyone who departs from the instructions provided in this manual must first establish that they compromiseneither their personal safety nor the vehicle integrity by their choice of methods, tools or parts.

NOTE, NOTICE, CAUTION AND WARNINGAs you read through this manual, you may come across a NOTE, NOTICE, CAUTION or WARNING. Each one is there for aspecific purpose. A NOTE calls attention to unique, additional or essential information related to the subject procedure. ANOTICE identifies a hazard that could damage the vehicle or property. A CAUTION identifies a hazard that could result inminor personal injury to yourself or others. AWARNING identifies a hazard that could result in severe personal injury or deathto yourself or others. Some generalWARNINGS that you should follow when you work on a vehicle are listed below.

• ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

• KEEP SOLVENTS AWAY FROM IGNITION SOURCES. SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE OREXPLODE IF NOT HANDLED CORRECTLY.

• USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE.

• MAKE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION, UNLESS OTHERWISE REQUIRED BYTHE PROCEDURE.

• SET THE PARKING BRAKE WHEN WORKING ON THE VEHICLE. IF YOU HAVE AN AUTOMATIC TRANSMISSION,SET IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION. IF YOU HAVE A MANUALTRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTEDOTHERWISE FOR A SPECIFIC OPERATION. PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKSAGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING.

• OPERATE THE ENGINE ONLY IN A WELLVENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDEPOISONING.

• KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING,ESPECIALLY THE DRIVE BELTS.

• TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR, EXHAUSTMANIFOLD, TAIL PIPE, THREEWAY CATALYTIC CONVERTER AND MUFFLER.

• DO NOT SMOKE WHILE WORKING ON A VEHICLE.

• TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE CLOTHINGBEFORE BEGINNING TO WORK ON A VEHICLE.

• WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF THECOOLING FAN BLADES!

TOOLSCommercially available hand tools and equipment are used along with Essential Special Service Tools (ESST) and Rotundaequipment. Power tools have become the acceptable industry standard and are used for disassembly only where applicable,unless specified otherwise in the Workshop Manual. The only exception to this policy is installing wheels in conjunctionwith the use of torque sticks, when possible.

Copyright © 2015 Ford Motor Company Produced and Coordinated byTechnical Service Support OperationsFord Customer Service Division

Version 8

ENGINE PERFORMANCE OPERATION AND DIAGNOSIS INTRODUCTION

INTRODUCTION

Engine Performance Operation and Diagnosis Intro 1 Version 8


ENGINE PERFORMANCE OPERATION AND DIAGNOSIS

Course DescriptionThis is a 4day course facilitated by an instructor. This course is designed to provide you a handson opportunityto apply knowledge learned in previous curriculum courses and improve your skills using various tools andequipment. Each day you will have multiple opportunities to practice selected skills. The results of your work arerecorded on worksheets.

WorksheetsAll activities and workstation worksheets are designed to complement the handson activities and are identifiedby number and by name. Students will complete the worksheets as they perform each Vehicle, Bench or CMTWorkstation.

Course RequirementsEach 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 andconcern 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 exerciseAND you must answer at least 80% of the written posttest questions correctly.

Course ObjectivesUpon 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.



Course Agenda

LESSON ONE:

• Prerequisite Review

• Workstation One: Secondary Ignition Operation and Testing

• Workstation Two: Evaporative Emission (EVAP) System Operation and Testing

• Workstation Three: Fuel System Operation and Testing

• Workstation Four: PC/ED and VCT

LESSON TWO:

• Workstation One: Fuel Control System Operation

• Workstation Two: Exhaust Gas Recirculation (EGR) System Operation

• Workstation Three: Dual Equal Phase Shifting (DEPS) and Twin Independent Variable Camshaft Timing(TiVCT) Systems Operation

• Workstation Four: Idle Air Systems Operation

LESSON THREE:

• Workstation One: Vehicle: MIL ON

• Workstation Two: MIL ON, Engine Runs Rough

• Workstation Three: Vehicle: MIL ON, Hesitation

• Workstation Four: MIL ON, Hesitation

LESSON FOUR:

• Workstation One: Vehicle: MIL ON

• Workstation Two: MIL ON

• Workstation Three: Vehicle: MIL ON

• Workstation Four: MIL ON



NOTES


LESSON ONE PREREQUISITE REVIEW

LESSON ONE

Engine Performance Operation and Diagnosis 1 1 Version 8


NOTES



PREREQUISITEREVIEW



PREREQUISITE REVIEW

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

Primary Inputs

1. Describe the function and type of signal (analog, digital etc...) of the primary inputs in the table below.

ComponentName/Acronym

Component Function Type of Signal

Ignition SwitchStart/Stop Button

Supplies power to the PCM and provides a start and runinput.

Digital DC

Temperature Sensors(ECT/CHT/EOT)

Two-wire thermistors that provide engine coolant, cylinderhead, engine/transmission oil and intake air temperatureinformation to the PCM.

Analog DC

CrankshaftPosition (CKP)

Variable reluctance (AC) or Hall Effect (DC) sensor thatsends an AC or DC signal to the PCM indicating crankshaftspeed/position. Used in misfire monitor calculations.

AC or DC

CamshaftPosition (CMP)

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

AC or DC

Throttle Position(TP)

Typically a potentiometer which sends an analog DC voltagesignal to the PCM which indicates the position of thethrottle plate.

Analog DC

AcceleratorPedal Position(APP)

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

Analog DC

Mass Air Flow(MAF)

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

Analog DC

Fuel LevelIndicator (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)/OutputShaft (OSS)

A signal that indicates vehicle speed. May be either hardwired or networked. May come from ABS module (wheelspeed sensors), VSS sensor, or OSS sensor. May be eitherVRS or hall effect.

Analog AC orDigital DC

Brake PedalPosition(BPP/BOO/BPA)

A signal that indicates the position of the brake pedal. Digital DC

Power Steering, A/CSwitches/Sensors

Monitors the power steering and A/C systems to determineif there is any additional load on the engine.

Analog DC orDigital DC



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 withina pack fires two spark plugs in different cylinders at thesame time.

Coil on Plug (COP) Provides high voltage to a single spark plug.

Knock Sensor A tuned accelerometer which converts engine vibration toan electrical signal. The PCM uses this signal to detectengine knock and retard ignition timing.

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

____________________________________________________________________________________________________________________________________________



Fuel Delivery System

1. Describe the function of the components in the fuel delivery system in the table below.


Fuel Pump Relay Controlled by the PCM. Sends power to the fuel pump orfuel pump driver module and injectors.

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 theexternal fuel lines.

Fuel Pump Module Contains the fuel pump which provides pressurized fuel tothe fuel rail, and the sender assembly which provides afuel level signal.

Fuel Pump Driver Module (FPDM) Varies the fuel pump duty cycle to control its speedin order to regulate fuel pressure on vehicles with anElectronic Returnless Fuel System (ERFS).

Fuel Rail Pressure Temperature(FRPT) Sensor

Provides a fuel rail pressure and temperature signal tothe PCM on vehicles with an Electronic Returnless FuelSystem (ERFS).

2. How is fuel pressure controlled in Electronic Returnless Fuel Systems (ERFS)?

____________________________________________________________________________________________________________________________________________

3. How is fuel pressure controlled in single speed Mechanical Returnless Fuel System (MRFS)?

____________________________________________________________________________________________________________________________________________

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

____________________________________________________________________________________________________________________________________________



Fuel Control System

1. Describe the function of the components in the fuel control system in the table below.


Fuel Injector Electrical solenoid that meters and atomizes fuel that isdelivered to the combustion chamber.

Heated Oxygen Sensor (HO2S) Sensor that measures the amount of oxygen in theexhaust.

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?

____________________________________________________________________________________________________________________________________________



Evaporative Emission (EVAP) System

1. Describe the function of the components in the EVAP system in the table below.


Rollover Vent Valve (RVV) FuelVapor Vent Valve (FVVV)

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

EVAP Canister Uses charcoal to collect and store fuel vapors to be burnedlater by the engine.

Canister Vent Valve/Solenoid (CVVor CVS)

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

EVAP Leak Detection ControlModule

Module used to seal the EVAP system from the atmosphereand apply vacuum to the system for EVAP leak checkmonitoring. Includes the vacuum pump. Used in HybridElectric Vehicle (HEV) and Plug-in Hybrid Electric (PHEV)vehicles.

