~~f series super dutvasset01.drivewebsite.com/site/52987b61-2697-4ad0... · zf i spaad manual...

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~~F" Series Super Dutv Features • Description • 8ervice

1

FOREWORD

This publication is intended to provide technicians and service personnel with the latest technical advancements incorporated in the 7.3 DIT Diesel Engine. The information contained in this publication will supplement information contained in available service literature.

IMPORTANT SAFETY NOTICE Appropriate seNice methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as, the personal safety of the individual doing the work. This manual provides general directions for accomplishing seNice and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for seNicing vehicles, as well as, in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must f irst establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.

The following list contains some general WARNINGS that you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the vehicle.

• Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

• Never perform any seNice to the engine with the air cleaner removed and the engine running unless a turbocharger compressor inlet shield is installed.

• Set the parking brake when working on the vehicle. If you have an automatic t ransmission, set it in PARK unless inst ructed otherwise for a specific seNice operation. If you have a manual t ransmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific seNice operation.

• Operate the engine only in a well- ventilated area to avoid the danger of carbon monoxid~.

• Keep yourself and your clothing away from moving parts when the engine is running, especially the fan, belts, and the turbocharger compressor.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbocharger pipes, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head.

• Keep hands and other objects clear of the radiator fan blades.

7.3L DIY

Direct Injection Turbocharged Diesel

Engine

7.3L DIT DIESEL ENGINE

TABLE OF CONTENT S ENGINE SPECIFICATIONS . ....... . . . . ... . ...... . .. . 4 New Features .... .. .. .. ..... .. . ........ • . . .... ... .. ...••• . . .. .. . . . .. . .4 Engine Serial Number .. . ... . .... . .. . .... •• . .... .. . ... .. .. •.. . . . . . . . .. .. .4 Emission Label . ..... ... ..... .... ......• . . ... ...... .. ..••• .. . ..... ..... 5

Horsepower Comparison .. . ..... ... ....... . ..... .. . . ... .. •• • .. ..... .. .... 5

Torque Comparison ..... . . ....... .... .... •••• . .. .. ..... . . •• .. ..... . .. .. . 5

PHYSICAL ID ........ . ......... . ... . ... ... . .. . . . 6

AIR CHARGING SYSTEM ..... . .. . ......... . .... .. . 13 Turbo ld .. . .. ....... ... ..... .... .....• • . . .... ..... . . .•• • . . .. . . . .. . . . . 13

Wastegate Control ... .... ..... .... ... ...... . . .. .. . ... ... ••• .. . . . . .. .... 15

TURBO REMOVAL AND INSTALLATION ........... . . .. . 18

FUEL CHARGING SYSTEM .... . .... .. ........ .. . .. . 21 Injectors .. . . ..... ... . ........ .. . . .... •• . .... . . . ... ... • •• •.. .. . .. . .... 21

Fuel Filter and Supply .. . . . .... ..... ...... •• ..... . . ... .. . ••• ..... .... ... 24

High Pressure Oil System ... ...... ... ..... •• . ... . . . . .. ... . • • . .... ... . ... 29

NEW AND REVISED SENSORS .. . .. . ... . ..... ...... . 31

SPECIAL TOROUE DATA . .. . . .. . ... . ... .. .. ... . ... . 33

7.3L DIT ANTHOLOGY .. . ... . .. .. ........ . . .. . .. . . 35 Fuel filter service . . .. ...... ... . .... . .... .... • • . . .... .. . . .. .. .. . . ...... . 35

DIAGNOSTIC GUIDES AND FORMS . . . . . ..... .... . ... . 50

GLOSSARY .......... . .. . .. . ............ .. . .. . . 71

INDEX . . ..... . .. . .. . .... . . .... ... . . . . .. . ..... 73

1

ENGINE SPECIFICATIONS

New Features

Eaglne Suiel Number

• There Is now an engine serial number on the valve cover as opposed to the oil reservoir.

• As with previous Power Stroke engines, the engine serial number is slill stamped into the crankcase at the rear oil cooler pad.

• The vehicle production date break for most of tl\e material covered in the front section of t1>1s book is Jan. '98, unless otherwise stated fn text.

4

"F" Series lacraaaad Harsapawer a nd Torque Charga Air Caalad llactranh:ally Controlled Waste gated Turbo All Split Shot Injectors laap ta Connect ICP Oil Lines Jla .. aignad Fual Systam

Econoline Snap ta Cannact ICP Oil Linas Radaaigaad Fual Suppl y Systam All Split &hat lnjactors (Carryover from

1817 Modal Yaar)

Chassis Power Train Changes Cha .. ia Mauntad Electric Fue l Pump ZF I Spaad Manual Transmission (F-Series only)

Law &aar Addad fa r Heavy Loads Diflarential Ratios Ava ila bla:

·r· Seri .. : 3 .73, 4 .10, 4 .30, 4.88 lcanalina: 3.55, 4 .10, 4 .&3

Biagla 35 gallon Fuel Ta nk (F-Series only)

RENSEIOHEMeNTS DE D~POLLUTION

lf«::M \WIM'IIC'I\IIIlO Wt'

UOf1MI '*~ NA.YitTM llfTIJUf.AnoHA.I.. TMHUOIIIT4TIOH CONt.

1500

1500 2000

2000 2500

Engine RPM

2500

Engine RPM

3000

3000

ENGINE SPECIFICATIONS

250

200

ISO

100

so

0

550

500

450

350

300 3500

Eminion L•••t

• The emission label Is localed on lhe right valve cover and Identifies lhe engine model. gross horsepower, and fuel delivery rate.

Harupowar Comparlaon

1999 ·r· Sarlo•

Peak Horsepower is 9% more than previous models and occurs 0 2700 RPM versus 3000 RPM.

Tar••• Ca•parlua

Similar to the horsepower 1ncrease. peak

torque is higher at 500 lb/11 between 1600 and 2300 RPM. This Is a 15% 1ncrease over prior models.

5

PHYSICAL ID

Crankshaft

• For improved strength and ease in

machining, the crankshaft no longer has lightening holes drilled into the connecting

rod pins.

• The counterweights are larger to counteract

the extra weight in the connecting rod pin.

• The engine serial number break for this

change is 576010.

Note: The "larger'' crankshafts may only

be used In crankcases with serial numbers

higher than 571930.

Crank••••

• The lower section of the crankcase has

been modified to allow larger crankshaft

counterweights to clear the crankcase.

• The serial number break for this change is:

571930.

• This change occurred on the crankcase

prior to the crankshaft.

Note: This crankcase may be used with

either crankshafts described above.

Ca•shaft

• The 1999 model year engine incorporates

a chassis mounted electric luel pump.

• Due to the use of an electric fuel pump the eccentric lobe on the camshaft has been

eliminated.

6

Engine Serial # 57601 0 and above

Coun terweight has a radius

Lightening hole

Mechanical lift pump eccentric eliminated

Engine Serial #576009 and below

I

Pra Jan. '98

0.137"

Pre. Jan. '98

0.435"

0 .402"

Under Valve Caver harness (UVC)

I

Post Jan. '98

Slightly deaper intermedia te

PHYSICAL ID

Ria1•

• The intermediate ring width has boon

increased to increase ring tension In the

bore.

• The intermediate ring has a larger chamfer

on "s inside race and increased w1dth to

diStinguish it from the prior seoond nng.

Note: The lntenmediate ring muat not be used on earlier pistons.

Pistan•

• The new piston has a deeper intermediate

ring groove to accommodate the new

increased intermediate ring width.

Note: Pistons and rings cannot be Intermixed due to Increased and narrow intermediate ring widths.

Valwa Caver &askat • •• UVC Harn••• • To reduce the number of electrical

connections and improve reliability, the

valve cover gasket now uses a single 9 pin

connector (versus two 5 pin), for injectors

and glow plugs.

• This new one piece des;gn UVC is st1ll

removable, and uses larger wires and terminals for the glow plug circuit.

7

PHYSICAL ID

Entine Harness

• Similar to the UVC harness, the engine harness also has two 9 pin connectors, incorporating larger wires and terminals for the glow plugs.

Valve Cavn Gas ket Breakaut Taal

Because of the new 9 pin connector, essential tool #418·F221 has been released for testing glow plug and injector circuits.

• The four White pins are for glow plugs.

• The Black pin is common for the four Injectors.

• Red, Green, Blue, and Yellow pins are injector ground.

Exhauet Up Pipn

• To improve joint serviceability, the exhaust up pipes are now common for both "E" and 'P' Series.

• On previous engines the exhaust up pipes were model specific. The previous "P' series drivers side exhaust up pipe is shown.

8

Essential tool #418-F221

9 pin valve cover connector

Pre Jan. '98 ' F" Series

side up pipe. Common for 'E' and "F" Series.

0

l'llst Jan. '98

I'N Jan. '98

PHYSICAL ID

Exhaual Manilalds

• The driver side "F" Series exhausl manifold

has changed co allow the use of a common

exhaust up pipe.

Maaaurln1 Exhaust Back Pruaara without Cold Weather Packaa•

• With the 1999 model year ·p Series, a

"Cold Wealher option delete" package Is

available. If the cold weather package has

been deleted, a new procedure for

checking exhaust back pressure IS

deSC(lbed below.

• To check exhaust back pressure on a

vehicle !hat is not equipped with an

exhaust back pressure sensor, you will

have to make your own cooling coils.

• The coils are to coot exhaust gases before

they reach the pressure gauge 10 avoid

damage 10 lhe gauge.

The coil should be made oul of copper

tubing oblained locally.

Aller making coil, attach tubing 10 the

exhaust manifold by removing !he plug in

front of the right exhaust manifold where

the exhaust back pressure sensor tube

would normally be located.

• Use gauge bar tool number 014..()0761 or

equivalent to read pressure; on vehicles

equipped with EPB this can be read using

the NGS tool.

CAUTION: TURBO WILL BE HOT. Do not

touch during or Immediately after test.

Route tubing away from parts that can be

damaged by heat and keep away from

ac,cessory drives and fan.

9

PHYSICAL 10

T•r• l•• lalat anol Cla•p

• The turbine inlet now uses a V·band style

clamp for mounting.

• To insure proper alignment a dowel pin is

used as a locator.

Dll Fill Lacalien and Dlpetick

• The engine oil fill location has been

extended to make it eas.er to change or

add 011 to the engine.

• The dipstick is now common for both · E" and ·p series. This makes It easier to

check the oil level on "P' series.

Cnnkc••• Prauura Tnt

• Place crankcase pressure adapter on oil fill

extension to check pressure.

• Crankcase pressure shOuld not be more

than 4 Inches of water usong the

Magnahetic gauge.

Note: Be sure to block oH crankcase

ventilation system (breather tube) before

performing teat.

10

Dipstick tube

Post Jan. '98 ' F" Series thermostat housing

Pre Jan. '98

Reservoir

I

Post Jan. '98

PHYSICAL ID

Water Pump

• Water pump seals are dynamic seals. During engine cran~ing, seepage past the seal occurs.

• A reservoir has been added to the housing to allow the small amounts of seepage past the seal to accumulate and evaporate.

• This eliminates the staining seen on prior water pumps.

Thermostat Housing

• To provide clearance for charge air cooler piping and improve serviceability during normal service operations, the •p• Series thermostat housing is shorter, has a thicker Hange and a new seal.

Water Pump Pulley

• The water pump pulley diameter has been decreased.

• If service is required, be sure to use the proper pulley to obtain proper pump speed and avoid cooling system concerns.

11

PHYSICAL ID

lati•• Mauah - ·r• Sulu

• Wrth the new Super Duty " F" Series chassis, the driver side engine mount is made from cast iron instead of stamped

steel.

Air Claaau

• The a.r cleaner tor the 1999 model year "P senes has been totally redesigned to use a flat rectangular filter element

• The air filter housing continues to incorporate a litter minder restnclion gauge

to mon.tor air filter cond~ion.

Sinal• Man Flywh .. J

• A single mass flywheel replaces the previously utilized dual mass flywheel for manual transmission appiiCabons.

• The flywheel can be identified by the

absence or bolts that would normally connect the inertia member from the clutch surtace.

Note: The single mass flywheel can only be used with the ZF 6 speed manual

12

Pre Jan. '9B

'F' Series Left engine mount

No bolts in this location

Post Jan. '9B

'F' Series Left en11lne mount

Single mass flywheol

AIR CHARGING SYSTEM

Turbo Charger

"F" Series Wastegate with EBP Waslegate without EBP

"E" Series All with EBP - Non-Waslegaled

Turbo bol t

Waste gate actuator

Turbo mounting bol t

Location for dowel

Exhaust back pressure actuator

• "P Series turbochargers are wastegated in

conjunction with charge air cooling.

• "P Series may be ordered without EBP.

• AII"E" Series turbochargers are equipped

with EBP and no wastegate.

Turha ·r· Sarin with Wastegate and EBP

• In the lront view shown, the EBP regulator

and new top down turbo to pedestal

mounting bolts are depicted.

• The wastegate regulates maximum speed

of the turbocharger by allowing excess exhaust gases to bypass the turbine

housing and be directed into the exhaust

stream to atmosphere.

Turha •r• Sari .. with Wasta g ate and EBP

• From the rear view, EBP and wastegate

actuators are shown. In addition, note the

locator dowel hole for positioning the

turbine inlet.

• As previously stated, the turbocharger

assembly is now attached to the pedestal

with two bolts from the top. This is for In

chassis removal and installation ol turbo

assembly which is explained in detail

starting on page 17.

13

'A I R CHARGING SYSTEM

Tnh ' F' Series with Wulagala aad wilhaal EBP

• Front view shown with ESP regulator removed from tUioo pedestal.

Turbo ' F' Sarin with Waatag ata aad withaul EBP

• Rear view shown without ESP actuator assembly.

• The turbine inle~ not shown, utilizes an alignment dowel for positioning on the IU11line housing.

Turbo ' E' Sarles without Waala1ala and with EBP

• Front view shown with EBP regulator moved to front of pedestal and top down

mounting bolts.

• Becausa the ·e- Series does not utilize charge cooling, wastegaled turbochargers are not incorporated in the Econollne engines.

1 4

Thrbo mounting bolt

No EBP regulator

No EBP actuator

Thrbo mounting bolt

Wastagate actuator

Location for dowel

1\irbo bolls

To waste1111te actuator

Waste1J11te solenoid

To manifold pressure

AIR CHARGING SYSTEM

Turbo "E" Sarin without Waslagala and with EBP

Exltaust back • Rear view shown

To air induction inlst

CAC Houai"l a11d w ........ c ...... . Note: The Inside of this housing will be

damp with oil mist carry over from the closed crankcase ventilation system.

• Oil is not an indicator of a turbocharger concem.

w •••••••• c ....... s ....... ••• Linea

• With the electronically controned wastegate. a pressure drlferenlial between

the induction system and the intake is used

to regulate boost pressure, via a duly cyCle

controlled (PCM) solenoid.

15

Waolagala Achaalar Dparalian

• The wastegate actuator Is a spring lOaded diaphragm acted on by manifold pressure and controlled by the wastegate control (WGC) solenoid.

• The wastegate control solenoid, duty cycle controlled by the PCM, is allowed to bleed pressure via a hose connected to the air intake system for precise control.

• Spring pressure closes the wastegate.

Note: A tampered or disabled wastegate will result In decreased performance and potential turbocharger damage.

Waotogala Aclualar Dlagnaallu

• To test the wastegate actuator, apply regulated air pressure to the actuator. starting at zero 11nd slowly increasing pressure while observing actuator rod movement.

• The actuator should start to move at 5 psi.

• The actuator should hold 5 psi lor

30seconds.

lnlaka Ia CAC Hauslna Hu ..

• The CAC intake air hOse has offset diameter tnlet and outlet, this is due to the diHerence in the CAC housing and intake covers.

Note: Hoses are of special material and should not be substituted during service.

16

INLET

Charge Air Cooler Housing

Open - Closed

Open+----~ Cloud

Non Charga Air Culacl

WGC Actuator

Green Hose (Vacuum)

Apply pressure horo

Charga Air Coaled

0

TURBO REMOVAL AND INSTALLATION

Nate: Because of th e addition of the charge air co aling piping, i t is normal Ia hear same turbo noise (whine).

• If turbo noise is reported, lirst check to insure all sound insulating material is in Hs proper location,

if not, install all insulation in proper locations.

• If all insulation material is in the proper locations, check for wheel to housing contact at the turbine or

compressor, if there are signs of contact then replace the turbo.

• If the insulation is present and no wheel to housing contact is present, the sound may be normal.

