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FCSD

Technical Training

INTERACTIVE STUDY GUIDE

FIRTFT 6.0L DIESEL ENGINE

EGR SYSTEM

FCS-13982-DL

FIRTFT 6.0L DIESEL ENGINE EGR SYSTEM

COURSE CODE: 51G06F0

27-OCT-04

Summary of Contents for FCSD

Page 1: ...FCSD Technical Training INTERACTIVE STUDY GUIDE FIRTFT 6 0L DIESEL ENGINE EGR SYSTEM FCS 13982 DL FIRTFT 6 0L DIESEL ENGINE EGR SYSTEM COURSE CODE 51G06F0 27 OCT 04 ...

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Page 3: ... avoid time by an increase in underhood temperatures even the danger of carbon monoxide though the ignition is in the OFF position Therefore care Keep yourself and your clothing away from moving parts should be taken to ensure that the electric cooling fan is when the engine is running especially the fan and belts completely disconnected when working under the hood The recommendations and suggesti...

Page 4: ... are important players when it comes to Expectation 3 Why Customers tell us Fixing It Right The First Time on Time is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to Fix It Right The First Time on Time We refer to this as compete...

Page 5: ... 1 1 Objectives 1 1 INTRODUCTION 1 2 LESSON 2 THEORY AND OPERATION 2 1 Objectives 2 1 EGR SYSTEM 2 2 LESSON 3 DIAGNOSTICS 3 1 Objectives 3 1 DIAGNOSTIC GENERAL INFORMATION 3 2 EGR SYSTEM SERVICE 3 12 ACCESSING SERVICE INFORMATION 3 14 APPENDIX Appendix 1 Appendix Essential Special Service Tools Appendix 1 Order Form Appendix 3 Glossary Of Terms Appendix 5 FIRTFT 6 0L Diesel Engine EGR System 27 OC...

Page 6: ...TABLE OF CONTENTS NOTES FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 ii ...

Page 7: ... for Successful Completion This course is score based Successful completion of this course requires a passing score of 80 or greater Achievement of 80 of greater will result in a PASS in your STARS training history A score of less than 80 results in a FAIL in your STARS training history If you logon and participate in the class but choose NOT to answer any of the questions your will receive an AUD...

Page 8: ... log on at the beginning of the broadcast session 1 Enter your I D number in response to the keypad prompt If you press an incorrect key press CLEAR and re enter the numbers 2 Press ENTER 3 The system validates your I D number by displaying your name on the keypad If your name does not appear on the keypad re enter your I D number 4 If you cannot successfully log on contact the FORDSTAR Help Desk ...

Page 9: ... call queue WAIT and SPEAK Lights The red WAIT light illuminates when your call is received and placed in the call queue When the instructor calls on you the green SPEAK light illuminates and your microphone is activated The microphone is the gray dot between the SPEAK and WAIT lights Speak in a normal tone of voice from a normal sitting position The instructor will hear you as will the other stud...

Page 10: ...agnostic Processes course code 51G07F0 The purpose of this FORDSTAR Fix it Right the First Time course is to present technicians with the basic information needed to understand the 6 0L diesel engine EGR system The benefit of taking this course is that upon completion you will have the knowledge that will assist you to service the 6 0L diesel EGR system effectively and efficiently and improve your...

Page 11: ...LESSON 1 OVERVIEW OBJECTIVES Describe the purpose of the diesel EGR system Identify the EGR system components FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 1 1 ...

Page 12: ...missions The cooled exhaust gases act as a heat sink to absorb part of the peak combustion temperatures thus reducing combustion temperature and NOx formation The EGR cooler can lower exhaust temperature as much as 371 C 700 F The system includes the following components EGR valve EGR cooler EGR valve position sensor EP sensor Intake manifold EGR throttle in 2004 25 Exhaust scoop for 2005 FIRTFT 6...

Page 13: ...her sensors used by the PCM to properly control EGR operation are Mass airflow MAF sensor Throttle position TP sensor on the 2004 25 Manifold absolute pressure MAP sensor FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 1 3 ...