Canister Purge Valve (CPV)/VaporManagement Valve (VMV)

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

Fuel Tank Pressure (FTP) A pressure sensor which sends an analog signal to the PCMindicating the amount of vapor pressure or vacuum in theEVAP system.

Natural Vacuum Leak Detection(NVLD) Module

Module that tests the EVAP system for leaks during bothKOER and key OFF conditions.

EVAP Check Valve/EVAP DualCheck Valve

EVAP Check Valve – Valve that prevents boost pressurefrom entering the EVAP system. EVAP Dual Check Valve –Valve that allows EVAP purge flow during boost conditions.

EVAP Ejector Valve that produces a vacuum in the purge line whichdraws vapors into the intake system, upstream of theturbocharger.



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?

____________________________________________________________________________________________________________________________________________



NOTES



LESSON ONE WORKSTATIONS

LESSON ONEWORKSTATIONS


LESSON ONE WORKSTATIONS

NOTES

LESSON ONE WORKSTATION ONE

WORKSTATION ONESecondary Ignition Operation and Testing

SUMMARY: In this vehicle workstation, you will investigate the operation of the secondary ignition system. Youwill determine the effects of faults on a CoilOnPlug (COP) system.

DIRECTIONS: Complete this VEHICLE workstation following the steps in this worksheet.

Part A: Ignition Workstation – Coil On Plug Ignition System Diagnosis

1. The vehicle has a misfire with DTC P0301 – Cylinder 1 Misfire Detected. The pinpoint test has been startedand the results are in the table below. Open the PCED and complete the remaining pinpoint test steps andfind the cause of the concern.

DIAGNOSTIC STEP RESULT

HD1 Check for DTCs P0301 Misfire Cylinder 1, go to HD2.

HD2 View PCM Freeze Frame Data, go to HD3.

HD3 Relative Compression Test, Pass, go to HD4.

HD4 Check for NonMisfire DTCs, go to HD5.

HD5 Check KOEO DTCs, go to HD6.

HD6 Check KOER DTCs, go to HD7.

HD7 Power Balance Test, Pass, go to HD8.

HD8 Check Ignition System, go to JB4.

JB4 Check VPWR to COP, go to JB5.

JB5 Misfire present, go to JB8.

JB8 Check for spark, none, go to JB10.

JB10 Component Inspection, go to JB11.

JB11 Check COP secondary resistance, found spring missing.



• Using your knowledge of secondary ignition systems, answer the following questions.

2. How are spark duration and peak kV related?

____________________________________________________________________________________________________________________________________________

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

4. What type of fault might cause high peak kV?

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

6. What happens when KAM is reset?

Part B: Ignition Workstation – COP Ignition System – IDS Recordings

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. Performthe 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 3, 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 thesuspect cylinder’s coil. The blue clip was placed on the coil from a good cylinder. Perform the following stepsto view the results of this test.

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



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

• Draw a copy of the recording on the IDS screen.

2. What is the average spark duration of the two cylinders? DUR1 1.2 ms DUR2 1.6 ms

3. What is the average firing voltage of the two cylinders? PKV1 15 KkV PKV2 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 GeneralInformation 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.



NOTES


LESSON ONE WORKSTATION TWO

WORKSTATION TWOEvaporative Emission (EVAP) System Operation and Testing

SUMMARY: In this activity you will learn how to use the IDS and a smoke machine to test the evaporativesystem for leaks.

DIRECTIONS: Complete Workstation 2 at the BENCH workstation, following the steps in this worksheet.

Part A: Normal EVAP System• Open a new IDS session.

• View the scan tool recording and answer the following questions.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Ranger 4.0L EVAP)

• Access the recording. (“Toolbox” > “Datalogger” > “Playback Viewer”)

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

1. During the recording, was the canister vent solenoid open or closed? Open

2. Explain what is happening to the canister purge valve (EVMV) during the recording.

____________________________________________________________________________________________________________________________________________

3. Use the “Information” button to find the description of the PID EVAPSOAK. Write the definition in the blankbelow.

____________________________________________________________________________________________________________________________________________

4. Did the FTP voltage change significantly during this recording?

Yes No

5. What do the O2 sensors indicate between –4 and +6 seconds?

____________________________________________________________________________________________________________________________________________



• View Recording 2 and answer the following questions. Play the recording from beginning to end. (To switchbetween recordings, use the forward and back buttons below the menu button.)

6. When did the canister vent solenoid (EVAPCV) first close?

____________________________________________________________________________________________________________________________________________

7. Why does the FTP voltage decrease during this recording?

8. What happened in the recording to the following PIDs between –20 seconds and the trigger point (0 seconds)?

PID Action

EVMV Starts closed, opens fully, then closes again.FTP Starts at about 3V, then goes to 0V after the canister purge valve is fully open.O2S11andO2S21

Goes rich for several seconds when the canister purge valve is fully open, thengoes lean again when the valve is closed.

EVAPCV Closed

9. Explain what happened just after 10 seconds.

____________________________________________________________________________________________________________________________________________

Part B: EVAP System with Large Leak (> 0.040”)•

Leak size (diameter in inches) Definition Associated DTCs

Gross leak – much larger than0.040

Unable to pull a vacuum on thetank

P0455

Small leak – <0.040 Significant vacuum bleed up oncethe vacuum is pulled on the tank

P0442

Very small leak – < 0.020 Vacuum bleed up once the vacuumis pulled on the tank

P0456

Fuel cap loose/off or caplesssystem damaged

Unable to pull a vacuum shortlyafter customer has refueled

P0457



View the scan tool recording and answer the following questions.

• Access the recording (Load Saved Recording button).

• Select playback display (Recordings Group EVAP FAULT, Recording 1). Play the recording from beginningto end.

1. This is a recording in which the canister vent valve (EVAPCV) was closed and the canister purge valve (EVMV)was opened between 10 seconds and the trigger point (0). What should happen to the fuel tank pressure(FTP) under these conditions on a normal system?

____________________________________________________________________________________________________________________________________________

2. Does this recording indicate a fault? If yes, explain.

____________________________________________________________________________________________________________________________________________

Part C: Diagnosing EVAP Concerns Using the IDS – CMT• The PCM sets different DTCs depending on the size of an EVAP leak. Prior to diagnosing a concern, you must

verify a leak is present. This can be done using the IDS EVAP test or the smoke machine.

• Click on L1WS2 CMT and perform the simulated IDS EVAP test. Select the IDS EVAP Test to perform asimulated leak test. (“Toolbox”>”Powertrain”>”Fuel”>”EVAP Test”)

1. According to the EVAP test instructions, this IDS EVAP test may be used to diagnose very small leaks (0.020”).

True False

2. What should you do if the engine shuts off while performing this test on a hybrid?

____________________________________________________________________________________________________________________________________________

3. To prevent inaccurate test results, a cold soak should be completed. Why is this cold soak necessary?

____________________________________________________________________________________________________________________________________________

4. What do the results of this part of the test indicate?

____________________________________________________________________________________________________________________________________________



5. What do the results of this part of the test indicate?

____________________________________________________________________________________________________________________________________________

6. What might cause the vacuum to bleed up slowly during the test?

____________________________________________________________________________________________________________________________________________

Part D: Diagnosing EVAP Concerns with the Smoke Machine• To verify small leaks in the EVAP system, the smoke machine can be used.

• In this activity, you will use the smoke machine and the Evaporative Emission System Training Aid to diagnoseDTC P0456 (very small leak 0.020”) on a 2011 Edge.

1. Prior to using the smoke machine, what solenoid must be energized with the IDS?

____________________________________________________________________________________________________________________________________________

• Assume that the valve from the question above has been energized.

• Use the smoke machine instructions or the PCED (Pinpoint Text HX for a 2011 Edge) and perform Phase 1 ofthe EVAP test procedure on the Evaporative Emission System Training Aid.

2. Based on the DTC (P0456 – very small leak), which orifice should be used to calibrate the smoke machine?

____________________________________________________________________________________________________________________________________________

3. When should the reading be taken from the smoke machine?

____________________________________________________________________________________________________________________________________________

4. After completion of the test, which way would the ball move if a leak is present?

____________________________________________________________________________________________________________________________________________

5. What do the results of the test indicate?

____________________________________________________________________________________________________________________________________________


LESSON ONE WORKSTATION THREE

WORKSTATION THREEFuel System Operation and Testing

SUMMARY: This activity demonstrates the relationship between EVAP and fuel delivery to the combustionchamber.