Door hinges

Sound insulating material shown from inside the lender

Sound insulating material shown from inside the vehicle

Sound insulating material shown out of vehicle, side view

Sound Insulating Material far Engina Naisa

• When diagnosing engine noise complaints,

such as turbo whine, you must first check

to see that all sound insulating material is

in place as shown in accompanying

photos.

• The material is in the fender and mounted

between the fender and the A·piller and is

used to isolate the engine compartment

from the vehicle's interior.

There should not be any holes or gaps

between the A-piller and the fender.

17

CAC Pip ..

• First remove the two nuts holding lhe Power Stroke cover in place.

• Then, loosen the four clamps that are holding the charge air cooler p1pes to the

charge air cooler housing.

Important: When reinstalling clamps, tighten to 71 lbl/ln (8 Nm), to Insure joint Integrity, performance, and Internal engine protection.

CAC Cenn .. llens

Note: Alter removing the charge air pipes

It Is normal to aee oil inside the flex ible hose area.

CAUTION: When the intake system is

open, care must be used to avoid any foreign objects from entering the engine or charge air cooler system.

CAC C•nn .. ll•ns

• Next loosen the two clamps on both lower charge air cooler pipe connections at the charge air cooler, and move charge air cooler pipes out of the way to access the

turbo.

18 D


CAC Cannecllan•

• Remove all wiring and hoses going to the charge air cooter housing.

• Loosen hose clamps holding charge air cooler housing to turbo and Intake covers.

Air l nduclian Hue

• Loosen the two ctamps hold•ng the air intal<e hose to the turbo.

• Remove the air intake hose.

Exltau• t Pipe

• Next lOosen v·band ctamp holding exhaust pipe to turbo.

• Move exhaust pipe out ot the ~ tor turbo removal.

• When reinstalling ctamp, tighten to 50 tbtlin (5.6 Nm).

19


lxllaaal Jalal Adaplar

• Loosen the v·band ctamp holding the

exhaust inlet adapter to turbine.

• When reinstalling clamp, tighten to

100 lbliln (11.3 Nm).

Tarloachar1ar AuamlolJ

Note: In-chassis removal and installation

of turbo requires leaving the pedestal

attached to the engine.

• Remove the two bohs hokling the turbo to

the mounting pedestal.

• When reinstalling bolts, tighten to 35 lbs/11

(4 Nm).

• To install turbo, reverse above steps.

20

Fill Stage Step # 1

First Injection Step # 2

FUEL CHARGING SYSTEM

FUEL SUPPLY PRESSURE

• INJECTION PRESSURE

While the lower land of the plunger covers the upper port in the barrel. plunger movement increases pressure, unseats the delivery check ball, and begins fuel delivery

Split Sh at Dpuatlaa

Split shot Injectors provide improved exhaust emissions and quieter engine operation, particularly at Idle, by talloring the injection of fuel, without a decrease In performance.

Split shot infectOrs (prime) have been used in Calllom1a engines since the 1996 model year and all 1997 Econohnes. Now they are 10 all Power Strokes.

Plunger

21


0 FUEL SUPPLY PRESSURE

• INJECTION PRESSURE

22

When the tower land travels past the upper port in the barrel, pressure decreases and fuel delivery is stowed.

When the upper land seals the upper port In the barrel. as the plunger continues to move down, the delivery cycle is completed.

Injection Pressure

End of First Injection Step #3

Second Injection Step # 4

- Without Split-Shot

With Split-Shot

Does not fill en tire IJl'OOve

Fuel lUter


More robust one piece seal

Post Jan. '98 oU

Reservoir

IRje<lor 0 -rlnt•

• The injector now uses a more robust one

piece seal to replace the two previously

used for the center position. No change

was made to the Injector.

• This change was Incorporated as of engine

serial number 642092.

Note: The O·rlngs are to be used when

servicing all previous DIT engines. 0-rlng

will fit loosely In groove.

011 Resnvalr

The new reservoir has the fuel filter

assembly mounted to It via two bolts that

pass through the housing.

Note: These bolts are not open to oil and

must be removed for removal and

installation of fuel filter assembly. In· chassis fuel filter assembly removal does

not require reservoir removal.

• The oil reservoir Is now a two-piece design

which allows for reservoir cleaning when

required, such as during an engine

overhaul.

• The reseMllr top is auached by six bolts

and is sealed by a one piece molded

silicone gasket.

23


Fu•l Filln

• The fuel fiber continues to incorporate a water separator and drain, whfle supplying fuel lo both cylinder heads.

Fu•l Filln

• The fuel filler assembly Is equipped with a heater to warm fuel to allow il to pass

through the fmer element In cold ambient temperatures.

• The fuel heater enables at temperatures Jess than 45• F (7• C) and disables at 75• F (24• C).

Fuel Pre•aure R•aulalar

• Fuel Is returned to the tank via a fuel pressure regulator and fuel return line.

• When reinstalling regulator, tighten bolts to 50-70 lbf/ln (5.6-7.9 Nm).

• Fuel pressure is regulated to a minimum of 30 psi independent of engine speed.

• Spool and spring are serviceable (not shown).

24

hose

EDT

0

Fuel supply to right l'l!aJ' head

Fuel heater and water In fuel switch

Drain valve


Tab

Element

Fual Filter Sarvica

Fue l Filter R• •••• l • Loosen the filter lid with a standard oil filter

wrench.

• To release fuel filter, depress tabs on side

of filter.

• A dual element fuel filter will be released

during the 1999 model year.

• Note: The fuel filter element Is smaller

than previous DIT engines and a correct

filter element Is required In the housing

for fuel to flow to the Injectors.

Fuel/Wa ter Drain Ro•on l

• For service, all parts of the assembly are

available separately.

• To remove the fuel drain, remove Ule four

retaining screws, tilt the drain away from

the housing and pull downward.

• When servicing. tighten retaoning screws to

20-25 lbflin (2.3-2.8 Nm).

Fuel Hea ter/ Water In Fuel Sens u Re•ewal

The fuel heater connector and water in fuel

sensor are combined on one unit.

• To remove heater/sensor remove Ule two retaining screws and pull away from

housing far enough to dosconnect Ule wire

going to the heating element.

• When servicing, tighten retaining screws to

20-25 !bflln (2.3-2.8 Nm).

25


Fuel Heeter s ... vl ..

• To remove the fuel heater. hrst remove the heater/sensor as shown pr6VIO\JSty.

• lhen remove the two screws that hold

down the fuel heating element.

• When replacing the element, tighten retaining screws to 20..25 lbl/ln (2.3-2.8 Nm).

r .. l FUt ... Staadplpe s ... vlce

• To remove the fuel stan<lptpe, first remove the fuel heater element as shown above.

• lhen pull the standpipe straight oot.

• When installing, be sure to install spring and valve.

Fuel rut ... s .... 1 .. r ... te

• The fuel fiHer assembly is shown here completely disassembled.

28

Fuel heater

Standpipe

\

Lid

Fuel liltar elemant

Fuel filter lid seal Fuel liltar

Drain valva r t = -0

0


Flo.alilllr 18 Lfli dw ._..lui......,. !boa

FueJ OUIIO

right rar

7

Fuel supply

Fuel inlet

Fuel out to lefllronl

Fuel return

Fuel inlet from Iilier

Fuel supply

Fuel return

F11el S•,ly Sys te•

• No return lu>es are attached to the cylinder heads. only supply Iones.

• Excess fuel is returned from the pressure regulator valve to the fuel tank.

• The fuel filter's fuel supply and return lines are a one-piece assembly.

Fuel Chock Valve

• The new fuel system Incorporates a fuel inlet check valve In the fuel supply lilting to each cylinder head.

• The check valVe Insures that there is a constant and steady fuel pressure in the head lor fuel delivery.

It fuel pressure IS low In one head and normal on the other then inspect the check valve lor debris; rl no debris •s found then replace the valve in the head thai exhib~s low pressure.

• A sc:reen in the valve Is used to stop debris from entering the valve.

27


Fuel S•,.ly Sys le•

Fue4 is supplied to the luel finer by an eleclric

pump. The fuel finer is pressure regulated. Excess fuel is returned from the fuel finer through lhe pressure regulator valve, to the fuel lank. Filtered fuel is delivered lo the cylinder heads where U enters !hough check valves. No fuel return from the cylinder heads exists.

Fuel Prnsure Check in Right Head

• To check fuel pressure in the right head Install a fuel pressure gauge In the plugged passage at the end of the head opposUe the fuel supply line.

• Fuel pressure should not drop below 30 pal. It is not uncommon to see fuel pressures as high as 80 psi.

• On Econoline, the lett head should be checked tlrst. The alternator and bracket must be removed to gain access to I he fuel pressure fitting on the right head.

Fuel Preuun Check In Left Head

• To check pressure in the left head install a fuel pressure gauge in the rear of the head near the turbocharger.

• Fuel pressure should not drop below 30 psi.

Note: When routing lines, be sure to route them away from hot or moving parts.

28

- RETURN TO TANK

Electric h>el pump

Left cylinder head

FUEL PRESSURE C=:J SUC'nON

High pressure oil line snap to connect fittings.

Snap to connect high pressure lines


Full Pressure Check at Fuel Pump

• VoHage at the fuel pump should be

checked to insure that the pump is being

powered by the PCM.

• If there is no voltage at the pump the

inertia switch, located behind the left hand

kick panel, might have been tripped.

• To check fuel pressure at the pump

install the fuel pressure adapter tee

(Tool #01 4-00931 -2) and install a fuel

pressure gauge (Tool #014.00761).

High Pressure Oil Line Snap Ia Cannect Fillings

• The fittings allow the high pressure oil lines

to be connected to the high pressure pump and heads simply by pushing them Into

place.

Note: Whenever high pressure system is

opened, air enters the system and the

vehicle needs to be driven to remove the air.

High Pressure Oil Lines

Note: Push the lines Into the fittings until

you hear/feel the snap ring "grab" the line.

Insure connection by pulling on the line.

• Hoses which have been specilically

designed to withstand the high pressures

(up to 3000 psi) and temperature

differentials are used to direct the high

pressure oil to the oil galleries in the heads.

29


Dlsunnut T••l

• To release line from fi«lng: While firmly pushing the line straight Into

the lilting with one hand, insert the tool beiWld the btacl< release sJeeye and gently pul on the line.

• The tool part number Is 303-625.

Injection Cantrol Preuure Black 011 Tul

• The block off tools are also ol a snap to oonnect style so thallheY can be oonnected to the high pressure oil lines on the engines.

• The tool part number for the block off plug is 303-628 and the ICP adapter is 303-627.

• These tOOls are necessary to accurately diagnose the ICP system during hard starVno start diagnosis.

30

Insert disconnect .----------, tool here to release

Essential tool #303-625

ICP Sensor



,....,

NEW AND REVISED SENSORS

New MAT Sensor

Revised MAP Sensor

Revised CMP Sensor

Relocated EBP Sensor

Manifold air temperature sensor

Manifold Air Temp Sensor ' F' Series Only

• The MAT sensor is used to control fuel and

timing when intake air is cold and adjusts

as air temperatures warm up.

Manifold Absolute Pressure Sensor

• The MAP sensor now sends an analog

signal to the PCM instead of the digital

signal previously used.

• The sensor is mounted to the heater and

air conditioner plenum on the passenger

side of the engine compartment.

31

NEW AND REVISED SENSORS

Ca•ahall Paalllan Sanaar

• The camshaft pos1tion sensor circuitry has been updated to be tess sensitive of clearance to the trigger wheel.

• The part number suffix on this sensor is C93.

• The engine serial number break for this sensor is 623916.

• See CAMP sensor usage chart on page 45 for information regarding different CAMP

sensors and their Identification.

Exhaust Baok Prauun Senaar

• The exhaust baCk pressure sensor has been relocated to the front of the oil reservoir.

• The tube has been redesigned to accommodate the new sensor location.

32

Part nwnber sultix location

7.3 DIT POWER STROKE SPECIAL

COMPONENT ~ Mlnanting Bolts (to podastal]

'l'urhcl\ugv Elcluws1 lnWI Adapter V-baNI Clamp Turbocharger Compresaor Housing (to center section) Turbocharger Turbine Housing (to center section) Turbochargor EBP Valve Housing (M6 bolt) (to turbine housing) Air Inlet Covon (M8) ~ntake manifolds) Exhaust Manifold (to cyUnder head) (M I 0)' Exhaust ManUold Flanges (to up pipe) (M8)' Exhawrt Ad•pter Flange (to up pipe) (M8)' Turbine OuUet Clamp

Step 1 CyUndor Head Bolt Torque Step 2

Step 3 Flaal Iapclar HaW U.W. Clamp MAnanting loll Flaallnjutor MolAl D..,. Clamp SILoahle Boll FuaiiWI End Plug Glow Plug

lnjoctor. Oil U.Ooctor Mounting Boll 00 RaU Dnin Plug 00 RaU End Plug .. Valvo Cover Mounting Bolt OU Pan Drain Plu~ Crankshaft VIbration Dampener Bolt OU Laval Gauge 1\tbe Adapter Nut Front Cover Mountini Bolts Water Pump Mounting Bolts Oil Pick-up Tubo flange Bolts

Connacting Rod Nuts (first step) lfinal)

Watsr Outlet Tubo Mounting Bolt lnjoction Control Preosure Sensor ocpy-Flywhool Maunting Bolts

Moin Bearing Cap Bolts (lim step) (linol)

Rear Cover Mounting Bolls High Pressure Pump Gear Bolt Injector Prossure Control Valve Body Injector Pressure Control Valve Nut Filtor Dral1t Volvo Rno""ir Lid Scnwo

To Insure proper torque, aU threads must be cleaned and lightly lubrt04tod. • Apply "Nover Son' compound to threads of bolts prtor to ossamhly. - 1'htea.d. of apply Loctito 11277 Ill bolts prior to assembly.

thana•• er ftiW l nhrmati1n. is in. •alii type.

TDROUE DATA

STANDARD METRIC 3511d- 11 47.5 Na 100 IId- ia lUNa 11- 14lbf- ft 15 17 Nm -15- 18 1bf- lt 22Nm 60-80 lbf- fn 6.8- 9 Nm 18 lbf-ft 24 Nm 45 lbf-ft 61 Nm -18 lbf·ft 24 Nm 18 lbf-ft 24 Nm 50 Jbf-in 5.6Nm 65 Jbf.ft 88Nm 85 lbf-11 115 Nm 95 lbf-ft 129 Nm 120 IId-ia ltNa 120 IId-ia 14Na 97 lbf-m II Nm 124 lbl-in 14 Nm - -

j lOB IId-ia 12Na 53 lbf-in 6Nm 59 lbf-lt 80 Nm::_ ___ -1 97 lbf·in II Nm 28 lbl-lt 38 Nm 212 Jbf-lt 287 Nm 24 lbf-lt 33 Nm 15 lbf-lt 20Nm 15 lbl-lt 20Nm IS lbf-lt 24 Nrn 52 lbf-lt 71 Nm 80 Jbf.ft 108Nm 15 lbl-lt 20N~ 22 lbl-lt 30Nm 89 Jbf. ft 121 Nm 75 lbl-ft 102Nm 95 lbf-lt 129 Nm IS Jbf.ft 20Nm 95 lbf-lt 129 Nm 35 lbl-lt 47 Nm 55 lbf-in 6Nm 20-25 1111-in U - 2.8Na 75-1! 1111-ln 8.5-10.7-..

33

7.3L DIT P11wsr Slr11he Diagnostic Information

Diagnaslic &uida•, Scha•alics, and Fault Cade

Ll•l• far all RIDdal yaar• ara pravidad in tha back

af this publicalian.

34

7.3L DIT ANTHOLOGY

Regulator housing

7.3L DIT ANTHOLOGY

Pra January 1998 Fuel Filter Service Note: All Individual parts are available lor repair as ne<:essary. Fuel Filter Rutrlclien Se•sor Reae•al ••• lns tallatlea

• To remove the fuel hiler restriction sensor first disconnect the one wire connector.

• Then use a w,.· sending unit socket and remove the sensor In a counler clockwise direclion.

• To reinstall reverse steps and torque sensor to 35-45 lbf!ln (4-5 Nm).

Fuel Prusvra Regulator Heusiag Rema•al and lns tallalion

• Remove the two (2) 1 Omm regulator retaining cap screws.

• Separate the regulator housing from the filter housing by approximately 1/4' to enable the fuel passage shOulder to properly clear the housing.

• Slide the regulator hOuslng upward to disengage it from the metal fuel l1ne.

• To reinstall slide regulator hOusing down to reengage rt wrth the metal fuell1ne.

Align the regulator housing so that the

passage shOulder rrts into the fuel filter hOusing.