Page 14: ...LESSON 1 OVERVIEW NOTES FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 1 4 ...

Page 15: ...LESSON 2 THEORY AND OPERATION OBJECTIVES Describe the theory and operation of the EGR system components FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 1 ...

Page 16: ...The exhaust gases are very hot so an EGR cooler is used to cool the exhaust gas before it enters the EGR valve Cooling the exhaust gas accomplishes two goals The first is to lower peak combustion chamber temperature thereby reducing oxides of nitrogen NOx The second is to keep the EGR valve from failing due to high temperatures FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 2 ...

Page 17: ...re sensor 1 IAT1 4 Turbocharger compressor inlet 12 Turbocharger turbine inlet 5 VGT control valve 13 Turbocharger compressor outlet 6 Turbocharger outlet to exhaust 14 EGR cooler 7 Exhaust pressure sensor EP 15 EGR valve 8 Manifold absolute pressure sensor 16 EGR throttle plate on 2004 25 scoop on 2005 The above EGR airflow schematic details the main components that affect the EGR valve operation...

Page 18: ...ures are higher than intake manifold pressures boost The EGR valve contains two valves connected by a common shaft that open and close in tandem The EGR valve may open at any time The amount of flow is variable depending on rpm load exhaust pressure and valve position The EGR is partially open at idle to reduce engine noise FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 4 ...

Page 19: ... before they enter the EGR valve The EGR cooler can lower exhaust temperatures by as much as 700 F The seals for the EGR cooler include Metal gaskets to seal exhaust gases O rings for the coolant connections The EGR cooler was redesigned for the 2004 25 model year FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 5 ...

Page 20: ...l of the actual voltage to return to the PCM The EGRP sensor uses VREF to produce a linear analog voltage signal Low signal with EGR valve closed High signal with EGR valve open The EGR valve solenoid works against spring pressure to open the valve The potentiometer is supplied with a regulated 5V reference signal and ground circuits from the PCM DTCs related to the EGRVP sensor circuit can be ret...

Page 21: ... important point to remember is that a VREF shorted to ground at the EP sensor on the 6 0L prevents engine startup by shutting down the PCM This can also result in a no crank condition The EP is a variable capacitance sensor The EP sensor uses 5 volt VREF to produce an analog EP signal The EP sensor uses signal return from the PCM as a ground FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 7 ...

Page 22: ...2003 and Early 2004 The intake manifold routes intake air and exhaust gases into the combustion chambers The early versions include a runner in the rear of the manifold that equalizes the pressure in the manifold FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 8 ...

Page 23: ...LESSON 2 THEORY AND OPERATION Intake Manifold 2004 25 and Later The later design intake manifold is shaped different than the early version FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 9 ...

Page 24: ...manifold also routes airflow in the EGR valve differently than the earlier designs Intake manifold divider plates have been incorporated into the intake manifold to aid in EGR flow The divider plates direct equal flow to each bank of the engine FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 2 10 ...

Page 25: ...LESSON 3 DIAGNOSTICS OBJECTIVES Identify pertinent diagnostic and service information for the 6 0L EGR system FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 1 ...

Page 26: ...the primary diagnostic scan tool used to diagnose the 6 0L diesel engine Self tests include KOEO On Demand KOER On Demand KOEO Injector Electrical Test Click KOER Glow Plug Monitoring Other WDS tests available include Power Balance Relative Compression Output State Control OSC FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 2 ...

Page 27: ...imited to 85 maximum KOER While running OSC tests you may find the following additional tests helpful All injectors Injectors can be disabled one at a time Monitoring mass fuel desired during the test will show cylinder contribution Fuel pump FP Allows fuel pump to be turned ON OFF Revolutions per minute RPM Can be set between zero and 1 200 Injector pressure regulator IPR RPM may have to be raise...