DIRECTIONS: Complete Workstation Three at the VEHICLE workstation following the steps in this worksheet.

Part A: Fuel System Recording• Start vehicle and allow it to idle until the engine reaches operating temperature.

• Use the IDS to start a new session.

• If the IDS detects a previous session, click the tick/check button, then “none of the above” at the bottom of thesessions list. Click the tick/check button to continue with the new session.

• Access Toolbox in the scan tool. (“Datalogger” > “Powertrain” > “Engine”)

• Clear the PID list, then select the following PIDs:

ECT Engine Coolant Temperature

EQRAT11_DSD Commanded Equivalence Ratio (Air to Fuel Mixture) Bank 1

EQ_RAT11 (Both PIDs) Equivalence Ratio (Lambda) (Bank 1, Sensor 1)

EVAPCP#(PER) Evaporative Emission Canister Purge Valve Duty Cycle

FLP Low Side Fuel Pressure

FLP_DSD Low Side Fuel Pressure Desired

FRP Fuel Rail Pressure

FRP_DSD Fuel Rail Pressure Desired

FUELSYS Fuel System Status (Open/Closed Loop)

LOAD Engine Load

LONGFT1 Long Term Fuel Trim 1

O2S11_CUR Exhaust Gas Oxygen Sensor Current Bank 1 Sensor 1

O2S12(VOLT) Heated Exhaust Gas Oxygen Sensor (Bank 1, Sensor 2)

SHRTFT1 Short Term Fuel Trim 1

• Display the PID values.

• Press the “Recording Times” button. Set the Duration to “30s” and the Pre/Post Trigger at “3s / 27s”.

• Prepare to use Output State Control to change the EVAPCP# PID to open and close the Canister Purge Valve.

• Press the “Capture” button.

• Increase the EVAPCP# PID to 80–90% (press “+” as necessary). Wait 510 seconds and decrease the EVAPCP#to 0% (press “–” as necessary).

• When recording is finished, shut off the engine.

• Select “Playback Viewer” to view the recordings you made.

• Rescale the following PIDs for detailed viewing: EQRAT11_DSD, EQ_RAT11, O2S11_CUR and SHRTFT1.Call the instructor to the workstation if you require assistance.



• Play the entire recording and answer the following questions.

1. Which component does the EVAPCP# PID control?

____________________________________________________________________________________________________________________________________________

2. What effect does opening the Canister Purge Valve have on the system (specifically SHRTFT and UEGOs)?

____________________________________________________________________________________________________________________________________________

3. What effect does closing the Canister Purge Valve have on the system (specifically SHRTFT and UEGOs)?

____________________________________________________________________________________________________________________________________________

4. Describe how the EQ_RAT11 and O2S11_CUR PIDs react during this recording.

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

5. What else would reset KAM?

A. Turning off the ignition for a minimum of 5 minutes.

B. Disconnecting the battery for a minimum of 5 minutes.

C. Clearing DTCs

D. Turning the key on and off three times in 10 seconds

Part B: Fuel System Tests

Perform the scan tool fuel system tests: (“Toolbox” > “Powertrain” > “Fuel” > “Fuel System Test”)

• Perform the Low Pressure Test.

1. Does this vehicle pass the Low Pressure Test?

Yes No



2. What would cause low fuel pressure to leak down?

3. When the Low Pressure Test is complete, click on the Engine Running Fuel Pressure Test icon (ignition keys) atthe bottom of the IDS screen. Record the low and high pressure fuel readings.

____________________________________________________________________________________________________________________________________________

• Next, click on the Reference icon (ABCD books) at the bottom of the IDS screen. Use this icon when youwant to know how to interpret test results.

• Exit the Low Pressure Test and perform the High Pressure Test (“Toolbox” > “Powertrain” > “Fuel” > “FuelSystem Test”) .

4. Does this vehicle pass the High Pressure Test?

Yes No

5. What is another name for the High Pressure Fuel Test?

____________________________________________________________________________________________________________________________________________

6. Based on the tests you performed, could you rule out the fuel delivery system as a possible cause if this vehiclehad a ”lack of power under acceleration” concern? If no, what additional tests should be performed?

____________________________________________________________________________________________________________________________________________



NOTES


LESSON ONE WORKSTATION FOUR

WORKSTATION FOURPC/ED and VCT

SUMMARY: In this bench activity you will use the PC/ED to diagnose a concern, and you will learn the operationof VCT systems.

DIRECTIONS: Complete Workstation Four at the BENCH workstation following the steps in this worksheet.

Part A: PC/ED• Refer to the 2008 Focus (2.0L,4V) PC/ED manual to complete this worksheet.

1. Refer to the Evaporative Emission (EVAP) Leak Check Monitor portion of Section 1: Description and Operationof the PC/ED. When is the EONV test performed?

____________________________________________________________________________________________________________________________________________

2. As the fuel tank temperature increases, the pressure in the tank increases and as the temperature decreases avacuum develops.

True False

3. What can you find in Section 2 of the PC/ED?

A. Vehicle Emissions Control Information (VECI)

B. Quick Test Description

C. DTC Index

D. Reference Value Symptom Chart

4. Refer to the list of PIDs in Section 2 of the PC/ED. What is the definition of the PID EVAP_EVAL?

____________________________________________________________________________________________________________________________________________

5. Refer to Freeze Frame Data in Section 2 of the PC/ED. When is freeze frame data stored?

____________________________________________________________________________________________________________________________________________

6. Refer to Section 3 of the PC/ED. What should you do if you cannot communicate with the PCM during theQuick Test?

____________________________________________________________________________________________________________________________________________



7. Where in the PC/ED would you find possible causes for DTC P0455?

____________________________________________________________________________________________________________________________________________

8. According to Section 6, which of the PCM’s three connectors is for the transmission?

____________________________________________________________________________________________________________________________________________

9. Using the Reference Values in the PC/ED, write the values in the appropriate spaces for a 2008 Focus with a2.0L 4V engine.

Sensors/Inputs

PCMPin/PID only

KOEO(Volt/PSI)

Hot Idle(Volt/PSI)

48 KM/H (30MPH)

89 KM/H (55MPH)

Units Measured/PID

FTP B65 2.6/0 2.6/0 2.6/0 2.6/0 DCV/PSIIAT B47 1.78/120.2

(K)1.99/111.2(K)

2.53/93.2(K)

2.66/87.8(K)

DCV/DEG F

10. What does the symbol (K) stand for?

____________________________________________________________________________________________________________________________________________



Part B: VCT

1. What is VCT?

____________________________________________________________________________________________________________________________________________

2. Label the VCT components in the graphic below

A. VCT SolenoidB. Cam PhaserC. CMPD. PCME. EOTF. CKPG. TPS/APPSH. ECT/CHTI. MAFJ. IAT



3. Refer to Section 1 of the PC/ED. List the 4 VCT systems along with a brief description.


LESSON ONE WRITTEN ACTIVITY

LESSON ONEWRITTEN ACTIVITY



NOTES




Exhaust Systems

1. Label the oxygen sensors on the diagram below with their position numbers

2. What test would you perform if you expected that the exhaust system was restricted?

____________________________________________________________________________________________________________________________________________

3. What is the catalyst delta temperature used to diagnose? What are the pass/fail criteria for the test? See PCEDPinpoint Test EM.

____________________________________________________________________________________________________________________________________________



IAC and ETC

1. Describe the function of the components in the IAC system in the table below.


Idle Air Control (IAC) valve Controls the engine idle speed and provides a dashpotfunction.

Throttle body and throttle plate Meters air to the engine.

Throttle Position (TP) sensor Measures the position of the throttle plate.

2. Describe the operation of the IAC intake air control system.

____________________________________________________________________________________________________________________________________________

3. Describe the function of the components in the ETC system in the table below.


Electronic Throttle Control (ETC)motor

Used by the PCM to move the throttle plate.

Throttle body and throttle plate Meters air to the engine.

Throttle Position sensors (TP1 andTP2)

Measure the position of the throttle plate.