• Reinstall the two (2) 1 Omm cap screws and torque to 100-120 lbtnn (11.3-13.6 Nm).

Reconnect the fuel pressure sensor one wire connector.

35

7.3L DIT ANTHOLOGY

Pra January 1998 Fual Filtar Sarvh:a

Watu Saa .. r Ra•nal ••• ••••• u.u •• • Disconnect the one wire connector.

• Use a 9/16' wrench and remove sensor.

• To reinstall reverse steps and torque to 18-241bf/ln (2- 2.7 Nm)

Pual Haatu Cannaclu R•••••l ••• lnalallatian

Note: W- sensor must be removed before removing fuel heater connector.

• [)jsoonnect the external one wire connector.

• Rotate the fuel healer connector clOCkwise until II clears the lOCking tab.

• Pull connector out and disconnect the Internal one wire connector.

• To reinstall reverse steps

38

Fuel drain valve

Left hand threads

7.3L DIT ANTHOLOGY

Pre January 1998 Fuel Filler Service

Fuel enol Water Drain Val·n Removal and lnatallation

• Remove the two phlilips head retaintng

screws

• Tilt dram valve away from the filter houstng,

note the location of the o-rings.

Pull valve downward to separate from

housing.

• To reinstall drain valve reverse steps and

tighten screws to 2Q-25 lbllin

(2.3-2.8 Nm).

Stanol Pipe enol Heating Elaaant Ra•nal enol lnatallatioa

• Drain fuellrom filler housing.

• Remove fuel filler lid and filter element

• Note: Stand pipe Is plastic and has tell

hand threads.

• Using a 7/8' crows foot remove stand pipe

by rotating It in a clockwise direction.

• Disconnect the internal one wire

connection at the fuel heater connector

Remove fuel heating etemei'IL

• To reinstall, reverse steps and tighten

standpipe to 120 lbflln (13.6 Nm).

37

7.3L DIT ANTHOLOGY

Craakcau

• The crankcase was redesigned starting with engine serial number 375549 with thicker valley walls to increase stiffness to the assembly which reduces radiated

engine combustion noise.

• The crankcase was also mod1fied in !he tappet sheij area.

Vain Traia

• The valve train was redesigned to replace the cam follower guides and retainer to

redesigned cam follower guide assemblies which bolt directly into the crankcase to hold the follower in place.

• The redesigned roller follower guide assemblies are now held in place with a capscrew for each pair of tappets which has led to the etimination of the roller follower guide retainer.

• This change occurred at engine serial numbar 375549.

38

Pre 1997 Model Year

1997 Modal Year

Pre 1997 Model Year

t t

1997 Model Year

Pre 1997 Model Year

1997 Model Year

Deaeration valV11

1997 Model Year Pre 1997 Model Year

Inlet port

7.JL DIT ANTHOLOGY

Cylla•u Had &askal

• Due to the change in the crankcase and valve train the cylinder head gasket was also changed.

• The redesigned cylinder head gasket provides Individual holes for each push rod which w1ll guide the push rod ball seat into lhe lifter.

• This redesigned cylinder head gasket can be used on previous engines.

Fralll Cnu

• A dearatlon valve was inserted In the front cover beginning w~h engine serial number 201681 through engine serial number 375549.

• The front COYer was redesigned starting with

engine serial number 375549 to help keep the oil pump primed for initial start up.

To accommodate lhis change the pump inlet port was rotated oo• which moVed the pickup tube from the left to lhe right.

• The front oil COOler header gasket was also redesigned because of the change to the front cover.

The front cover has been modified for the updated reservoir to front COVllr gasket and passages have been cast and drilled into the front COYer to incorporate the standpipe.

• The eng•ne serial number that the standpipe was incorporated is 201681.

3 9

7.3L DIT ANTHOLOGY

Oil Ruuvair Jar lho Hlth Puuau •••P As ol engine serial number 187100 lhe

reseM>~r has been cast and dnled lo Include 1he ~and is drilled. tapped and spo!laced lo use both a stralghlthread, o ring sealed engine oil pressure sensor and lnspectoo plug as sealing enhan<;emenls.

Oil Paa

Due 10 the relocation of the pickup tube the Otl pan baffle was redesig.ned to allow the pk:kup tube to pass through il to the bottom of lhe pan. This was done as of eng•ne serial number 375549.

40

~-,_ ___ .

One pieca molded gaskel

0-ring seal 0-ring seal ..... _____ _

1997 Model year

Pra 1997 Modal year

Standpipe location

...

Fuel Injectors Pari Numbers

Nawlelar lnjnlu Pari Num•u

Da lep ef Da 1eld screw Cenwerl .. le iajecler eelea•l• replanaeal aails Fer• aa .. er

FIDIRAL 18161 87C3 1821836C2 F7TZ9E527 ARM

PlUME 18228D3CI

All '97 •E" series and Colifornia "F' series

1825125CI F7TZ98527 BRM

Federal "F' sarles 1997 Modal

7.3L DIT ANTHOLOGY

Inje ctors

California calibration, model year 1996-1997, utilized a "Split Shor injector that in conjunction With the proper PCM calibration provides rate shaping capabilities. Our rate shaping provides an initial charge of fuel early 1n the injection cycle, followed by a larger quanmy of luel to complete the injection cycle. During the 1997 model year Econoline utilized the "Split Shot" injectors In all Federal and California calibrations.

Rate shaping of Injection proVIdes for a longer duration of tile injection process. providing a cleaner, quieter bum.

• Federai"P Senes (49 State and Canada) injectors were unchanged through the 1997 model year

Note: Injector solenoids are now white In color Instead of the prior black units. No functional change exists in the solenolda.

Fuel Sye le m

• The fuel system has been improved by new fuel supply pipe assembly and banjo frtbng.

The new fitting on 1997 Eoonollne and 1997 California "F" series incorporates an accumulator to steady fuel pressure tor the •split Shot' Injection system .

41

7.3L DIT ANTHOLOGY

Hl1h Prauun Oil P••P

The high pcessure pump has had the drain check valve deleted. This brings the variation o1 hogh pcessure pumps used on the DIT to three. The pumps may be idenlified by !he absence or pcesenc:e of the anti drain check valve.

• On 1994 1/2 and 1995 model year engines up to serial number 187099, the Initial high

pressure pump did have a drain check valve but did not have an edge filter. The

edge filter was part of the inJection pressure regulator.

• On 1995 model year engines starting with serial number 187100, up to serial number 201680, the high pressure pump did have a drain check valve and an integral edge filter. The edge filter was deleted from the

Injection pressure regulator.

• On 1996 model year engines starting with senal number 201681, the high pressure pump does not have a drain check valve. but continues to have an ontegral edge filter.

Hl1h Pnssan Pump Baoksl

• The high pressure pump gasket has been modified to seal the standpipe between the pump and front cover.

Note: The correct gasket must be used to pnevent Internal and external oil leaks.

42

Check valva No check valva

1994 1/2 1995 1996

No edge 61ter or plug

Seal added

"!'"Series 49 State

O o o D-ring locations

"E" Series and "!'"Series Callfornla

7.3L DIT ANTHOLOGY

lajac llan Praaaara Ra1alalu (IPR)

• On all engines starting with engine serial number 187100 and above. the injection pressure regulator does not have an edge fitter, but the high pressure pump does.

Note: There Ia now a service package lor the IPR o-rlngs that allow you to replace them separately II needed.

Oil Pump

The engine lube oil pump has been modified to include the words "our or "damper" on its

face, this is to Insure that the pump is installed correctly and no damage occurs to the front cover due to Incorrect installation.

Wlrin1 Harnaaa and &law Pl111 Ratay

• The wiring harness was redesigned starting with serial number 375549 to Incorporate gold plated terminal pins to Increase reliability and meet OBO II stancla!tls.

• The sensors and connectors that received the gold pins were CMP. EBP. ECT and ICP.

• The UVC harness ._ oncorporates a wire clip instead of plasliC tabs to attach to the ~

klr ~ reliability and ease of rem:wa~. • The oedesigllf!d fJcN P'Jg relay system is not

aflected by high opei81J11g lempelatures. This

redesign includes a new relay, relay cowr, and

mounting brackets. • The 1997 Econollne and 1997 Calilomia

models also include a new housing post (GPC sensing) in the redesign.

43

7.3L DIT ANTHOLOGY

Thnmaatat

• The thermostat. along with being longer to seal the lower bypass seat, opens at a lower COOlant temperature, eg• c (192" F)

from 96" C (2os• F) to allow the engine to operate at lower temperatures.

Wain Pump

The water pump has evolved since 1994 model year Currently there are two part numbers to sel'llice the Pre January 1998 engines. The F7TZ-8501·ARM pump is to be used on all 1996 and 1997 model year engines with serial numbers starting with 201681 through January 1998 production. The FSTZ-8501 ARM is to be used on all engines from the 1994 model year serial number 000501 through 1995 model year serlal number 201681. The FS pump comes with a bolt pacl<age that is to be used to mount the replacement pump. The FS pump also incotpOrates a larger bealing than the 1994

pump, au pumps, new and remanufactured, have an Improved silicon carbide seat.

44

1996 Modcl Year

1994 - 1995

1996 - 1997

1996 - 1997

Pre 1996 Modal Year

Either pump

may b. ...

Parts Suffix Summary

Sullix Kay Pin Lngth Features Malarial

cs6· CMP ssnsor at job! 94.5 Tin Plated 1.152 ±0.006"

C97" Tin Plated 1.152 ±0.006"

csa· Tin Plated 1.142 ±0.004"

C99 Improved Circuitry Tin Plated 1.142 ±0.004"

est· Gold Plated 1.152 ±0.006"

C92" Gold Platsd 1.142 ±0.004"

C93 Improved Circuitry Gold Plated 1.142 ±0.004"

· No longer available as service parts

Part number suffix location

No wear sleeve

7 .3L DJT ANTHOLOGY

Camshaft Pasitian Sansar (CMP)

• The CMP sensor has also been changed to

incorporate gold plated pins. There has also

been changes in length and circuitry since

1994. To identify each CMP sensor there is

a part number suffix located on the top of

the sensor near the sensor wiring connector.

The CMP with a part number suffix of C96

is 1.152" :t o.ooo· in length and has tin pins,

this sensor was used in engines with serial

numbers between 000501 and 033780. A

C96 sensor should not be installed as a

replacement sensor. The sensor with a C97

suffix is tin plated and 1.152" :t 0.006'" in

length. This sensor has improved circuitry

over the C96 sensor. The C98 sensor is

identical to the C97 except for the length, it is 1.142" ±0.004" In length.

• Due to the change in wiring harnesses three

new sensors were made with gold pins. The

C91 sensor is 1.152" :t 0.006" in length,

which was used in engine serial numbers

375549 through 408253, and the C92 is

1.142" :t 0.004" in length, which was used in

engine serial numbers 408253

through 623916. A sensor with a part

number suffix of C93 has gold pins and a

length of 1.142" ±0.004', this sensor has

improved circuitry over the C91 and C92

sensors. The C93 sensor is being used as

of engine serial number 62.3916.

• The camshaft position sensor circuitry has

been updated to be less sensitive of

clearance to the trigger wheel.

• The part number suffix for the gold pl:'lted

sensor is C93 and C99 for the tin plated sensor.

Crankshaft

The crankshaft's rear seal no longer utilizes a

wear sleeve on production DIT engines

beginning with engine serial number 201681.

The service rear crankshaft seal does utilize

a wear sleeve, no change has been made to

the service seal package.

45

7.3L DIT ANTHOLOGY

Dil Caalar K•• ••• Prauura R•t•l•t•r .,.. Fill., l yp•u

• As of engine serial number 286299 the oil

pressure regulator and the oil filter bypass

is held in with a c-clip instead of staking.

Note: Bypuaa valves should be In place to

avoid engine damage.

4 6

Oil pressure regulator with C-clip

' Staltad" ail pressure regulator

Pre 1996 Model Year 1996 Modal Yeor

~---------dW'v'lJ

i~"§"(£t7!8C

181431.50[ -cL.A"t>AP-_ ---------

Extra sealant required in these locations

Fleetrlte number CH1824392

7.3L DIT ANTHOLOGY

Intake Hun

The hoses connecting the Mbocharger discharge Y pipe to the intake manifolds have been changed as of engine serial number 201681 to delete the humps and may be used interchangeably.

Oil Pen s .. Unt

When reseal1ng the Oil pan, make sure that

the silicone rs apphed property. Extra sealant is required at the ends of the radius' on each end of the pan. Make sure to avoid applying too much sealant 10 pan rails since il can fall off in the pan and plug the oil piok up tube. Always use dowels (make locally), to locate the pan during Installation. Whenever lhe oil pan is resealed, add a bottle of anti foam concentrate to the oil available at Navistar dealers (P/N CH1824392).

-47

'7.3L DIT ANTHOLOGY

lalake Cawers

The number of bollS holding the intake covers in place went from eight (8) to ten (10) this change was done at engine serial number 174666.

F1exp1ale

The flywheellflexplate, as of engine serial number 201681, used in conjunction with automatiC transmissions has been changed lor 1996. The flyWheellflexplate's thickness

laje• ler Torque

tr;ector bOi1 totque is 120 lbf/in (13.6 Nm). Faiure to proper1y tighten the bollS may lead to engine damage U the copper washer at the

bottom of the injector burns away and the lower Q..ring mens. allOWing fuel to pass the outside of the injeclo< Ul!O the combJstion c:ytinde(. his

oommon lor relaxation to occur and totque

wrenches may 1ndicate less than 120 lbflln (13.6 Nm) on the boi1S.If less than 50 lbflin is measured with a wreriCh and an oveffueling type

corJCem exisls. such as a knock, smoke. or fuel out the tajpope, renlOIIe the loose lnjec:lors lor inspeclion. and repair as neoessary. Remember when servicing 1njectors to lubricate the boh threads to obtain the proper damp load and

avoid 011ertlghtnlng the bollS since Injector damage can oocur.

Oil Capadly

The oil capacity on all DIT engines Is 14 quarts when dlanglng the oil and finer. When released

"' 1994, the oiiiEMlt was described es 12 quarts Wllh finer dlange. The dipstick was dlanged at the introduction of the 1995 model to lnd'JCate lull when 14 quarts were installed. The benefit of more oil is less chance lor aeration.

4 8

Intake Cover

• Tea Ball Raplacu I Ball

• •••••• •••••• 17411&

• •••••••• laralolllly ............. 211111

Injector Torque

• Carracl T••••• la 128 1111/la (13 .8 Na )

• laaalllclaal T••••• Raaulla ln Engine ••••I•

• Allar •••••• ••• •••• •••••• • , II • ••• • • Is •••••••• U wlll loa lau •••• 128 1111/ in (11.1 II•) - lh•l• h •ighr than II llollla (&. 1 II•).

lalaaee• 1114 •• 12 Uaart Capu ily

ll,ellclll Racalllorat•• lar 14 Qaart Capuily Ia 1111 Mahl t .. r

laaraaaa• Ill Lawai Pravl•a• Ballar Oil •••• u •• ..........

Cll c

7.3L Diesel Pin Out Values - 1994 112

Pin I Name CircuH f 1 Wire Color

STOIMI 4 PBA 9770

JVS

BUS?.i!t~l=:iEGND

R=lf I EBI ' Bl'.l

MP

308

553

.§1§_

~

'95 I 64S

f!S.:_lG p.~

w

11)1 l.O·t --. .......

'RGND 'RGND

14 3618 5708 ~ ~

K·'-'

Key Off

1v

.SY

3-4 v/83 Hz. I

~ 1v

1v 1v ;--+-'

~ 552 T-11 )v

Ov/ 12v

12v/Ov .Bv-.95v

sv

)y

12v

Ov to 12v '""OV

)V

0,

6 08- .7 I Of I ICP t:a 08-lG )V .25·.4V

• 0 155 GY·W >v .5-4v ~EF 151 BA·W .41V 5.1 :iGRO ¥.-:;s 121

I CID 17 l7 V 1A ..... ,...,.,.,_

IGNO 5700

0

BK·W

~ 1v

1v

;v iv I+

Ov

low Idle

_.a±._ 12v/Ov

12v/Ov

.35v·4.5v .J:i . . -

High Idle

a. 12v/Ov

...1.2l!/Ov

.25~

.Sv ~v-4.5v .35

-R~·nae

)V

Ov/12v

'Ov

iy . 212"'f ~·F

Ov

7V 1 7v 1 13().720 Hz I Hz S.Sv/660 Hz 13():120 Hz

Ov

Ill 'feh!de ~ Ov 10 12v Ov to 12v I

>v I ov I Ov

i:V I . s _9y I )v ! !·!·~v ;6;~3jt

•. sv

Hz I 2.1v1200 Hz I 43/249 Hz !z 6v/720 Hz 5 Hz-720 H1

1v I Ov I ov

On. 'al1<ing Brako Aop!led Switch "Up/ lie Va!ldailon Switch PPS Pedal '

S!'.:!_ROM !'ower !