Page 28: ...is test is to start with the key ON and the engine OFF 1 Connect the WDS 2 Access the EGR DC and EGRVP PIDs 3 Record the closed EGRVP percentage and voltage 4 Access OSC and open the EGR valve fully 5 Record the open EGR valve position percentage and voltage 6 Subtract the closed valve position voltage from the open valve position voltage 7 If the EGRVP is changing as the EGRDC changes the value t...

Page 29: ... at idle NOTE The EGR valve may not begin to move until approximately 40 EGRDC Another recommended recording is the EGRVP at 50 duty cycle on the upward travel and the downward travel Look for a smooth transition in the valve position through the range of commands A sudden jump after no noticable movement can indicate a sticky valve An EGR operation quick check is to look at the IAT1 and IAT2 temp...

Page 30: ...forth to unseat it Rocking the valve can cause the shaft to bend and the EGR valve to bind To remove the EGR valve 1 Remove the two hold down bolts 2 Rotate the valve counterclockwise far enough to properly install the EGR Puller special tool number 303 760 3 Position the EGR bolt tabs into the EGR puller arm slots 4 Turn the puller bolt until the EGR valve clears the intake manifold FIRTFT 6 0L D...

Page 31: ...S Vacuuming the Intake Manifold After removing the EGR valve vacuum loose ash deposits and other debris from inside the intake manifold Otherwise engine damage can occur FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 7 ...

Page 32: ...fter removing the EGR valve do not be alarmed by carbon soot near the vent holes This is a normal characteristic of the EGR valves used on the 6 0L engine prior to the 2005 model year FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 8 ...

Page 33: ...CS Lubricating O Rings Before reinstalling the EGR valve Always replace the two O rings and lubricate with clean engine oil Then push the EGR valve into its seat by hand FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 9 ...

Page 34: ...est is to start with the key ON and the engine ON 1 Put the vehicle is PARK 2 Connect the WDS 3 Access the EP and the RPM PIDs 4 Increase the engine speed to 3 800 RPM with the engine temperature greater than 70 C 158 F 5 Record the EP PID value 6 A low RPM with high EP or an EP PID value greater than 244 kPa 35 psi indicates a restricted exhaust condition FIRTFT 6 0L Diesel Engine EGR System 27 O...

Page 35: ...ng is not within range it could be the result of a biased sensor a plugged EP tube or a wire chafe concern Improper readings could also be the result of a poor electrical connection To determine if this is so Monitor the EP PID KOEO while wiggling the harness If the signal voltage changes at all the connection is a problem NOTE Visually inspect the vehicle for aftermarket accessories and modificat...

Page 36: ...e hose toward the front of the engine 3 Rotate the hose slightly further in the same direction it was previously rotated in Step 1 4 Pull the hose straight back CAUTION Do not continue to rotate the hose beyond the stop points Doing so will allow the tabs of the EGR cooler hose to wear down the oil cooler housing ridges which are necessary to remove the hose FIRTFT 6 0L Diesel Engine EGR System 27...

Page 37: ... Gaskets Both the inlet and outlet for exhaust gases are sealed with metal gaskets It is important that these metal gaskets are sealing properly for the EGR system to operate properly FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 13 ...

Page 38: ...he PTS website In addition to the PC ED and service manuals the PTS website includes a section entitled Power Stroke Central Also the hotline diagnostic tool is located at the PTS site For additional information on 6 0L diagnosis refer to the FIRTFT 6 0L Diesel Engine Diagnostic Processes class course code 51G07F0 launching later this year FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 3 14 ...

Page 39: ...APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS ESSENTIAL SPECIAL SERVICE TOOLS FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 1 ...

Page 40: ...APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS NOTES FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 2 ...

Page 41: ...APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 3 ...

Page 42: ...APPENDIX ESSENTIAL SPECIAL SERVICE TOOLS FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 4 ...

Page 43: ...APPENDIX GLOSSARY OF TERMS GLOSSARY OF TERMS FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 5 ...

Page 44: ...APPENDIX GLOSSARY OF TERMS NOTES FIRTFT 6 0L Diesel Engine EGR System 27 OCT 04 Appendix 6 ...

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