4. Describe the operation of the ETC intake air control system.

____________________________________________________________________________________________________________________________________________



Intake Air Subystems (IMRC, IMTV, Swirl/Whirl Plate)

1. In the table below, fill in the subsystem name (IMRC, IMTV, or Swirl/Whirl plate) that matches the description.

Subsystem Name Subsystem Description

Swirl plate Has a butterfly valve for each cylinder that is partially open. Closing the valves resultsin high flow speeds and turbulence in the cylinders, which increases combustionefficiency.

IMTV Amanifold tuning device that affects the air flow volume of the manifold by connectingmultiple plenums or inlets within the manifold system. The control valve is located inthe center of the intake manifold away from the intake valve or cylinder head.

IMRC A charge motion device that supplies additional airflow at higher RPMs. Has bothlong and short runners with a control valve that is located close to the intake valve inthe cylinder head.

• Intake Manifold Tuning Valve (IMTV).

• Intake Manifold Runner Control (IMRC).

• The swirl plate is described in the 2003 and 2004 PCED. In the newer PCEDs, the swirl plate is considereda form of IMRC.

• IMRC was used on long runner/short runner intake and swirl is a single runner that is partially blocked atlower RPMs.

• The IMRC is also known as the Charge Motion Control Valve (CMCV).

Secondary Air (AIR) System

1. Describe the function of the components in the secondary air system in the table below.


Bypass solenoid Applies a vacuum to the AIR diverter valve(s) causing it toopen.

Air pump Draws dry filtered air from the intake air systemdownstream of the MAF/IAT sensor and delivers it to theexhaust manifold.

Diverter valve Used with the air pump to provide on/off control of the flowof air to the exhaust.

2. Describe the purpose of the secondary air system.



Exhaust Gas Recirculation (EGR)

1. Describe the function of the components in the DPFE EGR system.


EGR valve Valve used to increase or decrease the flow of EGR. Vacuumor electric actuated.

EVR Provides vacuum to the EGR valve.

DPFE sensor Measures EGR flow.

2. Describe the operation of the DPFE EGR system.

____________________________________________________________________________________________________________________________________________

Positive Crankcase Ventilation (PCV) System

1. Describe the operation of the PCV system.

____________________________________________________________________________________________________________________________________________


LESSON TWO

LESSON TWO


LESSON TWO

NOTES



LESSON TWO WORKSTATIONS

LESSON TWOWORKSTATIONS


LESSON TWO WORKSTATIONS

NOTES

LESSON TWO WORKSTATION ONE

WORKSTATION ONEFuel Control System Operation

SUMMARY: This activity will demonstrate the effects of vacuum leaks and how they affect engine performance.

DIRECTIONS: Complete this workstation at the VEHICLE workstation following the steps in this worksheet.

Part A: Large Leak At the Positive Crankcase Ventilation (PCV) Valve• Use the IDS to start a new session.




CHT Cylinder head temperature

EQRAT_DSD11 Air fuel ratio desired bank 1

EQRAT_DSD21 Air fuel ratio desired bank 2

EQ_RAT11 (Num/Ratio) Air/Fuel ratio bank 1 (Above 1.0= lean, below 1.0=rich)

EQ_RAT21 (Num/Ratio) Air/Fuel ratio bank 2 (Above 1.0= lean, below 1.0=rich)

ETC_DSD Desired throttle angle

ETC_ACT Actual throttle angle

FUELSYS Fuel system mode

FF_INF Inferred Flex Fuel

FF_LRND Flex Fuel Learned

LOAD Engine load

LONGFT1 Long term fuel trim, Bank 1

LONGFT2 Long term fuel trim, Bank 2

MAP Manifold absolute pressure

O2S12 Rear O2 sensor signal, Bank 1

O2S22 Rear O2 sensor signal, Bank 2

O2S11_CUR Exhaust gas oxygen sensor current bank 1 sensor 1

O2S21_CUR Exhaust gas oxygen sensor current bank 2sensor 1

RPM# Engine speed

SHRTFT1 Short term fuel trim, Bank 1

SHRTFT2 Short term fuel trim, Bank 2

• Display the PID values. Press the “Recording Times” button.

• Set the Duration to “30s” and Pre/Post Trigger to “6/24s”.

• Start the engine and allow it to idle until it reaches normal operating temperature.

• Press the “Capture” button to make a recording of normal vehicle operation.



• Disconnect the PCV tube from the PCV valve to create a large air leak and quickly press the “Capture” button.(PCV tube is located on the right front side of the engine).

• When the recording is finished, connect the PCV tube.

• Allow the engine to idle for 30 seconds.

• Select “Playback Viewer” to view the recordings you made. Play the recordings from beginning to end. Toswitch between recordings, use the forward and back buttons below the menu button.

• Change the display ranges of the following PIDs for better viewing. If needed, call the instructor to theworkstation for assistance.

• ETC_ACT

• LOAD

• MAP

• O2S11_CUR

• O2S21_CUR

• SHRTFT1

• SHRTFT2

• RPM

1. What did the upstream UEGO sensors and their respective desired PIDs indicate when the large vacuumleak was first introduced.

2. Was the system compensating for the vacuum leak? If so, how?

3. What significant changes (if any) occurred when the large vacuum leak was introduced to the system?

4. Describe any change in the LOAD PID.

____________________________________________________________________________________________________________________________________________

5. What would happen to long term and short term fuel trims if this condition was not fixed?

____________________________________________________________________________________________________________________________________________

• Turn the engine, OFF. Then, turn the key ON.



• Leave the Datalogger session open and reset the Keep Alive Memory (KAM) ( “Toolbox” > “Powertrain” >“Reset KAM” ).


• Display the PID values. Start the vehicle and allow to reach operating temperature.

Part B: Small Leak At the Brake Booster• Remove the vacuum line from the brake booster and quickly press the “Capture” button.

• When the recording is finished, reinstall the vacuum line to the brake booster.

• Allow the engine to idle for 60–120 seconds. Shut OFF engine.

• Select “Playback Viewer” to view the recordings you made. To switch between recordings, use the forwardand back buttons below the menu button.

• Change the display ranges of the following PIDs for better viewing. If needed, call the instructor to theworkstation for assistance.

• ETC_ACT

• LOAD

• MAP

• O2S11_CUR

• O2S21_CUR

• SHRTFT1

• SHRTFT2

• RPM

1. What significant changes (if any) occurred when a small vacuum leak (brake booster hose) was introducedinto the system?

____________________________________________________________________________________________________________________________________________

2. Describe any changes in the FUEL_SYS PID.

____________________________________________________________________________________________________________________________________________

3. Describe the difference in RPM between this recording (Small leak) and the previous recording (Large leak).

____________________________________________________________________________________________________________________________________________

4. What does the FF_LRND PID read? No



5. What is the FF_INF PIDs main function?

____________________________________________________________________________________________________________________________________________

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

• Start the engine and idle for 60–120 seconds. Shut OFF engine. Delete the IDS session for the next group inthe rotation.

6. What would happen if a repair is made and KAM was not reset?

____________________________________________________________________________________________________________________________________________

Part C: Affects of Faults on Fuel Control• Use the “Adaptive Fuel Diagnostic Trouble Code (DTC) Diagnostic Techniques” portion of Section 2:

Diagnostic Methods in the PC/ED to answer the following questions.

1. What type of concerns might cause an oxygen sensor(s) to indicate lean only at idle?

____________________________________________________________________________________________________________________________________________

2. What type of concerns might cause an oxygen sensor(s) to indicate rich?

3. What type of concerns might cause an oxygen sensor(s) to indicate lean under load?

____________________________________________________________________________________________________________________________________________

4. If a fuel system concern is only on one bank, what might that rule out?


LESSON TWO WORKSTATION TWO

WORKSTATION TWOExhaust Gas Recirculation (EGR) System Operation

SUMMARY: In this activity, you will learn about Exhaust Gas Recirculation (EGR) operation and the PIDs thatcan be used to diagnose EGR concerns.

DIRECTIONS: Complete Workstation Two at the CMT workstation, following the steps in this worksheet.

• View the scan tool recording of an EGR operation.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”> 8X637229 Grand Marquis 4.6L L)


• Select playback display (Recording Group L2 EGR OP, Recording 1). Play the recording from beginningto end.