:ase Ground P!K!al !'!!§i!!9n Switch "Uc

~xhaust Back Prm!!! Sensot . .. . .. !!l..:lJl - -lli!!U

a essure 1 1 Q{113 Hz ess :ngine Oil Tgmp 4.7v • 4Q•f/.68v = 230cf •take Air Temo. ~· -40' F/.358v • 230' F

11 12v freouer 'osition Sensor 650·3600 RPM 1 :_~ls!nal Reflected CMP Sional

9hidt Speed Signal - Con!JOI !IC!!aae w!ll .arv •

1DOOiliof

:>ower Groun< :>ower Grounc

I DO$Iti()O

OWi I On. 12v = Uoht Off

1/obaOE

l ContrOl rresw e 'edaiSenso<

..,. , Con!JOI~ 65(

Ignitions GlOw P1u Power Ground

On\

en ...

Enalne Mounted Compo!111nts

EOT ICP

7.3DfT Electronic Engine Controls 1994 'lz

...

42Woy Connector

Truck Mounlt<l Compcnonto

..... !AT

Q ~

Cab Mounted Compontntt

PCMConnecto< Pfn-(104)

a. r - - ---•••• -~~. •• •• • KAPWR ' /""' I .... .'!L... ~ AP i

I .:::: ,

I ••••• ~...... I IVS I

11 Slgo 1 . - - - - - •• • · .'!'\ · •·• · · ' I .... L .... ~-~S~I - - ... ~ I

.. ~:--- EBPSI Nil ..... ~······~s~a, I I

_l __u_ ... 1.... I Slana/Ground ••••• 90

....• . nai Groun< , K~VPWf! J .. 1) •• , ""'fj""" -·--.I

1 . :n. . . •c• s~anoo~ ........... . . . 1~... GPC ConlrOf •••• .t.o.t •••••

11 EOT5' 38 .. . . .. . . . . . ... . . . . . I "'""' .,,,.,., I ...,.-1 --~--- KEYPWR .. . ....... ..

I --~- - - CMP~ •••••• ~ ••••• - - - - ~SSntt - - - • - - - - ····i:·· .. ·l m ' 1'

et.IP

Otow Plug Rtlfty

... _ ___. ---,._.__)

~ IPA

BEQ ;~; 12 VObiS

-~0!~! . .. . .. . . . .. . . - -- - . - . . . . .... -

-~-·---~ --' '

120 ... Oflt

EDC BA

W.~-~ ~-~"

:. ~~!0:~ ... ~-~-'?- · - · - · - · -

.. : ;·: ..

••

11

- - ~--.1~ 0

17

• 24

_ CJ.O_-FOCS -------

EFF..cl~ck

IOM Connector

••••••••••• E:l I

2 ~·V!'M-- - J ·· ··;.;···· · BUS · A .::::~t:::: SUS• ~-----· · ·-~·-··· YSS · ----~---- - vss • ---- -~---··

...... ttL ...

• • •• :·..... CPP (5witch) lt_.VDWit

... ·3; ..... BPA (switch) KEYPWA

..... -.-.-..... """ /'"""\ ···-·· ........... -----~ -- --- I""'-ICont<ol! (

it I --~~---· c:Sd., ~mWR a.--l::,'if--:> ...... 1 ffiA ~t<•l 10

.. ~ ... -----~----- ICASE--- •

:::t:t-viWR·-·-\9mmaf;'£j] •. ~.. ___ _ II'RLC-.o _ _ _ ___ _ ,. .. ....... ...... ... ::#::

.s.t,t~1)',t.'!l. l PWAGHD • 71,117

::::::::::>..c !Conrrol! ("

·····,3····· ·:::.~~·:::.

FEPS

EPA (06tted Unft • F"ttqu~y or Switch F1.1nc:•lons) 61 sees (to Spttd CortltOI SWitohtt) ~ .. I SCGNO

GREEN • SIGNAL CIRCUIT PURplE • HIGH YOLTAj .•. . . .. . :/BlUE= : EE !5 VOLTS! BLACK - GROUNP CIRCUIT

Power Stroke 1994112

1

01~ oeo:t 151 0112

1

I

1:12" 1

""' 0>03 1>3" 01:!3

11

BARO PCED . 1AT PCED

AT

I'C£0 loPJN

eoo UJrVS

CPP

E01'

KAM

.... "

tAT clrciA 001 oi tti'Kil_tow PCM ROM 1Ht .. ~~u~.

PCM I iltJil

AP

..... (lnl()ll .,,.._.....,""" E01'

Til TR

t17" 1 ,. .. , .,, .... 01 ...

I 1

Til EOT TR PCEO

TA...,..o E ,III'IM hioh TR &er~50r dr n out .........

1 TFT Trans I

124. 0220' 1>1>/IVS .... "'""' 831 0113 JFT TtanS llhlid

1' APINS

• T 1 MA9

tlt1 •

,,.. -· ....... ... .,.. SS2

....... ,. 1NJ

031 ·~ • 1. .,.. INJ

PCEO

NIA

INJ

"'' J211 tPA. ""' ....... 1 1 ICP

1

m· 010

1NJ •1 I

CEO 1 •_871 1 ! ·1278 .... 0270' 103 12110

1

I 1 1

PCED

ISS t IPR .... 01171' INJ ...... 0274

fO INJ

02n

048 0278 PCEO

..., .... 091 1291

...

INJ

IN.l INJ

1'CEO ..., INJ

NA

143 1501 NIA 818 0340 CMP

... NIA

41

863 ....

52

CMP P6A

1 _,__. --·-..... ·-1-2 Shill EffOt Low

Low &Ide • 3~ Shi I EtT'Of

""'""'' ..... ""' ICP

Low.,._.

CfO ~tuck lOW

•1 .. ..

• ..... -....... "'" "''· ....... Hiatt lo CVII • 18

C l~r'* If •

H I 1·18

Low t"'- theft 10 o:d. lnL C!l<:b •<&

1CP """"out"..,..,.. ......... . ......... ICP

Low· INJ

...

........ .

c,.,.., ,...,, •. ccr "' ..

l..ow tide .. ~l'kl •7 ·- •

--._ ................. -. .. . .

- IIOER I""'"" CMP ..,_ lf'!Yalid CCT I mont

Noise At eel

P8A ptlrkinQ ~k.t ~lied Mil

...... '"""'"not _,..,. Oel'a..ftt 1 1

I d • EO

""""'' ............. -'"""'' -E d ....,

s-t .... t<O£R ......... · I<C£A

_,l<()fR

s..!!d>TH4•

• '· ....... _

i otwr

............................

........ •

"""""' no1 · >Ina CCT I*" NoPCM l«n FMEM ... 4

FUEM ti"'Idt • on 4 C¥1 S..C. IIMf .... ICDEO

~cct..........,...., " .. .

CM. ~rwlllce1 1 ~ onM

Flo4£M .-.""'"'" .. run on • c;t.

""'' •"" lo>A1 "'" .. """m"""" oil nder nol t' 'lSI

Bank Wllh will m&f'lded <II

FMEM modt..ltiOM'IIIit_!\I00"-4 ~.

"'".,..,..oep ·-... .......... ................ ol

.... =--.. ..-._ ... _ ........... u:. ... IIII:M1 to DM. .... 0111 -s

~EM 4 low lkle tho« eo bllt. lf'lt,. c11t1. 18

Cvfndtr t101 CMttlbu~ durino CCT le9l ................... ""'""'""'· Fix IOW&Jdt ... ... .. .

Aborts KOEA THI No CMP ,._ ,..,.. ........... , ... '""'dna

-..><OE Beclf!C*I Hi I I

Swib:tl Tete • KOER

I IOSV biMed!Mif'ISOtOI'

.. .. f>uOvPCM Gt I blciMCI Mln&<W 01 PCM lnt~l PCM lflllute

I ~-~ <PCM lnl I M •iture

..

..

O<I'CM

l . b4 .. ed....,..O<PCM._,ooOV

,.,, ..,.,.IO<.PCM

1-....

.... .. ..._. . ........

-.....

,_ ... -010 I to around mo&l llkefV IMMfMtttll_ cnlv ~....wtd connettor or 1\&.Mess

II. lhortad Wector. falkld I

~or · ector I n I lallo(I IOM

.... c:ifociAI baaed sew.ot Of PCM ......... _ .. _

........ """"'"'I'CM wt...kM« .... IPA-

H 10 FMEM modt. f(lgtlt will rvn on 4 f;'tt. ............... -,

WIIYertaii\Of'

........ -· .. """""

... •

Ot ham$$& snort 10 .. ........ .... .,.. . .........

Hr d\a eii'Cuilr

Ol>t!V'fhM drcult, Swlldv1"Ct.4 !Qllunl lalltd to

POWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE

= :;: Clo<uit e..- =· - ..,.,_, eornrr..nra ... .o3<4 . .~ CMP """ ... 1 ... PCEO IOU EH ofQliot ,_..,. .,.. &obOe-occ . """' ...... - ...... ...., - d"""

"'"" GP GP,.,., , ....... Glow Pluo """ OOC • KOEO ..... ................ ' t.<IIOM FOCS cftcuh l Fuetdemend • OCC cl)fck. • KOEO """' 10M

1 I GP p • " Glow PI 0 Clrtuh Ia

960 1 1 MIIOM coo. I I ·-· > ontv :I""'<"IAIYIOM

••• 0<72 Elll' EBP cit Disables Melt: , di'CIJI ~ stntOr or PCM .., 1 ... PCMIIOM PQO.IOM ..... ........ ,.., .. ,. __ .,., """""""',.. EF 01 FDCS .... ~10M

• -"""" - 5Y biased s.ef'II!IOf Of

TR TR

~1· ... .... -- .. ... .. .. EPA EBP - "".,._, ..... t«lEA EPA-1 t 11 1FT 1FT ·-EPA .,.,.,.... - ........ -1 r,. n " ... mal

091 11211 4)1(4l AX4lOW

PCEO ....... 1100 1 '"" Aboltt KOER THI ' ll''lllemcr

4 EPC PC I I PCEO ....... ... .. ..,., . c I"""'"" "' • 47 EPC

S17 0503 PCEO a. .... -. - bo ,.,_.., . V~Jqr,rt ·.CN<onoSvo.-1741 EPC EPC

*31 - PCEO SlldO*f OH""' ,.....s ............ . 10)(11 tCcdl• ilouse not~ ()ptn Ot ~tot cwcuir. ~ ...... ........ 1 ccs .,....

83t F A -' CI\Jise 1'101 .. 1«)£"'"' .. , mt TCII. TCilOI'C\IIl .,. 0507 PCED Sod Cnttl R , ........ ~ THt • I<Of!A fCoclt Mtlll Cf\Jise not orHtl'ltl ... 1700 res T .1 ..... _

C.IM ... T 1 1101 il cruise no1 ..... 1 w• be sel on eYef

1 7 1 4)(-tl •x'"- 1 I

135 ED SodCn• ' ... • · K ••• lso noc_ Dt9Mnl) Wllh c:rv1se CO!'flrot 007 ., .. TFT TranamiNion OY.rto~ Conclbon

. ..., ..... ___ ..... _ --------------' IUD• _eo-._o...-_

KOEO - Standard Test Turn al accessoM$ off

Set STAR tes1er to Fast Code position

Latch STAR test button on (ground STI)

Turn key to ON position

Unlatching tile STAR tester during "lasr oode transmission will clear al ODdes in tile PCM (They wBt be SIO<ed In tile STAR teller lor viewing)

KOEO Key On E.ngine Off- Buzz Test

Tum all accessoM$ off

Latch STAR test button on (ground STI)

Tum key to ON position

After "fasr code transmission depress and release brake to aborl slOw codes

Depress and release a~erator pedal to start tssl

Codes will be displayed at end o1 test

(Tasl can be repeated by depressing and releasing accelerator pedal twice)

Note: The engine will run rough during the KOER Stsndsrd snd Cylindsr Contribution Tests/

KOER Key On Engine Running -standard Test

Turn al accessories ott

Engine oillemperaturo must be up to a minimum of 176' F (SO'C)

Set Star tester to Fast Code position. latch Star test button on (ground STI), start eogine

After Code 50 is transmitted, deQress at1d release the lotlowong swftches:

-AcceleraiO< Pedal (must de9<ess and release first)

~ Control On. Off, RMume, Sei/Accel. Coast -Emergency Bral<e and Clutch PIKiat -Brake Pedal (must deQress and release last)- Stab firmly to

activate brake pressure swi1ch

At the end of the switch test the PCM will perform the ICP and ESP step tests

Depressing and releasing the brake pedal after the last test will stop the CCT test and allow the PCM to transmit oodes

KOER Cylinder Contribution Test

This test wil run automatiCally alter a KOER test

Codes 51 thru 58 wtfl be transmitted to Indicate tile cytonder under test

Pass or lail oodes will be transmitted at end ol lest

This test can be aocessed directly by starting a KOER tes1 depressing and releasing the accelerator pedal once and the brake pedal two times (Ignore resultaot switch oodes)

53

Cll ...

J

Pin I Name

1. ....§§L_ Chad< E!!Qioeliaht P8A

2

l I FEPS la 4X4l

..§!&(:l BUSC< CASE

_ SSI l0 TCC l CP!:\~anl)

I TCS<Aulol

30 EBP 1' BPA

33 VSSC·l MAP

~~·~~ar ....... O &T

...

t ,, PWBGND "38 ccs

TR

I .. I CMPGND 10M I VPWF

I~ PWRGNO PWRGNO

I~

) T IL

18 GP EP< IPR BARO

;p

GAD

DCS

GPC D3 I PWR GND

11 E400 ttanemlulon only

Circuit 1

658

mu. .m.. 107

306 ...w... ~ .1QL

R7A

~ ..m... ~ ~

198

199

"'796

356

..§2L _m_ ~ ~

b 152 (LOlA) for Econotlne appllcatlona c 810 (RI'LG} for ECOI'IOtil'lt applkaUone

WJreColor

PK-LG

p.w

~ PK-LB

.• e TO

!:Q_ (:fL ·-w

LB-Y

LB W·BK

Q_ .& N

BR-0

BK-W

Key Off

Ov Ov

>L /A

lv

.2V-.5v

lv

Ov

lv

.75v-:N

Ov/12V

IV

7.3L Diesel Pin Out Values - 1996

Key On

8+

~~ lA

12V/Ov 1~

~

5v .3v·4.5v ~.5v

~ Ov ~

SV.§y 3.3vavo

~ lv

.. sv

Ov

Oy !gy!Oy C¥12V

>v-.4v

lv

Low Idle

8+

(/!):L /A /A

12vl0v _jgv!Ov .av

~ IV-4.5v

~-4.5v

.dl "' ~

6y.§v

.4V•2.2V

4.5V

ov

12V/Ov

..lli:!!L .5v·.9Y

lv-49 Hz SV~Z

h. 112 Ov

d $63 (OIY) for l!cot~ollnt appOcatlonl • 347 (QKN) lOt lconollt~o~ •pplleatlone f 53.5 (LBIR) tor l!conotlne applkatiOf'l•

High Idle

12v B+

12V NIA

12V/Ov NIA

_!:!!6.. Ov

12v 12v/Ov

.JJ,!tLOv

.2~_v-

~ ~.Sv

..;lv-4.5v ~ .3!

12v/Ov ---ov-1.9Y-2.2v

!Y_ lv l+

4.5v

12v/Ov 12

L1V·1.5v

'12V OO"H'Z

Bv/720 hZ

"'

"'~'"""''V Comments Ran

itt 12 = '"On• 1 e f' B+ Ov•Ugl\l On, 12v:Ughl Off

i~~~~~~~~~~-~~ Fla EPROM 4x4 Low Swil( Data Unk • Data Link '

..l:J/A NIA

SWitch.

12v/Ov 12v/Ov

1JG-18§ H .46v• 2 12' .7SV=211 3 .0,.,..61

Ov·IOv

Ov/12v

Ov-4.5v

iV

2m~

Clulch Pedal Position Switch ' - ission Control Switch f

t Back Pressure Sensor

:naioe ~

ss 01 3 12 = At. Press. 1 Fluid Temo. 4·.5v--40•ft.3V•

4.7v:-4Q4f/.68vt?®'f 4:~-4Q"fl358y=23Q'I

<ad< Pressvre VOII Foedback Une digi!ai12V 1 8Q\! Position Sensor §59:3609 RPM er Signal Beftecled CMP Signal

ioaSf Chi!@ SolenOid Ov • "'n". 2v \(tep Alive Power B+ = bat1erv volUme 'ehicle Soeed Sianal

,,_,,.,_,_,,Range Sensor P = 4.5v, R • 3.7v, I • 2.9v. 0 • 2.2v. MAN2 • 1.4v. MAN1 • .7V iamshaft position sensor ground JM Belav 12v : 10M OH Ov ~10M On

~ Ov/12v

tans Control indicator liol!t t2V . "Qfl". 0y • ·en· ilow Ptua lamo Ov ~ Liohl On. 12v • Lioht Off

'Coni

.Sv-4v

Oy, 2y

43-240 Hz 5 Hz·720 Hz

"'

~troll

COOf!OIIed 2.6v •I 60 kPa Ill ,.,.,83 .

r Pedal Sensor 'ollaoe

I Sianal< \iylinder 1

laniUon source owr.

Power Ground

9 Not uatd on Eoonolint applleeliOI'It

I Dfll

Cll Cll

EMjM M9"D'"' Cpm1?9fVtDI!

1.3L DJ Turbo Djssel Pqwgctcaln Control SVsfem SciJtunaUc • 1995/199§

Vtbiclt Mpunlfd Cqmponenlt

CUP EOT JCP E8P .... ,--,

IAT TR

PCM COnnector Pin Numbero (104)

Cab Mounted Componenlt

abti ~ ~ ~ ~ "·!:·--· ) - APSi N t

••••••••••• g

_ KAPWR

T_!l ~gn.!' l .... -~~ .... 5 IVSSig"~'

''"';3""'" vss.- - -

~-.:i I ' :- P"f.il I

... .. 42Way ConMCtor

"" I

• • -- - :::::;.:::: VSS+

[l!¥J IVS 1

I I I I II 20 --- -- --- ••••• ~ ••••

I

I' . . . . . . . . . . . :10 ,. . ......... . I ····;;••••• ..... t\. ... ~=~~~.}---,

I • • • • • • • • • • • YAEF - VREF

22 ·····-···· I ••••;;••••• ..... ,t .... I ·••••·••••• al ••••• ~ ••••

I I 33 CUP 0 • •• • .~ •••• ~~Uiil!!lll.. • • • • • • • • • • • round ~~ BARO I ----- ___ ____ _______ .... ~?..... _ _ _ CMPS~al ·····'\~····· ..... '.iS..... ------ - - O'Pc- cont;o,------ ''''1ot''''

35 KE.YPWR ••• ·• •• • ••• f • ••••• •••• • IDM ••••• ~~ ••••

Connector • • • • -~ • • • '] SCAN TOOL

EAOO •••• ,2,1,,,,,

........ 0t1 SO<.EHOIO .. • .. ~t • • • • • , · · · · · · - · - • - · - • · • ••• - · - · - · • · - · - · - ••••• ~..... • • • • • ••••••••••• ASSEMBLY ····~\,,,,

~ }DI 1\'Dl rggrv..

1 Injector 13 J 2'1 ° 0 0 0 0

•

0 0 0 0 0

i 1·-·-·-·-·----~-~~,t.;;·.~- ~ ::::::::::: ~· :·.: .: .: :::::.:::::: :::::}i::::·~~~l'$~~==tj=t.J I ; I · • • • • • • • • • • • • • • ' ''"""" • • • • • • • • • • "'"''"'' '''''''''''l • • I : ,, CID ..

ABCOE ABCDE ·····,·7····· -- - ;oci - - ----- ••••••••••• ··········· ------ - ----- ••••• 1.5. ••• 1 1111 1 4 EF,Hdblck a" GlowPiug ••••••••••• - - - - - - - _ _ _ _ _ ••••• 4 ••••••

RtfDy ~ I t=::y:::'l HlghVOi t.ogo 12 IN.JHLA 24 ~.':~~·!?:~~. PWAGND APCMOOUL.e:

1 • , [ " " " " " • ... . ·;e . . .. PWR ONO .... ~_1. • . • • ACC ............ KE.YPWA

...._ - l~ : HlghVoltage 11 tNJHI_L ..... ; 3"" " ..... ~~ •••• 4X4L KtYPWA

SU<M<U04ot -(_ ...... , d::. • I ...1-.T . . . . . . . . . . . . . . . . . . . . . . IOILEN 20

ra=~-::,+.-'~~-·········· .....__... ! IIII I 1 1111 1 2f K!YPWA E 0 C 8 A l 0 C 8 A 14 "'"ij"" CPP(i,bnu81) KEYPWR

: ~ J I lrrljecr« f8 10 • • • • •; • • • • • • • • • • • • • • • •

~ , , ~--·- · · · · · - •••••;••••• ..... . ... ·····;g···· ..... ~····t~BOO;===~.__~~~It£Y=~P'W~A I f tnjectort4 • • • • • • • • • • • • • • • • ••••••••••• • • • •• • '" •••• •• ••••• 'ln~IOfi2 ' "" ' .. . .. . ... . .. . ... . .. . ... . ... . . . . . . . . .. ... ~..... .. . . . . . .. • •••• ?..... . .... ':'; .... TCIL . @ KE"YPWR

' · · · · • • • · •· · •••• • • • • • • • • • • ••• • • · • •• • • ••••• ~ ••••• • • • • • • • • • · ••••• ~.... • •••• ~ •••• GPL(CO<Itrol) @ KEYPWA

2S ''''' ''''' -----,.1

J .... ~..... VPWA • •. r/,ti·.. PBA ....._ Kt(::WA

1 - - - - - - - - - - - - - - • • ... ,, .. • • • PwA GNO - - - - - - - - -'~ <£o1!.tro.!l - .... ~ ... •• . I

~ .. • .. • • .. .. • Kt!YPWR 25 CASE GNO 23 EPA ............ 1·•

~ 1 • ' - -- - ........... - -- - - -- - - -- - - -- - - - - ~~"!!) .... ~~..... TAC

• I . . ... ~.. .. TAC (Control)

1 - 21 SPA KEYPWR

1PR .......... . EPR •••• • ? .. ... a-_...,..@. K!YP'WR

., sees

(OoaldUMs s~orSwlkhf~) ~=\..ooldflgiNo,__.W.ol~ ·::::~:::: SCGHD (loSpeedConerol...,_)

BED al2 VOLTS BLACK • GROUND CIRCUIT GREEN e SIGNAL CIRCUIT PURPLE: HIGH VOLTAGE BLUE : VREE !5 YOLTSl

Power Stroke I 99511996 c; ~';" .,., ...... 0107 woo 0100 """' ............. .,.

.,...,.,. 10 I S'C ·.1'00 ,._,, uosv O<tt 0123 ,. 0105 ;m •ors... ... .., ,

; """ ....,.o«lf:A < ,_ .... """ """"""""cc•- . ............

<.PCM

1)220 YS 0221 \PJIVS Th .... ~ .

0,,,. ... ,.. .... Ooen. '""'to........, •• . ··- ...,_..,,

0261 tu .... tu -~· ,...M ""' 'I ....... ·-=- ._,...., •• ,_ ... .., ... , """""' .... tu

I 0201 NJ

1- NJ -~· ...... ,_ ........ ............ ........ . ....... 111m NJ 10273 .... .. , . .... I ,_ • """"" 5 . ....

••• -· '""" ... ,OOU <

I 02n .... 0278 'NJ

0279 NJ ,_ """"'' ""' . c"'"""' 1 .... .... I ,..,. • """"" 7 .-.. .,., ... .,. ,,.., ...... '"" ' ""- " I om NJ

1028< .... .... ""' .,_...., - .......... ........

10300 llPc "'""" 0381 ..... 0470 '"" -· .................. ...... 0173 . """ .. ,. tPR .. ,. tPR . .,. tPR ·- Pt ...... . ..........

• PCM. ........... ............ . ........ .... PcEO .... PeED c ..... On •OEA....., , .... PeED c..-"" """" ........... ' 10 ,,..,

l«l£R ,_... .......... .... 0571 "" ...., 'CEO _.,.._, .......... .... eo..PCW ........ , ,_..., 070< ""' 11707 <RS ......

- to """""' ' """ ' Ooon . "''" ... tow ....

................. _ .. _, ···~· 074< rcc

0750 ;SI so .......... . . e&cvo ~"""·

'"' KOEOoM • "'""" .. nu. •.

""'" . PCN

0702 UA 2 ''"'""""'

c.""' ........ . PC¥

58

:c-.~ .. I!'R .... lOP 1218

::· INJ

:~ ·""'

.... ~. 1 ... INI•

121<1 1:194 ''"' "'"' oNJ

..... IS3t ~" .... ,_

1083 , .. , .... mL 1711 ~FT

1129 ......

''"' 1771 m:a.


""""""" """"""" ~c-

I IOaoun<l

lOP ""' '""'"' "'"""' ' . '""" .... Cl"""'ll ' c.- lloao~nd.

High 10 bY t«<e sho!1 cyl• 1 •t Cylh:let with .... ~~~ nol open!• $hOn <*OJit. at!orled injeell:)t,ll!liltd 10M

~ 11010w tide open CJW1 • •e Cyfir1der Mlh ...... not~- ~ ClfQIIt, open~. Wed 10M

o&I<OEO • , .... , ICP aalure • abMs KOE.R _.

:"' :.:.:. 1282. 1283. 1211 ---"'"""""'' '"' '""'""'

"""' .... ""'" ...... (tell} l•i · ,.....,.,,., ,, '"''" '""

... _ .... , .. "" ..... " ''""" ... ! I f'b< ' ......... , '"""""'"'' ·-""' ........... .,....,.,

""" --· ........ --· a--.... ............. ...... ....... _ ace """"' """

_,, IPCU-

Cl d ...... '""'"' "'" 1 "''""· laullY IDM PCM•DMdoo....., , .... . I(()E(), ..... ' •. l «~nd

TR-~ oul · ..... , trt _..,.,... OUI ol MIIHI ,..,..._

cio

,...., , '...;.."' ' ~too hOt ot«*t,

... ·-£PC-,

: ... 1 SoniO......,, PCU TCS """' OUI ..... ,.., ,.,_ """"· ""'"'· .......

In "''""'" 17113 ITF1 1 ....... , ,,,.,...,PCM

~ .. Chedl Engine LighC lltumrn.t.d wMn lauft ptHMrt

...... .._. I I ICocllrolllldlc.aorUgM(rCL ....................... -----' PeED • ~Control~ '*lo I tla ........

57

7.3L Diesel Pin Out Values 1997- ALL Eeonoline (49 state and California) adn F-250/F-350 (California only)

Ul I Pin • Name Circuit t Wire Color Key Off Key On low Id le High Idle I 0:'::!~9 Comments _I 1111 12 Check 658 PK-LG 011 OVI12v 0v112v Ov/12v OY/12v Ov=Ught On, 12v=Light Off 1

Enolne Uah!

~ i ·R Ov Ovl12v Ov/12v 112v Ov112v Parkin Bra A li w· ~~ a I 1 7 y Ov (Jv Ov /12v Shift . 11• • ·Qn· • • ~

GPM GY Ov Ov/12v 011/12' - ··- - ..... ..... .... ·· - -·· · •· ·- -- · ~ - -- .... 1087 - - - ·- - -·· -

4X4l BUSH

..lll!§.{! !Ill

- {Man!) ~·· EBP SPA ~ PML 'T

' KAPWf vss + sees

63 BAAO

64' TA3A IE Serjesl

03 j PWA GNO

a £400 tratlsminlon only

I

306

.!it!.. lli... 914

306' ...ru.. ~

~ ...ill. -m

356

"'199

m-464_

161A 1086

5700

W·P

B!l_:!

HB

;y. ,y. :-;-;:

_ v_ GY·BK LB·BK

09-LG

LilT

BK·O

ov

0

ov ov

liV

.9!.1

.!:!L Ov/10.: m&2

Ov/12

~~

ntrolll 'ROM ~

link Cc Unkec ~ ~!"fflt~~:

1!1:. .!&!

Ov/12v OvJ12V

Ov/12v Ov/12v 0.9v ~

Ov. 112v. L:Ov. /12v CMch Pedal Posltlon Switch (Manual} _ OY_l12v__ Qv:/12v Tra · t n n rof Switch tA.utnml'lrid

Pr ~ -···· -...... .. .

~ ~12

""

llL

''"' ''"" . ..

""

6.6v 6.6v 6,6v OV· 12v

2v ... 9v 2v ... 9v 2v•4.9v 2v ... 9v

0.7v-4.Sv Vat ios with OOW ___ . ___ QyL1_.~_

b Not uftd in 1 Gt7 Eco"'!Jne

..!MJ ~'@.

>v-12'1

'"" !Y.:l!J ~ Sv·"·

3at*; 0v = PJugs off 12v ip. 4.5v:-4QDC/.3v:t3(r =-4crCI.3'f=150"F

Intake Air Temo 4.5vs -40=cl.2v-13Q•F Soeed Control r.:;,,..,,. ... Aic Cond!tionln §~Must.B!ck

Keep Alive Pow Vehicle Speed 1

v freouency \12=0v MAN ..... _.,. .......

,...,..,J ..... ,...ontrol Command SwitCh; C>n=t2v, ort~ev. Set-2.8v. 4.7V Coast=O.Sv Hol<l=6.6v

___ ·-----· .c Pf'9SSurG Sensor; 4.6v 0 tOO lc:Pa (sea level), 2.6v 0 60 kPa {10 000 ttl F.§ories: P=4.5v, R=3.7V, Nz-2.9Y, O=Q.2v, MAN2=1.Av, MAN1=v.r\ E§eries: P=Oy. R=J,6v. N• 1.6V .. 0.1.&.o • • u ..... - ...... .._

:::amshaft DOS!f ~01 ..... . .. _

9"""'

•on ~

rake 0!\IQff Swil9 uel Delivery Contr vtinder ldent!!Jcat~ !n!J!on sou roe pow 1 ...... at ..... ,... ..... ~ .. •·

'ower Ground

I!!W !;.§§:2:

~ ~

c Nol ueed on 1997 F-Selies

Ul Ul

7.3L PI Turb9 Diesel Powertraln Control Svstem • 1997 E·Series and Cal/fomla F·$trlu Cab ;

Engine Mountod Componenta Veblete Moynttd Comoonenta

CMP EDT ICP EBP mb; § ~ ...... ... .1%.

14 r-11-"'""'i--.;c;~ .,

~ ~1 _v!TRSSF~ J::::::::t:::::: - · : (~ ;l I

- - !AT~ -- _ ,, ............. . •2WoyConnecto< _ ~SIP.! - - - - - ........ ~......... I .........,. . I

- - - - ~AD- ~~~ • - • - • -,,;!!!, .... Ill. .... 21. .. n.. ... ll. ... ~.

-~-... n .. .l!. .. ~1

40

L~.Y_PWR roM ' --

r~~I~·i:::::::::::::::: :~:::::::::::::::::.~===== -~·::.:~~-~~-~·::.:~·:: I I _!!,'~~.!•----- ......... 7. ......... r----- ......... , ........ .. I I I __ !!)11!,<!9',!7 __ ......... !.. ....... t-- ---- ........ 29. ...... ..

VREf ICPSiaNO

t - -~~~~

...Ill.

...It,

. .. ...

.. ... .. - _ , ......... 21 ......... ,

.. IA1

..H . ......

... 1. ... ~

•

......... 29. ........ ,

......... M ...... 1. E400 ..

SOUHOIO

,

J~ I

SCA~TOOL ~

1\ .' OGODQ2~oo I \fD 000\,IQQII

I o. ASSEidBl.Y 9 -..E.2C • .. U .. .,,.. KEYPW_!!.

I I I ....... J.o ......... __ ca - - - - -

r-~-, 4o;·~~·c~~o•nJ A e c o e ....... J.? ......... __ F.DCa ___ _

......... L ...... .. - l:.f - - - - -High volttge ....... J.i,,,..,,, INJH.I_R ......... at ...... ..