1. What does the DPFEGR PID indicate while the vehicle is at idle?

____________________________________________________________________________________________________________________________________________

2. What does the EGRVR# PID indicate while the vehicle is at idle?

____________________________________________________________________________________________________________________________________________

3. Play the recording, stopping at each EGRVR# Increment listed in the table below. Record the missing values.

EGRVR#Increments

ETC_ACT MAP PSI MAP V DPFEGR MAP_GAUGE

0% 1.50 4.49 1.20 .59 20.6710% 1.50 4.49 1.20 .59 20.6720% 1.50 4.49 1.20 .59 20.6730% 2.03 5.80 1.64 .77 18.0140% 2.12 7.50 2.12 1.35 15.0050% 2.56 8.50 2.40 1.98 12.4060% 2.56 8.70 2.60 2.60 12.1070% 2.68 8.70 2.70 2.83 12.1080% 2.62 4.78 2.70 2.90 20.0090% 2.62 4.70 2.70 2.90 20.00100% 2.62 4.70 2.70 2.90 20.00

4. What was the EGRVR# value when the DPFE single first changed? 30%



5. What was the DPFEGR value when the EGRVR# was at 100%? Greater than 2.7V

• View the scan tool recording of vacuum applied to downstream connection of DPFE sensor.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”> 8X637229 Grand Marquis 4.6L)


• Select playback display (Recording Group L2 DPFE, Recording 2). Play the recording from beginningto end.

• One way to test a DPFE sensor is to apply vacuum to the downstream port while monitoring the DPFEPID. This recording shows the results of the test.

6. Play the recording and fill in the missing values.

DPFEGR PID

No vacuum applies (5 second mark) Approximately .50 to .90 VVacuum applied (10 second mark) Approximately 4.8 V3 Seconds after releasing vacuum (18 second mark) Approximately .50 to .90 V

• The DPFEGR PID voltage must be between 0.25 and 1.3 volts with the key ON and no vacuum applied.

• The DPFEGR PID voltage must increase to greater than 4 volts with the vacuum applied.

• The DPFEGR PID must drop to less than 1.5 volts in less than 3 seconds when the vacuum is released.

7. What do the results of the DPFE test indicate?

____________________________________________________________________________________________________________________________________________

• View the scan tool recording of the electrical connector disconnected from the ESM.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”> 8X637229 Grand Marquis 4.6L)


• Select playback display (Recording Group L2 ESM Recording 1). Play the recording from beginning to end.

8. Document any PIDs and values that indicate a concern after the ESM was disconnected.

____________________________________________________________________________________________________________________________________________

• View the Log Data to answer the following questions. Click on the Vehicle Tab (top of IDS screen), then clickthe Log Data Tab (Paper scroll at bottom of IDS screen).



9. What KOEO ODDTC are present?

____________________________________________________________________________________________________________________________________________

10. What CMDTCs are present?

____________________________________________________________________________________________________________________________________________

11. What code set the freeze frame data and why?

____________________________________________________________________________________________________________________________________________

12. What code(s) were set during the KOER self test?

____________________________________________________________________________________________________________________________________________

13. Why should you clear codes and rerun self test after performing tests/repairs on a vehicle?

____________________________________________________________________________________________________________________________________________

14. Explain why a DTC may not clear with the scan tool.

____________________________________________________________________________________________________________________________________________



NOTES


LESSON TWO WORKSTATION THREE

WORKSTATION THREEDual Equal Phase Shifting (DEPS) and Twin Independent Variable Camshaft Timing

(TiVCT) Systems Operation

SUMMARY: This activity will demonstrate how to use the scan tool to learn how to interpret DEPS and TiVCTPID values.

DIRECTIONS: Complete this workstation at the VEHICLE workstation following the steps in this worksheet.

Part A: DEPS VCT System• View the scan tool recording of a DEPS VCT system with a concern present and answer the following questions.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Expedition VCT)


• Select playback display (Recording Group VCT, Recording 3)

1. What is DEPS VCT and what does it do?

____________________________________________________________________________________________________________________________________________

2. Which PID readings best indicate the fault?

____________________________________________________________________________________________________________________________________________

3. Which bank would you suspect has the concern? Explain why.

____________________________________________________________________________________________________________________________________________

4. Could this fault be caused by an open circuit in the VCT bank 1 solenoid circuit? Explain why or why not.

____________________________________________________________________________________________________________________________________________

5. Could this be an electrical fault? If yes, what type of fault could it be?

____________________________________________________________________________________________________________________________________________

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



• Below is a list of the DTCs that are associated with the VCT system.

DTC Description

P0010 Intake Camshaft Position Actuator Circuit/Open (Bank 1)

P0011 Intake Camshaft Position Timing – OverAdvanced (Bank 1)

P0012 Intake Camshaft Position Timing – OverRetarded (Bank 1)

P0016 Crankshaft Position – Camshaft Position Correlation – Bank 1 Sensor A

P052A Intake Camshaft Position Timing – OverAdvanced (Bank 1)

P052B Cold Start Camshaft Position Timing OverRetarded (Bank 1)

• For a 2008 Expedition, view PC/ED Section 4: Powertrain DTC Charts and Descriptions. Use theinformation there to fill in the table below with all of the DTCs above that can be set by each concern.

Possible Cause of Concern List all DTCs Set By the Concern

Open or short in the VCT circuit P0010, P0011, P0012, P0016Open VPWR circuit P0010, P0011, P0012, P0016Open or short in the VCT solenoid valve P0010, P0011Camshaft timing incorrectly set P0011, P0012, P0016, P052A, P052BContinuous oil flow to the VCT piston chamber P0011, P0012, P0016, P052A, P052BVCT solenoid valve stuck open P0011, P0012, P052A, P052BVCT solenoid stuck in position P0016Camshaft advance mechanism binding (VCT unit) P0011, P0012, P0016, P052A, P052B

Part B: TiVCT Theory and Operation• Start vehicle and allow it to idle until the engine reaches operating temperature.

• Use the IDS to start a new session.






APP Accelerator Pedal Position

RPM Engine Revolutions Per Minute

VCT1_EXH_F Variable Cam Timing Bank 1 Exhaust Status

VCT1_INTK_F Variable Cam Timing Bank 1 Intake Status

VCTSYS VCT System Status (Open/Closed Loop)

VCT_EXH_ACT1 Actual Exhaust B Camshaft Position Bank 1

VCT_EXH_DC1 Exhaust B Camshaft Position Duty Cycle Bank 1

VCT_EXH_DIF1 Exhaust B Camshaft Desired Minus Actual Bank 1

VCT_EXH_DSD# Variable Camshaft Timing Exhaust Angle Desired

VCT_INTK_DSD# Variable Camshaft Timing Intake Desired Angle

VCT_INT_ACT1 Actual Intake A Camshaft Position Bank 1

VCT_INT_DC1 Intake A Camshaft Position Duty Cycle Bank 1

VCT_INT_DIF1 Intake A Camshaft Desired Minus Actual Bank 1

• Display the PID values. Press the “Recording Times” button.

• Set the Duration to “30s” and the Pre/Post Trigger at “0s / 30s”.

• Start the engine. Select the “Capture” button and increase the throttle a few time, then hold a steady throttle atapproximately 2300 RPM for 510 seconds.

• When recording is finished, shut off the engine.

• Select “Playback Viewer” to view the recordings you made and answer the following questions.

1. What is TiVCT and what does it do?

____________________________________________________________________________________________________________________________________________

2. Explain the advantages of controlling the camshafts independently of each other.

____________________________________________________________________________________________________________________________________________

3. Describe what is happening with both the intake and exhaust camshaft timing during steady throttle.

____________________________________________________________________________________________________________________________________________



NOTES


LESSON TWO WORKSTATION FOUR

WORKSTATION FOURIdle Air Systems Operation

SUMMARY: In this activity you will learn about the similarities and differences between IAC and ETC.

DIRECTIONS: View the scan tool recordings of a 2003 5.4L Expedition with IAC and a 2008 5.4L Expeditionwith ETC while answering the following questions. Use the “Typical Diagnostic Reference Values” portion ofSection 6: Reference Values to answer the following questions.