... lilt....... ~ "

... RL..... Jh

.... !.......... •••• "" 11.1 ... IL ..... -;;;-;;;- ' APC

1

MOOULE ... lA... ... .. ~~g~~~~~~g~~~=;~;~ ........ ~~. . ... . .. . I•

(f~~~P .. _ • . -- .:.:lt:: :f~~ I .. !L ..... • "• · KEYPWR

~ ......... aL...... , ~ . ......... fll...... ... .__ ......_. .. l.1,7.f.T7.,!Ra. PWR GNO , '"'

GrowPfug ..... I E lo c al ~olo<oo.fl ......... lA ........ ,._ _____ ........ ~.......... B+ 0

1 ·-=rw----- , I I t_!~------ ................... ,r ----- ....... J.9......... PC*.,..-.,

.......... "Y I I 1.......... . .................. t------ ........ L....... ~ Fu....,..UnQ -;;J.~:.·~---------------- B+

BAT• L!~!!----------------- "'"""~"""'"'!------ ........ ~........ 0 •• VPWR

41 ACC .......... KE'¥1 '"'if'"'"''' TCS (Au•om.lkl) ~

... ~. .. 12. 70

.... n .. 7tJ7

1:: I BOO

__ ('D') KEYPWR

_/ltl - BAT•

~ IPBA iii, KEYPWR

0 - ........ .u........ - ___ _ JPill~ - -

~. ---------------t ..... %li ........ t -----------~ ~4=-: --~ ,m.;,o -- ------~ --- -- L '->

IJ'A ICEYPWR BLAC .. (Ooeool..._.,_,.,.__ . KEYPWR

K- GROUND CIRCUIT GREEN • SIGNAL QBCU!T PUBPL;---•......,....,...__,..,._, KEYPWR - HtGH VOLTAGE BLUE • YR£F (S YQlJSl REP =12VOLIS

Power Stroke 1997

',.,;;.,;

,.,.. --= -... ~~ :""""""'. -=---...- --=.--;;;;;;- --;;;;- -===

r= """" r= ---...-r= --= :;;-

r= f'PP

r.:;;;;;:- ---;-.;-

60

~ ~

=

=

= ~

=

=

=

"""""'""' , ~· ....... -=-=~-~.;;;;.;.;..;;;·

=~~

=

....

·=

Econoline (ALL) F-250/F-350 (California only)

"'"""""

,pe ..

·- ,.y

, ___ ,_ , ....... _

---;.,

Open or lflotl drWl ~ lallir .. PCM Mllure or faJecl tO IIC'IIYIM swtiCt'l dl..lltlg KOER twlldl INI

Crl.illle control anc:t 8F'A c:oc~ee; d be Mt on ...-y ..-n ... OI'I .......... not~--cn.tOOMrol.

.....

._ ......... """'---_ .. - , .. ............

' -noid. ""IIY """"· PCM

,......


l.:•utt Code !>=•

lnd"" Condltloo Oe!lerintion

1000 HIA Oleck. olal 09011 ;;;-ems no~ , .. EDT ~Oite~MOr~SCIII--;, l~ 120$" II'R ~clion contro&-=-$$Urt --=::;:-m hwll 1210' IPA I com"' , ....... "'""" 211" I I p ' ' 1212 ICP tcP.::ress ~ ~ed~crank 1218 a CI S!udt~ t2"'1G Cl Cl ;;tvc:k 1c1w 1247' MAP Tl.Mbo bo06l resaure lOw

1248' MAP Turt>O boost re~re not doCIX!lod

1261· INJ H9lto ICJN W. short cyD 1 • 1!8 12 ..

1271· INJ Hi!11 to lOw &idt q:,on cyiU • *$ 1278 1201r ICP ICP eiteuil out Of lOw 1211" ICP I " cui! I ' ,zw;-. IPA ~-~-ICP~Mre 1283 IPA IPR drcuil tailurfl

12 .. NIA ICP t.a._,ro • i'lbotl' KOER t.cl$1

1201 INJ Side Short 10 «a. bank 111 ( t

1 INJ I k -~llllftl ,.., INJ ·-Minh side o;:;;n bank~~ 1294 INJ ~side 0081'1 batll< 1'2~ ..,....

INJ Mol-;:;:-~k ~ whh , ... INJ fa~ on btlf!k. 112 It with lOIIi &Ide 1297 INJ H Sides Shottbd ' ,,.. 10M IOM itliluM

,316' 10M ~droulli'IOM <XXI$8 detected 1391 ' GPM Glow~ Cii'Wit lOW ~1,11 bMk .~, .,..,.. O PM ~nk~ ,39$' GPM GlOw I moohor favlt bft ~ 1 1396' GPM GlOw I tn0t1i!or fault. bank t'2

I .,. , VPWR I •II- out~ ~If t,.,.j ,.....,.... .... NIA AIC clemancJ out ol eel' test~ 1501 NIA VSS OUt Ol Selll&St ~ I'M w. lnv~·A 153"1 NJA lf'!YillkJ test - acce~emor mowomem 1530 PBA bnllce SWiK:h dreuil failure

'""' occ ,.., ..... ., ...... 1661 occ OCC~aiiOW 1 ... IDM...E lOM_EN d rcuil tai;,:;;-10<3 FOC$ roes ¢rcult fa~re

1667 Cl Cl Cftuil tailure

1 EF P M•IDM · n• o= 1PO" EF EF ~at 1'10( de*IOO

1704 TliS ~181 TRS faied 1J0 lratlSiticn statAl

1706 T"Fj;" TA: nsor CCJt Qt Mtrl="st ;;;::::-1711 TFT TFT &en&Of oot o l &eM lest tMQil

17 t4' t l tiJ;&f1'1a11~ 1715" SS2 Shin SoiMOkJ 2 lndiJc:llw -,;;;-naMe mtllltndon

1728 TCC Tl"'lttii'I"'IHIC.ltl~etrcr:

= ~ = 1740" TCC TO< (l()C"'II8ftGf Clt*:h IndUctive ma!t\Jnetion 1748 EPC EPC so!onoid cl"""' •• 1754 ccs Coasl dutlth solenOid droult malllA"'Ction ,.. TCS TCS c:in:JJit out ot self 14$1 n'l(IQO

178 1 4X4L 4X4l eitcull OUI ()I &ell teSI t

1713 TFT T~ CMUI~IIibJro oond~

• (0806) MIL 1ttumln.11tlon oocurt .11ft~f 2nd ~on$e<:U1N• fault (FM'EM) Mll. l llumiMtlon oc~u,. ener 1tt fault

Comment&

~;;;;;;;;=. R---,::r.;r.;::: .... NCHtar1 ti\Od& af'ld KOE ....,.,.,..,.1

~and I(OEJ\ ~oo t(ISt

Crank00117 Cull~ · ~

---,:::cnder idoolikdon Une SIUCk iOW

~r WW\ lault Wll not opeca1e

o,tnOet v.ilh r.u1t wil not opeca1e

tJ:sK i!'llotred ICP stra1 .,., ,...,...,ocp .,.,_ --~m,auu

coO.~ .. -;;;;;-Abott$ KOEA CCT and oiKSemand leSIS See ooeles 1280 1281. 1282 1283. 1211 ... circuit short . ""';""·~· "' 11 ritaoll s~ ttv~Arates oo 4-;,:.;.IOOer'$\ .. eilcuh-~i;w;~~;;!es on~' --w~~~=•-;;;.

F; "" and l$Wil lies Fix lOW side shOrt aoo rer~ ... Fix shurtlf; a rvn~n In

lntemf!I IOM ~"*lure Alln KOEO Of'Kferrwld tJeS( ro re!lfe¥e eodes Abot~~~~~ --.=,...~mo..,.l Continuous & KOER mor'lilor tJeU

Contirw R .... AbottsKOE~ ~-~,;;-monitor te$1

Aborts KOER CCT lest

~ts~~R ~$Wl h te ~ • KOER on.tJemar'ld OCT. or 8W1!Ch tesl

Abott's Ileal • KOER OCHietnatld Or CCT !est

EA .I

Abott$ KOEO Of'Kiemand fl88l

Abotts KOEO OtKienwld Ulst = ~ Fuetdemand ~8 81 • KOEO Ot'Htematld ltS1

C inder idetllifica . ~,nd' !Mit

~~line· KOEO Of'Hietnand tw c_, KOen;;: NOl k'l PA~K dol'~ I<OEO or KOEA ThWIStniasion ft.lld temp 100 high CC tow b K0£0 Of KOER lntd • 1• I PCM

~. Corb'luous

• COtlfi'luous

""'" Coolff'IUOUS & Kc:iEr\ Ol~nc! IOSI

KOER~te;(

In 4X4l duri'l KOEO CQflDn(tou;

1\'an•mllalon ConlrOIIndlcator Ughl {TCIL) fla.,... when t.ullla present. "1' IL llumlnlllet on 4t .a... ~lcallont only

For F-250/F-350 (49 state) and F-Super Duty (ALL) refer to Diagnostic Guide #FCS-70230208

Probable Cau ses

lne not watm h leak. ' tn'IOSial c:kt '" IPR valve Sludl

I:PR valve tailed Sltll'!k ot Ahnrll)d ID nrno.•rvl

t ....;,.,n dnr131 rerurn lOw ollln ~, Cl cirCUli "' intermll!eM

Ct circuit ilhOrl to aound. orob.-,t:t, lntl'lo~911C

Hose diSCOMeeted

$~ cfrtuil, ShOftod ki~OI, f;liltcii()M

Open Cir'euil. open ir;&clol, JaiiOtS IOM

clrclic biased &eMOr. PCM

Citeuil Shorred to SV biased~. PC:M F:.,uf!v IPR r•nul"''~' t .. tir~~ fP

l#lded clrcd $11.d: IPA. 1ooee COI'Ineef Sensor Circuli taull

Shorte~ circuli laullV 11>M Shorted c:ir<:uil taullV 10M l'lnlln ,.;..,a l:'llloiN IDM

n circuit f!WI IOM Mlswlr~ con~ (If t.ar Shorl lo

Mi~ htlmess. sllort 10 nroo~ S,_, ,._ lavllv IOU .,Utmai iOM lailure

"' -.. 0 <*cull Shon to eror . taut ' 0 <*evil s ,., '"""" l(lilecl One « mote nk:rN nluM lfliled

"""""'-~ ~-·· ., ,.k-,.:; mon4of 1$81_

""' .. hnonedto rawe«ot

APCM 8Ciive wh K R lost '

Oocr~AtrOf

Falfed 10 a~ats sWitCh durtM ttiSt Cte~.Ji!. SWi!dl PCM

Him S~WiblnA in!O:rMII PCM ttuoll

~ -~Mm""""•· n!er IPCM lault IOMrel blown fuse rounded eire •

IDM drallt. fa.Jtv 10M

CtwV'siWU!cl EF or FDCS.. l"'nnll\ 10M ftmunrl

"""n'•"""""<fd~il

""' PQ.4 mechatlieel I ...... ;, , ... PCM T~ 100 hOI Of OOid,

SOief\Oid Or PCIA

~enoid or PCM

Solei'IIOid ta11Ute or l'l'led\anleaf laluro c; Ia;

Soleno~ or PCM

0oen Cii'CUII laullv &Ok!t'IOid PCN Shotfeit010f ' "'"' ..... Ci~llt fallut$ iii•""' &Oienoid PCM Cireuil. ~td\. PCM, !ailed 10 atMt.e $'Mid\ « &wrlch alwil ""'" • ""' . .. IIOEA Oooct~lor Ett tOI' $110rt lo nroond. POM llll&mal tl'3J'l$1'TliSsion 18lklro,. drc;uc &a!ltlfe, tensor, PCM

FCS-70230207

61

7.3L Diesel Pin Out Values - 1997 F-250/F-350 (49 state only) and ALL F-Super Duty (49 state and California)

• Pin I Name ClrcuH I Wire Color Key Off Key On low Idle High Idle o:r:;g Comment$

~ I I P 12'1 12'1 12'1 0Yl l2'l ' ' In 0Y • "'On' 12'1 = "Oll' 2 Cheek 658 PK-LG OY B+ 8+ B+ B+ OY•light On, 12'l• Ughl 00

Enaine Uaht

IVS FEP 4)(4L BUSC·l

...!!l.!§!:t I CASE SSI ICC (Mal11) TCSIA!!!ol ESP SPA.

170

U2.. )14

57Z ~

480 306

.ru_ ~ 307

P-W OV 12v/Dv 12vi0v 12v/Dv I~

PK-LB

T-LB T/Vi

lA lA

)v

IV

ov

2)1 12)1}0V 12)1/0v

.Bv-.95v

I.2Ylll:l N/A

lA

_..lb_ 12)1/0v 12V.!Jl!!.

~

12)1/0v liiZ

_211_ J2)1}0V 12VIDv

Ov

_!M

12)1/0v 12VIDv

~ PK OV

1 34 MAP----r LG-BK !v .2V-.5v ! .5v 2.5v 1 ~H · - • - 0-BK .3v-4.5v

3 V•4.5v .3v-4.5v I ' I

354 LG·R lv .35v-4. 5v-4.5v .35v-4.5v • ' I '"' I 743 GY .35v-4.5v - v .35v·4. v • "I

••• EPA EF

• CMP fl T. I PWR 1

,. ccs ; KA~

58 ~

64"

-rs-

l"

l7

sees TR

~MP GNO IDMrlENm VPWA PWA GNO ~·~~GNP

BARO Jl{P AI _, -

REF !!L@.!

BOO FOCS e10

103 I PWAGNO

~ '""",... "'"· ..... ..... Ov nv ~ag :-oo:o o; 12)1/0v !2VLOY_ 12)1/0v I <MQv_ 318 GY-R OV 6v-811 6 • v OY ·IOV

818 GY·W OV 3.3v avo. • . 1.9v·2.2V ~' 795 OG OV 12V/2.5v 7v I

12)1 I . I K.w I ~ 't 0v !>L 0v

>4 BA-0 I Ov I OV OY OY OV/12)1 •e v ..! s. .1 s. 79 GY-BK 51 LB·BK l9 LB-Y

796 LB J!L W-BK ..miL 5700 s;

- 57Pf I BK 9 W-l ~ BK· 925

Oy

iV

bL bL H

·LG 1 ,75v=3v -- !!L

51

I§!A. ~ i700

BR-0 Y·LB

BK·W

!v

OV/~ lv !v

!v

1.5V

__ Dv 12)1

12)1/0v Dv/12)1

.25Va.4V I-4V

Dvi12V :sv ;v

)v

4.5v

iV

...JI:L. 12)1/0v

sv-1v

Oy/!?v lv-49 Hz 6\1/5 liZ

!v

4.5v I Ov·4.5v

iV

bL _ )v_

.J.Z.l!&x.. I~

12)1 .75v-4.9v 1.1v-1.5v

Oy Ov/12)1

2.7v!59Q Hz 6va20h

B+ £l!. ov

...JI:L. 12)1/0v

Qvt12y 43/240 !:!L.

I Hz

ov

'ali<!a!loo Switoh '\11 _ as 1 EPROM Power Suppty

lx4low Switch 12v • ~ow. ov =:: "Oo"' tata I

;onve r Clutc!J Solenoid OY = "'n". 12)1 = "Oll' lutoh Pedal f'l>sl1ion Swllch I

::0..1101 Swllch C

' 110/113 Hz = AI. Press.

ower Ground :oast Clutch Sol!! eeoAii>'e~

~

mo. 4.j)v=•..tttri"'J.;

v• -40°fL6Bv=?3Q iv-~O~F/.35Bv•2~

12v :"'n'. ov = ·o (011. only when enabled

dioital 12)1 I r 65()-3600 F led CMP Sic

ov . -on·. 12v . -ott• 1 vollaoe

i'ansmission Range Sensor P = 4.5v, A= 3.7v, I =:: 2.9v 0 = 2.2y. MAN2 • 1.4v. MAN1 a .7v :am§haft position oenoor ground Pl,l_Rel~ .. ~~ ~ .. 1£lM Oil ov = 10

Grounc tower Grounc ·rans Cootrot iOW'A

kohl 12)1 - "'H'. Oy = -on· :ln. 12)1 = I

64v aiiOO kPa Cot~a lovell 2.6V at 60 kPa C!O.OOQ tt.l tMin .. 83v rea. for startino.l

12r..a111 ~ Of! Switch 'Uo/PO

·ue1 ueuverv Control Slanal 1 )de' ldenli

I RPM

• E400 llaJW; ·sslon Ol't1 d 5&3 (ON') 11or &ono~ne u : r t •• • M7 (8ICIY) tcw IEOonoliM ; e r r • t 53:S (I.8IR) tor ECOI'tOIIM ..,prcltlc ,.

1 NotuMdon~ so ' 1tc,. b 112 (LGIR) tor Econo1M ;; I ' ._ c tlO(M.G)bEconolne~

1 l

en w

7.3L Dl Turbo Diesel Powertraln Control System- A/11997 F-series except California

Engine Mounted Components

CAMP EOT tCP ESP

cub!§~ ~~~~ I

I

I

I

I I - - - - - - - - - -- - - - - - - - -- -

~' ~ EPR

42Way onnecto• ~

(Oot1ed Unet: = F~cy Ot Switch Foo<:tlona) R£Q; 12 VOLTS BLACK= GROUND CIRCUIT GREEN ~ SIGNAL CIRCUIT

yeh!clp Mounted Components PCM Connector

i ~ ~ms~. ~ - - -~~r_""'_-y~-~~~~!".'~ .. ,.,n_._~,

.. :\!i .. .. 2L

.;'",."~

lt!;.VPWA

IDM _L __

(Orienl:ttion • look;ng ifl10 h~ tide of ton1~or)

PURPLE e HIGH VOLTAGE BLUE e VBEE CS VOLTS)

Cab Mounted Components

KAPWR ~ .. ,

... I

AP.

I

so

Data 1..rn1<

KEYPWA

~

...,..

Power Stroke 1997

' .... IAT

""" --.9 rn;;;- --.9 ;-;;;;;;- --.;;;;-

I """ ""' ro;,--,- -=< r= .... r;;;;;

I""'' "" 1-.;;o:,- "" r=- -...:

~ ,...,

"" - ., . ... -,., .... ---;;;;;- "" -=- --....-

...., CUP

""' """ ""' -~...-

-= I """ ...., 1-.,.,,- FliP

"""""' ' ,..;;.;

""' .... ''

I .,.,_

.,._,,

. ,_. ......

_.,.._,

""" FOP • .._.., ·~--""" FOP ,_u_,_ ..

·-----

1212 ICP ·--64

--·!COER

....... ..-. ......... ""'""'""'· Od""""CCTIHI .......... ~ .... ,._ -

FMeM I""'""'""'· Od ...... CCTIOII

'"""""

·-"'"

"''"''""""" tdelo>C<ed

o.-.... """"""' 01 CMP lmnolilM ""-"IS

! ,_,__

.. ......... , tH!

h ... , !Code ... . .... ,,.,..., .. .

·-I KOtO. !COER. ""' I .,.o_ ICCI!:A. ...,

.. ~--·

"'

F-250/F-350 (49 state) F-Super Duty (ALL)

......... -=~-~ ... -

~ ............. ~ """"'M ... ~;;

=

;;;.;;,i:- lo..O. '""" m... ~,~ ~'"' '

()ptfl t1t shc:w1 Ql'tiUil .,..tiCh ._......._ PCM iaik,Q or lai!M

to tcelll'a1• 5W11c::t1 6..1"'"" KOER t~Mtctt le&f

Cfulse ~rol .oncl 8PA COCIM will be Ml <ln .....,.,.,. ...uotl MM on~ not~ -...hCNMconwol.

.........

·- []

POWERTRAIN CONTROL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE ·-eo.. I;:' Condition .. _

c:o.nn-ts 1211 leo eo-- I o.tndo< _..., ... '"' '"""~-1211 leo "'"""" .... I C>.linclo< ; ·~""'"" 1261· INJ Mlgh ~ lOw $iOt $hoft cyM 1 • •8 cyr.•r W!lf; llull .,.. not .,..

I""' 1271 • INJ tollgh '<> lOw $ido opon ql•l • •• Cy!ind&r wiltl l#lull .,. not Cl)t!lltt

1278

121!0 ICP ICP di'CI.Iil. oul (If I'1III04t lOw Uses tllerted K:f' trr~WitiY

I ..... -I IPfl E~lCP ,. ....,,_

JPAdrcul...._. I<OEO 1 ... ... ICPWuq·-=--~- Ab;wts; KOER CCT •

I I ... ~---. ................ 1 ...... 1 ...... , 1 fOoeMiel Oft.~)

I _,,. .. e. 1 .. _

~-·~ I - ....... I .... 1294 "'·-~banlt·

I ..... ~

1 ... INJ Mull~~*! fauhs oo bEtnl; 111 (~) <Mifl FCx low $ldt: &hof1 •nd rtn.~n Oollgnootrq

~~ akl& ShOll 129$ INJ Mutl'9'0 M~$ on b~ •2 tat~fl~ Wlll'l Fb: lOW ~;Ide 111'100 •n4 !IIIMI ~Ilea

' low - ....... H ekie$ shOt~ Fix &l'lon8 and ~un

12M I I ... Internal 10M

1484 ... A'C dtmand out ol..., te.C fltlat_ Abott$ C.. t<OEA ,.., 1'1" ... vss calli d .. - tii'IOt Abott!! res: - I<OEA L CCT. o<-""' I • A&or!s-- KOEA LCCT t!I...,.,IMI

I b81d*'.-~ R ·-I .................. I«)ER--1100

1 .. 1 occ 1occ ......... I -..I<OEO 1002 I)M EN IDM EN Citeub '-il1.11e KOEO ~net lost

FDCSd ..... '"""" -KOeo ..,.....,..., ,.,. I ""' nt!ri .... I PCM·IOM d r n ' Eleetto!ie ll!ltdbaek demand !e!d

lro6 TR '"' Mil 1 .. 1 >1'101 in PARI( .OJ~ ' R 1111 TFT TFT Mnsot out d Mil lest ,.,. Tr~ n'-'CI '-"P 100 hign lot KOEO Of I<.OER teat

T

I • ••• l..cw SW«h fll'rot

" EPC- IICEO .... 170 .l'C luc-·;,..- Pc 1754 ICS

Coati '"""' KOeO

I

"""" ""- I KDEO I

I ~ TCS ei!QIII out 01 ... KOER~tett ,., 4i(.<l •X.4,!,._ ~il eut ol wlf .latt reMI. ln•X , ... TFT ,.,.. .......... ""'*-"

(Ft.iE\() ... 11.~~..,. fttu..ll""'-----------~------,

!Ju•• I 'Or:lrWJCillrdollor Ligtll (TCL)' ...... ti~Wi .... ~ , FW.tl) Mil. •n6 TClL iOuminaae wMn fM • P"...,_

For Econoline (ALL) and F-250/F-350 (California only) refer to Diagnostic Guide #FCS-70230207

Cloooo..o< • -Cl """' """'"' ......... Shofl OIIOUit. lt!Oflocf ~. tilled 10M

Open (if'OUII, open tnjOCIOJ, llltilocxf 10M

df'ttJd ~sed SeMOr PCM - 1'(;1,1

•• IPfl ... l. IPA Shot'ltd ..... ---I ... -. 1200. 1201 1202. tzn 1211 -----II ,_I~JON.

M•IY..recl OOflntletOf Of hatne$$. ahor110 piOUI'Id

Mlawlro<l OOf'IMCIOr 0t Mroc~ $hor1 to gtQUOd

.. 10M

I ' I o.-... . I Sf)ortEid 10 OCMet

"""""' - -~

PCU-._..,,_,.._,_PCU_ I OOflo'IIDM ,..IW. ~lute.

• 0 ...... """' 100. lr ... 10<.1

I I For IDM

I a .. , Miluro blulfv 691'1601' PCM 1'tllntii'IMIOn ~hOI« COld, Cireta failure,

....... ' ""' PCN

-POol I so...., - .......... lc.a..l """

' ' Mlled 10 aetNal8 swl1Ctl

' .. 1'(;1,1

' l...mii l ........................... PCM

FCS-70230206

65

F-Seru:~s PeM Cab Mounted Components

(. .. · ~- · · ·'\;:enabla .::- 'KE~~~B II• ........ .... Vehicle Mounted Components

...-....E!!2Lllill!UII:ill.-j ..... \W..... ,... • ii;;,.iM;.~.;..y- . I

~ ~IAT ~i~!lfH---J. TRSA ... ,_ :::::~:::: ;BATT~ ,.,.. i ~ .=;i. ..... ~!. .... f--' - - - - - - -

rr; ~~KA::..:PW'"'"~ .. ~<~i<~ AP G~~ I L It-~-A~: 1= 1\[~~~~fJ~- ~p~~A~-~t. J:~I!; t- Ski····~· ···· I ,J; i

42 way I r 't''r') J ~I=~ M " "" · • · · ib" .... l ws S9>al • v Connector '"' F' IATSional f ·::::~::::: I ~ l

'\ ~ ... .!L.. , r-{~lJ IVS

20 ~m :: ::~::: ::l1~ Sian•::'' R::•'"'"~m~L-=~"U:. _:] ~ ......... jjj" ~ 90 KEYPWB ········ · ·· ~y · ....... .

· • · • • · • • • 22" • Sloo>al ·:::. ~?.. ... (i). ···········w· :::JL:: ~p ·· ::::::::: ~;.:: MATSioMI .••• . ~!?- ....

-~:::::::::~· -- -~ ------ .::::~63.:::::.· 1 ~~!L_ _ _J BABO •.. . .....• • 39. . - - - - - - - - - - {;A ••• • •f

......... )~. . .... ~ ..... . ~~~!"'"" ~§:::::\Qi... . •••.••..••• 27. ~ ••••.• 1! •••••.

....•.... ~.1. ..lii!Mfl. ••• ..• !! ..... lr • - - - - 1 · · · · · · · · · ~ll. · · IDM • • • • • :;!!. • • • • Econoline

< .... L.~ _ l ~~Dfiil \£:~;.\ :::::i::::· :~ en_~ J oataLink •

·-·-·+···I,······ r · --~ss ~ rss fi ~ 1'- ·· · ··~ ·· :: , - , - , • f ••••• • a·. . . . . . • NoCE_::.:::r;:_ on I ~I .;, o.::;::;:-;~f ..... 54" . • • I \ I I a •

I ~~-- I EI~o. ······t····· · - · - .. f·-····20····· ----- ~~~ l::m :::: :Jc:: · - · - " 1·· ····.,:.;·· ··· PWBGNO E400 l~ ~

• •.•••. •.~ •. • • · _.. SOLENOID ~--~Jl'-- ..... ~).. ... " 16 e10 ____ - - - - - , 1- - - ••••. !1!>.... .. ,#';,~ ~

f·····H····· :_FQc§ ___ - - - - - - l- - - ..... ~..... tt:=4=1~ I············· EF r ..... ~ ..... I"""" ~~~

INJHUl l·::::k :::: - - - - - -.: .. -=. ~ - - - - - •• • •• l L ... ~~#.i--IJ "\!,

S. · ···· {~ ·····I BUS APC 'e

12 • •• 0 •• • ••• • 0 • •

2 .............. ...... ...... ~ ..

7 ···· ···· ······ 4 ...............

11 • ••••• ••••• • • 0

INJHI L ..... ~ ..... ::l][BtJ :::::i~:::: I PCMRelay L- · ·,;;;;,~;·;~ PWRGND _,. ;L---·---~~:1•

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6 7 - ~g ..... 3;···· I RPA ··•·· ·• ·· · ····· · - · - · · ..... •... •.. .,.. 1-- ·····92··· · I 8()() - -

3 ~ 22 = · ' ··-··- f·········· I . ···•·•·•·2··; · - · - •- • -..:.·····• · 7 . VI'WH •••• 7.1,~7. .•..• ~0~ - --~- =~-~®:~"_!5!r!fl!t!i ........... ~- ..... .s ..... ·I """ . , . • • • • • • • • • ~ KEYPWR IPR (COtllro!l ___ - - - - - - · • • • · ~- ·" •• " L...::.: ...._ '•

· · ········ ~~ ··!- -- ------- -- }P.fl(?;<iii'lll) _-- - ----- ..... ~~---·· ,,. ···· ······2a· ·+ ----- - ----- wGc.1~•(91)_ -- _,_ - - -: - - ..... 1? ..... 'T.,. TACH ·········is ·+ -.,. .. =_.,._ •. ------ - - - 1 · 1=;; ~ ·····Z···--1-l~~~-./ ············· ,,. ~~ ::JF::h~e•t ~t:~~

Fuel Pump II ·· · - -~-- · ·· .!>_N_Q_ ~ . ~>i::# ,. f·····§{···· -.

~ · · · · · 6i · · · · · I sees ::=::. Swfld1es ~-··········· ~-;:;- -, ":.:::'. - - - ., )

· · · · 4~ · · · · · • ; l.Q24. Opiioo lor F.SOrlas Only • \.. ./ _ • _ • (To Tr~~""!r) _ • 1

67

Power Stroke 1999

&8

1998 1/2 E-Series and 1999 F-Series

r.


• (08011) Mil. lllumln~~tlon CX-~Ut'$ •tttt 2nd cone~~fv• fault (FU.EM) MIL l lul'ftlndon occurs att.r ttl fault Transm'-$1on Control Indicator Light (TCtl..• ,...,.._when tauh It ~1. TCIL ..,......on tt t&IU~ Ol!f/lt

69

1998 1/2 Econoline

Hard Start I No Start Dlaanostlcs ..Of lt A '*~ MII'V N~ "'" c~n wit" lOT

1, fldttwe CIOalhlwl T!OIII* COCitt ..... 10> Olow fllwt I WtltM 0pt.tll«< ..,_ ... '""'' below tol" ~rm s.tt~~ 10 llr~l. · UTC.......,_.,.,_ .... .,.......,. ... !•· QQtr lllpQ

,..., ttJM ~~~t~Mt .. ore. - ... -...,., • GDoo"'-oOH""'it__,.,.on .. ......,..

' ' ~· ....... -.o..._...__$11~

- I I , .............. _____ , .. ,..,. ....... ·- I ' L KOfO IINjlcW ~ ... , ... .. ... . .,.,.., ...................... .......... ~- _.._ ...... ca. .........

L CIIMI. ...... a. tAoNt ..... . ,. ....,_., .. _.., ...,,, .. ~ ............................. • Orecl ... --. ......... ""111101"--.a·- , ........

,_..... ___ ,.._..,.. __ ·O.O...G_,,_... • IOWOlCI_, .. _... ...... _.......

---·~ ·~----...., ..... .,. on:.- 1 ... . ...... -~-'ON' ...

.~ ,-.,*"~ . u..--QOf"CRI• ('0'1'-...., ............. 1*4<0H' ....... ~ ...... I L t. NOS Tool • O.Ct UM MMIIOtlnf ..... ~--§·~i·:: I • NG&,,.....,.,....'*"-u~~G~~tt.

• '""ttl'()-...1 ~nc..lOtl .. 1'11111. • a.ct "* ,.._.....INioiiM *""'IM HOI II·,..,., '.... = ....... -• ~--WOKtf•~tl.,_

' .... ---~- ....... ,. . .. Nf,J .... I ....... I .,....__ ...... ~~'"OW"-...... I I a..blto.-. • • .......... C.. ~lit "-""'ot ..... o-.s.

~ lrillmc._.C!tM"- ..... ·- ... - . .......... ,._ ....... _ . o-.• .. w.r.ta•FUB. .... ._ __

.... ...... - -- -. ,_,.....,.. ___ ..... _ ....... - ·- ·-........ --~" ............ ....... . ... ' .,.,.. -· .. •· y,..._ ...................... ...-..-. ..... I (NCI( ~ ........ -... .,_ .. ,....

-~~--l'(al L liKIIIO ''* ~mp PressuN ..... OO.O~If81A

• AAeP.-.~¥-Q ... -. • ...., Ill .... ,. .. ltJrM • Low IIII'M u• M til ........... 01 MW!Ifltl

... .,..... .. llef:oOport,wtot. ""'111"1a'l'JMm ........ HO """'~._, ... ~.ti:-IOOtf._,_~llftll- ....,.. era,._. • -IM CW C'IM I1IA, Cfltdl I , .... NlO......,.. -~, ... c.... ...

l . , .. ~---.. -"'-~· OOlO~lUJDO

"'

~ I e. ..:.0· A .............. "' p ....... ,.....,..

r= ! ·= i I - 4 ;.;;. ............ _ .................... ••• "* aPSt- -.-. ..-........... o--.. .. ...._ ... .,.._ ................... ,...,...,__ _._,.._. __

M

... ·~ - o. ................. ~ ..... .... ! .. &. ,...... iiCOIO 0. 0...0 T- ..... .................................. -. .. . ............. , ... ........... NW...,._It_.....lflltll ....

• olCI .. ....., .... _~...._ CJ"'* -.,., • , ... ..... u, • • .. .. .. .. .. .. n " " '" ..... 111M brCt ..,.,_-..... ... -- •· Rlll. PW·~ ... . ~ .... ,_, .. _ ., .... -· ~ lati!IOMI•.,.NOI• .. ..,.• ... IDM.n

....... I I ~ ............ "" ............ ................... -'*' .... ' ,_ ldCft"""¢10011C .... IOU. WII»J ., .. ...;,. ......... -uo -Ill.

See PC/ED manual, sectton 48 for more detail on all of the above test steps.

70

1998 1/2 Econollne

Performance Dlagnoatlca .. """""''' oc:r........_ ... ,..,.,........ ...... ...., ......