Part A: 2003 Expedition with IAC• View the scan tool recording of a normally operating IAC system on a 2003 5.4L Expedition.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Expedition)


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

1. What does the DPFEGR PID indicate while the vehicle is at idle?

____________________________________________________________________________________________________________________________________________

2. What does the EGR VR PID indicate while the vehicle is at idle?

____________________________________________________________________________________________________________________________________________

3. Under what conditions does the EGR VR become active?

____________________________________________________________________________________________________________________________________________

4. What is the TP PID value when the EVR becomes active?

____________________________________________________________________________________________________________________________________________

5. What is the maximum DPFEGR PID value during the recording?

____________________________________________________________________________________________________________________________________________

6. What happens to the DPFEGR and EGR VR PID values when the TP PID indicates wide open throttle?

____________________________________________________________________________________________________________________________________________



7. Are the DPFEGR and EGRVR PID values within specifications?

____________________________________________________________________________________________________________________________________________

8. What is the IAC duty cycle while the engine is at idle?

____________________________________________________________________________________________________________________________________________

9. What is the IAC duty cycle specification at hot idle?

____________________________________________________________________________________________________________________________________________

10. Why is the IAC duty cycle out of specification?

____________________________________________________________________________________________________________________________________________

11. What does the IAC do as the engine RPM increases and the throttle opens wider?

____________________________________________________________________________________________________________________________________________

12. Why doesn’t the RPM suddenly drop as the throttle snaps closed?

____________________________________________________________________________________________________________________________________________

Part B: 2008 Expedition with ETC• View the scan tool recording of a normally operating ETC system on a 2008 5.4L Expedition and answer

the following questions.

• Identify vehicle (“Vehicle Identification” tab>”Previous Sessions”>Expedition)


• Select playback display (Recording Group ETC, Recording 4). Play the recording from beginning to end.

1. What do the VCTADV and VCTADV2 PIDs indicate while the vehicle is at idle?

____________________________________________________________________________________________________________________________________________



2. Under what operating conditions is the camshaft most retarded (moved from base)?

____________________________________________________________________________________________________________________________________________

3. What happens to the VCTADV and VCTADV2 PIDs when the APP_MODE PID indicates wide open throttle?

____________________________________________________________________________________________________________________________________________

4. At 5 seconds, what does the APP_MODE indicate?

____________________________________________________________________________________________________________________________________________

5. What happens to the voltages on APP1, APP2, and APP3 as the accelerator is depressed?

____________________________________________________________________________________________________________________________________________

6. What happens to the voltages on TP1 and TP2 as the accelerator is depressed

____________________________________________________________________________________________________________________________________________

7. What happens to the RPM as the accelerator pedal is suddenly released as indicated by the APP PID?

____________________________________________________________________________________________________________________________________________

8. What happens to the O2 sensors between 40 and 60 seconds? Why?

____________________________________________________________________________________________________________________________________________

9. Define ETC_DSD and ETC_ACT.

____________________________________________________________________________________________________________________________________________



NOTES


LESSON TWO WRITTEN ACTIVITY

LESSON TWOWRITTEN ACTIVITY



NOTES




ThreeWire Sensors — Potentiometer

The Accelerator Pedal Position (APP) and Throttle Position (TP) sensors are threewire potentiometers. The PCMsupplies a reference voltage and a ground for the sensor and monitors the signal circuit.

• Fill in the table below with the expected TP PID values for each condition.

Condition Expected TP PID Value

Normal operating condition 0.6 V to 4.5 VVREF circuit open 0 VSIG RTN circuit open 5.0 VSignal circuit open 0 VSignal circuit shorted to VREF 5.0 VSignal circuit shorted to VPWR 5.0 VSignal circuit shorted to GND 0 VSignal circuit shorted to SIG RTN 0 V



TwoWire Sensor — Thermistor

The IAT, ECT, and CHT are twowire thermistors. A thermistor is a temperaturesensitive resistor, which along witha resistor network in the PCM provides an output voltage inversely proportional to temperature. As temperatureincreases, voltage decreases. This is referred to as Negative Temperature Coefficient.

• Fill in the table below with the expected IAT PID values for each condition.

Condition Expected IAT PID Value

Normal operating conditions 0.24 V to 4.5 VSIG RTN circuit open approximately 4.7 VSignal circuit open approximately 4.7 VSignal circuit shorted to VREF 5.0 VSignal circuit shorted to VPWR 5.0 VSignal circuit shorted to GND 0 VSignal circuit shorted to SIG RTN 0 V



Mass Air Flow (MAF) Sensor

• Fill in the table below with the expected MAF PID values for each condition.

The Mass Air Flow (MAF) sensor receives power and ground from the battery. As the amount of current needed tomaintain a constant temperature on the hot wire increases or decreases, the voltage on the MAF circuit varies. ThePCM MAF sensor circuit is grounded at the MAF sensor through the MAF RTN.

Condition Expected MAF PID Value

Normal operating condition 0.5 V to 4.75 VVPWR circuit open 0 VMAF RTN circuit open 0 VGND circuit open 0 VMAF circuit open 0 VSignal circuit shorted to VREF 5.0 VSignal circuit shorted to VPWR 5.0 VSignal circuit shorted to GND 0 VSignal circuit shorted to SIG RTN 0 V

1. What is a common cause of MAF failure?



Output Devices — Canister Vent Solenoid

A canister vent solenoid is a normally open solenoid that seals the EVAP canister from atmostpheric pressure. ThePCM controls current through the coil winding by opening and closing the ground side circuit. When energizedthe vent closes to obtain a vacuum in the fuel tank.

• Fill in the table below with the expected voltage and PID values for each condition.

ON OFF

Voltage Fault PID Voltage Fault PID

Normal 0 V No B+ No

VPWR circuit open 0 V No 0 V YesControl circuit open 0 V No 0 V YesComponent open 0 V No 0 V YesControl circuit shorted to VPWR B+ Yes B+ NoControl circuit shorted to GND 0 V No 0 V YesComponent shorted B+ Yes B+ NoControl Circuit Resistance 0 V No B+ No


LESSON THREE

LESSON THREE


LESSON THREE

NOTES



LESSON THREE WORKSTATIONS

LESSON THREEWORKSTATIONS


LESSON THREE WORKSTATIONS

NOTES

LESSON THREE WORKSTATION ONE

WORKSTATION ONEMIL ON

SUMMARY: In this VEHICLE workstation, you will diagnose a customer concern. Use the steps in this worksheetto determine possible causes, separate those causes into a list of systems and components, then systematicallyeliminate 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 andcomplete the necessary information on the pages that follow.

Repair Order

Year Model

Engine Trans Other

Customer ConcernMIL is ON.

Vehicle History/ OASIS results/ TSBs. REPAIR HISTORYNo related history.. SPECIAL SERVICE MESSAGES

EFFECTIVE DATE:. TECHNICAL SERVICE BULLETINS

EFFECTIVE DATE:

TECHNICIAN NOTES:KOEO CMDTC P2282 Air Leak Between Throttle Body and Intake Valve.

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



DIRECTIONS: As you go through your diagnosis, use the chart below to cross off component(s) that areeliminated by that step. Complete the Pinpoint Test steps first, then answer the questions in this workstation.

Primary Inputs and PCM

Ignition switch CKP CMP BPP

MAF TP APP A/C Sensors

ECT CHT IAT PSP Switch/Sensor

VSS FLI PCM PCM Power Relay

Ignition System

COP Boot Spark Plug Knock Sensor


Fuel Pump Inertia Switch/RCM Fuel Tank/Lines Fuel Filter

Fuel Damper Regulator

Fuel Control System

O2 Sensors Injectors MAP

EGR System

EGR Valve DPFE Vacuum Regulator

EVAP System

VMV/Canister PurgeValve

Canister Vent Solenoid FTP Sensor Fuel Cap

Fuel Tank Rollover Vent Valve Canister EVAP Lines

PCV System

PCV Valve PCV Hoses

Intake System

Intake Gaskets Intake Manifold/Tubes Air Filter Hoses

ETC Motor Throttle Body

Exhaust System

Upstream Pipes Catalyst Muffler Tailpipe

Other

Base Engine Transmission Brakes

1. According to the pinpoint test, which components are intended to be diagnosed?



• As you complete your diagnosis, fill in the pinpoint test step and its result in the table below.

Diagnostic Step Result

Verify concern MIL ON

QT1 No SSMs, History, TSBs visual OK KOEO CMDTC P2282 AirLeak Between Throttle Body and Intake Valve

Repair recommendations

2. The smoke machine is another method of detecting a vacuum leak. Use the smoke machine at the brake boostervacuum hose connector to find the leak. Where was the source of the leak?

____________________________________________________________________________________________________________________________________________

3. Why is it necessary to reset KAM after the repair?

____________________________________________________________________________________________________________________________________________



NOTES


LESSON THREE WORKSTATION TWO

WORKSTATION TWOMIL ON, Engine Runs Rough

SUMMARY: In this activity, you are diagnosing a 2010 Edge with the check engine light ON.

DIRECTIONS: Click on L3WS2 CMT from the workstation PC. Read the information in the repair order* tostart your diagnosis.

Repair Order

Year 2010 Model Edge

Engine 3.5L Trans 6F50 Other

Customer ConcernMIL is ON

Vehicle History/ OASIS results/ TSBs. REPAIR HISTORYNo related history.

. SPECIAL SERVICE MESSAGES

EFFECTIVE DATE:. TECHNICAL SERVICE BULLETINSNo related TSBs

TECHNICIAN NOTES:



LESSON THREE WORKSTATION TWO

DIRECTIONS: When directed, use the wiring diagram below to identify the types of fault(s) that COULD bethe cause of this concern. As you go through your diagnosis, indicate your results for each step by crossing offcomponent(s) and fault(s) that are eliminated by that step.

1. According to QT1, in what order should you diagnose DTCs?

2. Use the wiring diagram and legend to identify the types of faults that could cause DTC P0204 (Injector CircuitOpen – Injector 4).

3. What was the cause of the concern?

A. Faulty injector

B. Faulty PCM

C. Open in the injector control circuit

D. Short to power in the injector control circuit


LESSON THREE WORKSTATION THREE

WORKSTATION THREEMIL ON, Hesitation



Repair Order

Year Model

Engine Trans Other

Customer ConcernHesitation. MIL and Wrench lights are ON.


. SPECIAL SERVICE MESSAGESNo related SSMs

. TECHNICAL SERVICE BULLETINSNo related TSBs



LESSON THREE WORKSTATION THREE

DIRECTIONS: Use the wiring diagram below to identify the types of fault(s) that COULD be the cause of thisconcern. As you go through your diagnosis, indicate your results for each step by crossing off component(s) andfault(s) that are eliminated by that step.

1. List the DTC(s) that you received. Go to the appropriate pinpoint test, and list the components that the pinpointtest will diagnose.

2. According to the pinpoint test, which PID should you monitor?

____________________________________________________________________________________________________________________________________________

3. What was the cause of the concern?

____________________________________________________________________________________________________________________________________________


LESSON THREE WORKSTATION FOUR

WORKSTATION FOURMIL ON, Hesitation

SUMMARY: In this activity, you are diagnosing a 2008 Ranger with a 4.0L engine with the MIL ON and ahesitation concern.

DIRECTIONS: Click on L3WS4 CMT from the workstation PC. Read the information in the repair order* to startyour diagnosis. Diagnose the concern and complete the necessary information on the pages that follow.

Repair Order

Year 2008 Model Ranger

Engine 4.0L Trans 5R55E Other

Customer ConcernCheck Engine Light is ON and vehicle has hesitation on acceleration


. SPECIAL SERVICE MESSAGES20382 20042008 RANGER TRUCK BOX DRAINAGE PROTECTIONCERTAIN RANGER VEHICLES THAT FREQUENTLY CARRY OR STORE CAUSTIC OR ACIDIC CHEMICALS IN THE TRUCK BOXMAY REQUIRE DRAINAGE PROTECTION FOR THE FUEL SENDER FLANGE. REDIRECT THE TRUCK BOX DRAINAGE ASFOLLOWS: 1) WASH THE ENTIRE AFFECTED AREA WITH MOTORCRAFT DETAIL WASH ZC3A. 2) REMOVE THE BOX. 3) ADDA BEAD OF MOTORCRAFT TA2 TO THE SHEET METAL SEAM AT THE OUTSIDE BOTTOM FRONT OF HEADBOARD TO THELOWER SILL PLATE. APPLY A 30 INCH LONG BEAD OF MOTORCRAFT TA2 (15 INCHES ON BOTH SIDES STARTING FROMTHE BOX CENTERLINE) TO SEAL THE JOINT AND DIRECT FLOW TO THE OUTBOARD SIDES. 4) FILL THE AREA AT THEUNDERSIDE FRONT OF THE BOX TO SILL PLATE JOINT WITH MOTORCRAFT TA2 TO MATCH THE AREA SEALED AT THEFRONT OF THE HEADBOARD. 5) INSTALL FOAM PAD SHIELD KIT (9A213). FOLLOW THE INSTALLATION INSTRUCTIONSINCLUDED IN THE KIT.EFFECTIVE DATE: 08/13/2008

19950 VEHICLE EQUIPPED WITH VAPOR MANAGEMENT VALVE WITH A SERVICE PORT.SOME VEHICLES ARE EQUIPPED WITH A VMV (VAPOR MANAGEMENT VALVE)WITH AN INTEGRATED SERVICE PORT ORA REMOTE PORT. THE SERVICE PORT IS COVERED WITH A GREEN COLORED CAP THAT IS TETHERED TO THE VALVE.AFTER SERVICING FOR EVAP CONCERNS, BE SURE THE INSIDE OF THE CAP IS CLEAN,THE SEAL IS IN PLACE ANDTHE CAP RESECURED TO THE PORT. (FINGER TIGHTEN ONLY).THE CAP PROVIDES A SEAL FOR THE SERVICE PORTSCHRADER VALVE.EFFECTIVE DATE: 09/07/2007. TECHNICAL SERVICE BULLETINSNo related TSBs

TECHNICIAN NOTES:KOEO DTCs P0122 Throttle/Pedal Position Sensor A Circuit Low, P0405 EGR Sensor A CircuitLow, P0452 EVAP Sensor/Switch Low, P0642 Sensor Reference Voltage A Circuit Low



LESSON THREE WORKSTATION FOUR

1. Which code should be diagnosed first? After answering this question, use the wiring diagram to identify thetypes of fault(s) that COULD be the cause of the concern. Then follow the pinpoint test in the PCED.

____________________________________________________________________________________________________________________________________________

2. What component(s) and possible cause(s) were tested in this step? Indicate your results on the wiring diagram.

____________________________________________________________________________________________________________________________________________


____________________________________________________________________________________________________________________________________________


____________________________________________________________________________________________________________________________________________

5. What is the cause of the concern and what repair is required?

____________________________________________________________________________________________________________________________________________


LESSON FOUR

LESSON FOUR


LESSON FOUR

NOTES



LESSON FOUR WORKSTATIONS

LESSON FOURWORKSTATIONS


LESSON FOUR WORKSTATIONS

NOTES

LESSON FOUR WORKSTATION ONE

WORKSTATION ONEMIL ON



Repair Order

Year Model

Engine Trans Other


Vehicle History/ OASIS results/ TSBs. REPAIR HISTORYNo related history.. SPECIAL SERVICE MESSAGES

N/AEFFECTIVE DATE:. TECHNICAL SERVICE BULLETINSNo related TSBs

TECHNICIAN NOTES:DTC P0455 Evaporative Emissions System Leak Detected (Gross Leak).

Part A: IDS EVAP Leak Test

1. What description is given for the P0455 code?

• Go to the IDS EVAP Test screen.

• Open the “EVAP System Toolbox” and read the description for each test. Be sure to read each introductionscreen. Then click on the “tick” mark to open the “EVAP System Test” screen. Note that you must launch theindividual EVAP tests from this screen.

• Run each of the 4 EVAP tests (Target Vacuum, Bleed Up, EVAPCP Check and Vapor Generation). Eachtest will take 12 minutes to complete.

• Once the individual EVAP tests are completed, close out of the EVAP test screen. Reopen the EVAP screenand click on EVAP System Test.




2. What is the preferred fuel level percentage recommended for the EVAP tests?

____________________________________________________________________________________________________________________________________________

3. At what point during the test did the engine shut off?

____________________________________________________________________________________________________________________________________________

4. Which test(s) is done Key On Engine Off (KOEO)?

____________________________________________________________________________________________________________________________________________

5. Did the vehicle pass the IDS EVAP tests?

Yes No

• The IDS EVAP test may not be able to detect a leak. Proceed to Part B, and perform a smoke machine leakdetection test.

Part B: Smoke Machine EVAP Leak Test• Calibrate the smoke machine with the 0.040” orifice.

• Use the Output State Control (OSC) function of the IDS to energize the Canister Vent Valve (CVV) andcommand it closed (ON). Use the EVAPCV#, (Mode) and EVAPCV (Per) PIDs.

• Disconnect the EVAP hose from the Canister Purge Valve (near the throttle body). The elbow has a greenretainer clip.

1. Canister purge valve

2. Smoke machine hose

2. EVAP hose and green retainer clip



• Using the smoke machine instructions (or Pinpoint Test Step HX45), perform a Phase I pressure test with thesmoke machine.

1. Was a leak detected?

Yes No

2. What action should you take next?



NOTES


LESSON FOUR WORKSTATION TWO

WORKSTATION TWOMIL ON

SUMMARY: In this activity, you are diagnosing a 2010 Ford Edge with a MIL ON concern.

DIRECTIONS: Click on L4SW2 CMT from the workstation PC. Read the information in the repair order* to startyour diagnosis. Diagnose the concern and complete the necessary information on the pages that follow.

Repair Order

Year 2010 Model Edge

Engine 3.5L Trans 6F50 Other



. SPECIAL SERVICE MESSAGESNo related SSMs

. TECHNICAL SERVICE BULLETINSNo related TSBs



LESSON FOUR WORKSTATION TWO

DIRECTIONS: When directed, use the wiring diagram below to identify the types of fault(s) that COULD bethe cause of this concern. As you go through your diagnosis, indicate your results for each step by crossing offcomponent(s) and fault(s) that are eliminated by that step.

1. What description is given for the DTC(s)?

2. What is the cause of the concern?

____________________________________________________________________________________________________________________________________________

• Call the instructor to the workstation.


LESSON FOUR WORKSTATION THREE

WORKSTATION THREEMIL ON



Repair Order

Year Model

Engine Trans Other



. SPECIAL SERVICE MESSAGES

EFFECTIVE DATE:. TECHNICAL SERVICE BULLETINSNo related TSBs



LESSON FOUR WORKSTATION THREE

1. What description is given for the DTCs?

2. According to the Diagnostic Aids in the DTC description, what could cause this concern?

____________________________________________________________________________________________________________________________________________

3. What is the cause of the concern?

____________________________________________________________________________________________________________________________________________


LESSON FOUR WORKSTATION FOUR

WORKSTATION FOURMIL ON

SUMMARY: In this activity, you are diagnosing a 2008 Focus with a Check Engine Light ON.

DIRECTIONS: Click on L4WS4 CMT from the workstation PC. Read the information in the repair order* to startyour diagnosis. Diagnose the concern and complete the necessary information on the pages that follow.

Repair Order

Year 2008 Model Focus

Engine 2.0L Trans 4F27E Other


Vehicle History/ OASIS results/ TSBs. REPAIR HISTORYVehicle was at an aftermarket repair facility 2 days ago for tire rotation.. SPECIAL SERVICE MESSAGES20377 VEHICLES EQUIPPED WITH 2.0L/2.3L I4 ENGINE LEAN CODES DUE TO VACUUM LEAKSOME FOCUS,ESCAPE,MARINER (INCLUDING HYBRID),RANGER, FUSION, MILAN EQUIPPED WITH A 2.0L/2.3L I4 ENGINEMAY EXHIBIT A MIL ON WITH DTC’S P0171 AND P2195 AND ROUGH IDLE. THE CONDITION MAY BE CAUSED BY A VACUUMLEAK AT THE PCV VALVE AT THE OIL SEPARATOR OUTLET HOSE BETWEEN THE INTAKE MANIFOLD AND THE CYLINDERHEAD AREA, UNDER THE #3 AND #4 INTAKE RUNNERS. THE HOSE IS HARD TO SEE AND MIGHT BE LEAKING, PERFORMEDFOLLOWING PRIOR TO ANY PART REPLACEMENT. INTRODUCE PROPANE UNDER THE #3 AND #4 INTAKE RUNNERS. IFTHE OXYGEN SENSOR STARTS TO SWITCH NORMALLY WITH ENRICHMENT, REMOVE INTAKE MANIFOLD FOR FURTHERINSPECTION. IF NOT FOLLOW NORMAL DIAGNOSTICS. AFTER IDENTIFYING THE ROOT CAUSE (VACUUM LEAK) RESET THEKEEP ALIVE MEMORY AND PERFORM 3 CONSECUTIVE DECELS FROM 6040 MPH WITH NO BRAKING..EFFECTIVE DATE: 08/12/2008

20555 FOCUS CLOSELY INSPECT AIR INTAKE SYSTEM FOR LEAKS BEFORE ELECTRONIC THROTTLE BODY (ETB)REPLACEMENTSOME FOCUS VEHICLES MAY EXHIBIT SYMPTOMS AND/OR DIAGNOSTIC TROUBLE CODES (DTC’S) WHICH LEAD TOELECTRONIC THROTTLE BODY (ETB) REPLACEMENT. THIS MAY ALSO BE DUE TO AIR INTAKE SYSTEM LEAK(S). BEFOREREPLACING THE ETB, CLOSELY INSPECT THE ENTIRE AIR INTAKE SYSTEM FOR ANY SIGNS OF LEAKS. PAY PARTICULARATTENTION TO THE SEAL AT THE MASS AIR FLOW (MAF) SENSOR AND THROTTLE BODY LISTEN FOR ANY AIR NOISEWITH THE ENGINE RUNNING. IF PRESENT, REPAIR AS NECESSARY, AND RETEST BEFORE REPLACING ETB.EFFECTIVE DATE: 11/18/2008. TECHNICAL SERVICE BULLETINSNo related TSBs

TECHNICIAN NOTES:DTC P0148 Fuel Delivery Error.




DIRECTIONS: As you go through your diagnosis, use the chart below to cross off component(s) that areeliminated by that step.

Primary Inputs and PCM

Ignition switch CKP CMP BPP

MAF TP APP A/C Sensors

ECT CHT IAT PSP Switch/Sensor

VSS FLI PCM PCM Power Relay

Ignition System

COP Boot Spark Plug Knock Sensor


Fuel Pump Inertia Switch/RCM Fuel Tank/Lines Fuel Filter

Fuel Damper Regulator

Fuel Control System

O2 Sensors Injectors MAP

EGR System

EEGR Valve

EVAP System

VMV/Canister PurgeValve

Canister Vent Solenoid FTP Sensor Fuel Cap

Fuel Tank Rollover Vent Valve Canister EVAP Lines

PCV System

PCV Valve PCV Hoses

Intake System

Intake Gaskets Intake Manifold/Tubes Air Filter Hoses

ETC Motor Throttle Body

Exhaust System

Upstream Pipes Catalyst Muffler Tailpipe

Other

Base Engine Transmission Brakes

1. What is the minimum fuel pressure specification for this vehicle? Hint: use the Reference tab.

2. What type of fuel system does this vehicle have?

____________________________________________________________________________________________________________________________________________



3. If the fuel pump ground circuit was open, would there be fuel pressure?

Yes No

4. If the fuel pump power circuit was open, would there be fuel pressure?

Yes No

5. What components could cause the fuel pressure to leakdown during this test?

____________________________________________________________________________________________________________________________________________

6. How much air pressure should be applied during this test?

____________________________________________________________________________________________________________________________________________

7. What is the root cause of the concern?

____________________________________________________________________________________________________________________________________________



NOTES


ENGINE PERFORMANCE OPERATION AND DIAGNOSIS APPENDIX

STUDENT GUIDEAPPENDIX

Engine Performance Operation and Diagnosis Appendix 1 Version 8


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The fuel system has 5 operating modes:

OL: Open Loop (Normal Operation)

• Cold engine startup

• Cold O2 sensor warmup

CL: Closed Loop (Normal Operation)

OL – Drive: Open Loop because of driver input or PCM strategy

• KOER selftest

• Catalyst overtemp condition

• High load or WOT conditions (for maximum power)

• O2S Monitor in progress

• Extended idle

OL – Fault

• Open loop with a lack of upstream O2S switching or

• Primaryside coil failure

CL – Fault

• Closed loop with a lack of upstream O2S switching and

• The PCM is using the other bank for feedback


Documents

31EnginePerformance StudentGuide FCS21413REF...LESSONONE PREREQUISITEREVIEW PREREQUISITEREVIEW DIRECTIONS:Answerthefollowingquestions.Theanswerswillbereviewedinclass. PrimaryInputs