. v.., ............................ . . ~-.................. ,..,. .. ~ ........ """*' ..... OOMtOMIIIOr~ . ~ ..... ..,._ ... _ .... ._.

CAlfflOM ,._-..... _,. ._ ...... M1 ~.

I '"1§;"--;. ....

I .,..........,

I 1·· ..... t ..... _ . ...,,_ ................ ~~,_ .. ..... -_...... ......... .. ,.,.....,..... ............ .. ...

. ...._.,..,._. ... -.......... ·f .............. .., ...

ol. CI'Met. fiiiOitle 011 1,.-,tl • CIMdlflll ......... ,..~.

"':!~f""= I I .,........,, j .: ..... = ........

• eo-sOtoolw; .. . .,.,,_ ....... _,...,.......,_...,.. ,...,,_ .. ................. , ... lllotMc,... ~ ,._. .. ,..,

I ..... ·--·-----~..- ...... I =?l ?_.: I ,, .. ...,,

.. """''"'-- I ·--.. ..- I - .,__ .................. ,......_., ..........

7~~~~!!'!':-t:::::~~!--''------::::~-1 - o.drtl "'* ,.,.. 1111« ~ .. ,_ .. "'-:-::.:.:o..-.·... .. ... ( -~~ ·z:~,--:·r: ::. -...... _ ... ____ I ::..:..-: J ~...... I ,...,.Met.,..,_...,...., .. ,....

"" ' - , IWili!Ot " _,........, .... , . Hf. ... ,., ~ OMfl!l.... I I ....,~ .,_ ,_,Mtd,..., ..... ... • Wlllfiii/MI9-.t_,~ ........ ,......,..,...,..

.. Mlr'"l C0nlln!IOUI f~ CoO.. • U..NNOIT ..... . ore.....,..._.-. .. _..._..,..

................ O'I'Cit_ ............ -· ,- I

.....

.. ...

.. ' I :: I to.. ..-.~....._, ....

PI .......... • ,_ ... .,._.. • ,.. .......... 11»-""""-N()IIT..,

-~· I .... ....._ ...

'7. JCQ£0 1--r 1JM:~II .... T ... •tiMN~T-, ·wu tat!!' • AI ........ ••If .....,._IMfy llo.t:U, 11*1 ~---~ ....... ulll....-1~1. _ ... ., .. ·~ ...... ..._ ...... ,_,.,.,.,

I ~ ......................... .., ...... _......, ...... ,., .. .-~,.....,

, .. "" .... ~ ffCI' ,........ ..... • C~Jod. .... ... , .,.....ICP..-fRfW""'fltHOIT...,

.................. ......_. .. ICP_ Ml)tlte;, .......... Tft,. .... .......... . . ,.. .. _ __..,....,. ...... _ . ... _...... ........ ......., .. .... 1t, ~ .. ,...,,.. '""'

. ._ ...... -................... . . w.-···---..., ..... ~~~~oe tM1 P,N. !IQI .. Ot +oool'U ~. ............. ~-"'._ ........... •"~ .... I ~ ;;

1L CJ'MIIOII OOntl'«<uCIM '""' • .... IN! fOtii .... N P•

· f'W AJIIJ"·~-

..

' ..... ~~~~-.. -IIIOm.:......,.~~·-··,..,.,-

I I 1L ~-----. ......._,....,_.,_.w .....

• ._... .......... lliiOf ..... ..._. • ~EII'-O.HOIT ........ fM .....

110.'

I ... I .. ....... I ·--14 ..... """'" , • . ....,_....,._ .. _..., ............ . ............................ ........ IG!It-.

• !Woo, ... .-cJ ............ . ....

~~ ....... .,. ....... ~

.. ...

·I .....

I

I ........

1"':=;.- r:::; ... J---j -. ...... -.......

See PC/ED manual, Section 48 for more dsts/1 on all of ths llbove test steps.

71

1999 F-Series

Hard Start I No Start Olaanoatlcs .,_,.,....~, ..... e.... ..... 1e. Glow ...... .,..._~ ... ......

I'IOTa " ,_. ..._ ... llWI CIOfiC*fl _. EOT • on:. .................... .....,....._. 11111111 , ......................... , ..... ,._..,,._..,.,.ore. - ....... ....,. oiJIIII,.""QH ... II ......................

t. VI .•. ...--.r .. o.,..,....., ....... .,.....,_ I -I I ,., .... *"" ................ , .. .. ....,,.,,

\'ltll .. .. 11.0!0 lllfKt9! ·~''"' ... ,. .. , Soo~t . ~ ....... o-. ................ 'u.. ... NOir.... .....,.. .... (IOtll ""' Ol6w ~ ...,,

1. CIMCII lf'IOIM 011 Lt¥11 ..... • AI tlltdO!t ... IIIQ~ IIIIU, ""' ._.,..._ • I11Nie ~ • 'N flfNI JlwO IMII.,.....

• ~-OIIfMilolll-l~toOU~ ilrfH:IO't ... OW"I•Iol......,_ 1 fi!OIOIII. Cit•~ - M OIOMI ......, 01 fOMMit .....,_.. 0.

oOOf'otCIIO.~, • 10M DT¢f""fllf........0.,.. .. 11t......., .. ...,.,. C.l......,, • ........ tteo;~t t11 • M!Na IIWII

__ , .. • T-'*J•M(IJOiiiiiiii.-•'Oif'~mt - I • Wf'Otlt,.,.O"C'fW""'CO'I' .... _.. .......... 'ON" ...........

I "*•• t. NOS Tooll • DIU u.l *'II ..... ...... l '?l·~~j I

• HCII ,_.., _, _........, ,_..,.. " """" • .........,~ "-llldNI ... ,.. .. \. ........................... ... l()f ...... --.. --·,--; , .... I

-__ ..,...._ __ , .. ..., - .... I ,..,_ I . ._.__ .... ...,...,._._ - _ ... . ..__ ...........................

• _..__

...... ... I -- I ................ __.. ....... _ .c-. ... - .... ~ ... -.. __

.... ! -:· - _..., -. ...,.,...,..._ .................. _, .... ·- ·-_.. ....... -............... ~-- ........ I ..... I --"""' .. ,. •· Vhlfi · II~ • IW ............... ..... ................ ClfiWtiMt ............

• .............. II'CW.

•• • ..,.,.,.. 1\1111 """'- , .. _.. .. ... 00 lOf'N'OHrt'Qf" • AIW ... ..,.... ... fltNit'Hflll .. ._ •· .. ,... • \eW ..... """ .... ~-... ., ........ .,. .. ,_...lll~pcloo4fM. Cl't~ ............... ,.,..~WM-

..... _ ........ '1\t •• ~--- ~ .... '"'0 . ...... OoiP ~ .... "** t 10-Ito H ll OWfll -OII~T~O...

~~~ I f§§~"r:=:]-!:;;. 00 t()I'IN'CM ti!SfOO

I •· "' . ...... _.,tot .. .,. .................. ....... .,.._. ............. .. .,. ..... ,_.._.,_....,........,o,...,....,.,. .,_, ..................... ........_ -------I'M: I!" 0. •......, .......... N JOIO ...._... lit ' j: ! .. ,.,..... 110010 o-~ ., ... ... ... ....... .............. ..,_ .... -.

• ...... !Oit- -.. -,.,.. ...... ,..,...,., ......... .OfCt ... ..,.... ..... ___ ..._

qCilt-......... ........ ,_ • • ,...,oro_....,,.....,..,. __ •· ....... ........... , .... flt;lk - • " M M " - - ~ ............... _ .......... ...... . - ,_., ......................... . ............................. --· ---IDk ,........ .. See PC/ED manual, Section 48 for more detail on all of the above test steps.

72 n

1999 F-Serles

Performance Diagnostics ,.,..., ... ~ ..... ~ ... "'* '"'""'' .... .... ..... ..... • .. ~ .... _,. fiCP,.,....... .. ... . ....., ____ ..,..,._.,......,......._ . ....,.._ ........ -..... ,.... ............... ·~·---. ..,. .. _ ....... ..,......, . .,._,.....,,_ ... ,_.,...,. .... • """"'pwf!!!!!'!t!I!Cilf-

. '"'!§''"t'•;_- I I t~:::o:ES' i , - I ...... I I ...... I .... _

• ........ - ... _......__ .. D_ . Ill""',_., ~ 0. ........ WOllt iC,. ... .,....., m MI.-. ..............

L tufllc:'-!1 C$Ntt fWI ..... . 111,.......,..._ ......... ~ .......... . 11/ff>M,. ... _....,.. ~,. "" Mil,.... .. ,. I • eM4fWAT(AIN,IKI.IIIf9~._.....,.,.,. .. r_. --.. - ... .... *"' '"'" ..... . il,.,., .--....oat .. ~..,.. • ., ...... • Oo.- ..... llo:onlloo-' .......... ~..,. ....... 011. ............. ,._ . .,.---~ H. Crfl"lllc- ll'feuun Test .....

NOm""" .. CAurJOIW ..._-lioN -.y ._...,.. _. ~ . ....,.. ....... _.. .......... . ""!If"''"'·:..- i I

. ...._ ...................... - ..... • tl'k tDt a 01+GOJo......, , ...... ~ ,.,._ . .................... _ s.ea.c-,....<* ....... ..... ·§fi--oa.CJio;W ................ .....,_,__, ......... _....,,..._ .... ....,. :I '""' I • c:....o o..o.._... ..... ~ .. -. ................ . .. ..,._- ~= ... IIIMIII'Il,.,.. ~ "'""',.. .. ...

• *-•W-ItOoii~IWI ........ fl ......... ........ """"'...-.~----I

Vlau• I ·~~ ... -.. !f .. c,u,.... co ... tr~W~~on '"" ..... I ~·~

• l '*'tNI EOTtl~JO, ....

•• lnllb Rasalkdon ..... I ..... ~'f ~.:- • l""'.VC...., .. -.... • • 01.-1111 ....... . ..... 0,.00.~--~--

' • w..--,.... -... cc. •.,. •

/IIIOfll ,..,..........., _________

.. . ,_,_. ... --...,. ..... ,....---.. pt-------.. 'PI""!\,.

I .:-- 1 I'· ••• I ....... """'--.~~ ..... ... I a.,....._ ICOEO 0.-...... , ... .. ... · , =t;-i-==·r: ::. I 1::-'. -- ....... LU~ ... .......... ~

• ... NGI$t..._ I ...... .. ...... .-....~ ..... .,.. ......... • oro. .. ..,... ____ ....._ -....fWI"--•-•WO'I .............. -Dol tnt:.~ .......... _..., .,..., ... ,.~ ..... ,.,.. ...... ,., • --··-NHJ&T_ .. ,..,..._ ·=· ....... o.....,.,. ... -' ....

Y:~"~··~M· I .~·::- -1 I lllwi ..... Ia- IWO~W. .....,, ,....lOt Nlw

t. fltt.rfotott Conti!IUOI!I• TtWblt COGM ..... t. ~KOlA On o.m.ld TMI ...... . .> J j.:; 1 ..... _, . ~.~~o~ .. ,.asr..- ~ · .. 1 ... 1o.M '"""'" T.-. -flfUJ • ore. ... _......., • .,.........._..._ I .... I I ............ .,., .................. ,...,...

.._ • -.raton::.- .. ,.,,.. ........ -.................. _ ...... • .... ......... eo..r.t _..__.. , ... ....~ .... ...........................................

, ..... OMII I ................. ...,. .................................. . ............ o .......... .,., ... flll'w._ ... ,.,., ...

'· coeo~ ......., .... , ... _,., ·--:--·-~

,_., ....... .....,.. .... _ • UM ... HOST-. ...- I ........... .,.... .................. · AI~--Iarlft~ou.~....,_ r~ .. =~ l u; .. ::

e~F~~"'f ... ~l ........ '*" ~ ~ '""""' '·

I --·•c. • It let' .... -- ....... , ,., I'll.,.,

'-<~""' I ' ........ ,.. ..... _ olf --- ..,. .......

·-~ ..._.,.. ...... ~-_,,....., ._..._ ... -· ... SM PC/ED manual, Section 48 for more detail on all of the above test steps.

73

APS Acce lerator Position Sanaor A potentiometer style sensor that Indicates the operators pedal position.

Actuator A device which delivers motion in response to an electrical signal.

Analog A conlinuously variable voltage.

BARD Barometric Prau ure Sensor An analog device which indicates atmospheric pressure which allows the PCM to compensate for altitude. A BARO sensor has three connections, signal return (gnd), BARO signal, and Vrel.

CAC Charge Air Coolinr A process of oooling the air coming out of the turbo before it enters the engine.

CMP Camshaft Position Sensor A Hall effect sensor used to Indicate engine speed and camshaft pos~ion. Speed is indicated by the number of vanes counted per revolution. Camshaft position is indicated by a single narrow vane which indicates 11 cylinder position or a wide vane in dual sync application !hat indicates #6 cylinder.

DVOM Digital Volt Dhm Motor A meter that uses a digital display to Indicate a measured value. Preferred for use on microprocessor systems because a DVOM has a very high internal impedance and will not load down the circuit being measured.

EBP Exhaust Back Prouuro Rogulator A pulse width modulated controlled but1erfty valve mounted on tha exhaust side of the turbocharger used to create exhaust back pressure to insure faster engine and cab warmup.

EBP Exhaust Back Prouuro Sensor A transducer style sensor used to Indicate exhaust back pressure.

EDT En r ine Oil Teatporaturo A thermistor type sensor which indicates engine temperature.

GPR Glow Plug Relay Relay which supplies power to the glow plugs.

GLOSSARY

Hall Effect Sensor A Hall Effect sensor generates a digital on/off signal that Indicates speed and also engine timing. The signal is created by a switching action caused by the passing of a vane thru a positive and negative voltage potential. When the vane is between this potential , a signal is created. When the gap in between this potential is open, no signal is generated. The wider the vane the longer the duty cycfe of the signal, the narrower the vane the shorter the duty cyde of the signal. A narrow van is used ti indicate the position of •t cylinder and a wide vane tl indicate the position of #8. A Hall Effect sensor has three connections: ground, Vref, and signal.

IAT Intake Air Temperature Sensor A thermistor style sensor used to indicate air temperature.

ICP Injector Control Prou ura A ll'ansducer style sensor used to indicate gallery pressure.

IPR Injection Control Rogulator Controls injection oil pressure. An electrical signal to a solenoid creates a magnetic field which applies a variable force on a poppet to control pressure. The quantity of fuel delivered to the combustion chamber is proportional to Injection control pressure.

IDM Injector Drive Moclule An electronic unit which has the primary function of an electronic distributor for the Injectors. It also is the power supply for the injectors. It supplies 90v @ 7 amps to the Injectors.

IVS lclle Valiclatlan Switch An on/off s~ch sensor that indicates when the accelerator pedal is in the idle position.

Impedance A form of opposition to AC current flow measured in Ohms.

KOEO Kay On Engine Oil Tnt A self-test operation that Is performed with the ignition switch in the ON position with the engine off.

KOER Key On Engine Running Test A self·test operation that Is performed with the ignition switch in the ON position and the engine running.

75

GLOSSARY

MAP Manifold Absolute Pressure A MAP ~nsor Is a ~nsor that generates a digital frequency thaltndicates manifOld bOOst pressure or varuum. The signal is created by swnohing action caused by manifold pressure on a diaphragm connected to a capacifor circuit in the ~nsor. The digital frequency increases as pressure increases. A MAP sensor has three connections: signal return (gnd), MAP signal, and Vref.

MAT Manifol d Air Temperatu re Sonoor A thermistor style ~nsor used to indicate air temperature after passing through the charge air cooler.

Normally Cloud Refers to a switch or a solenoid that is closed when no control or foroe Is acttng on it.

Normally Dpon Refers to a switch or a solenoid that is open when no control or foroe is acting on II.

PCM Powartraln Control Module The housing which contains the micro computer, Vref regulator, Input conditioners and output drivers.

Potontlomotor (Pat) Converts a mechanical motion to a voltage value. Most often used to ~n~ the position of a component. This ~nsor works as a variable voltage divider. The wiper arm IS mechanically connected to the component desired to be ~nsed. Potentiometers have three connections: Vref, signal out, and ground.

Puhe Width The length of time an actuator, such as an injector, remains energized.

Split Shot Injector (Prime) Split shOt Injectors provide improved exhaust emissions and quiets engtne operation by tailoring the injection of fuel, Without a decrea~ in performance.

Thormlator Sensor used to determine temperature. A therrmstor changes It's resistance value in relation to temperature change. lncreastng temperature results in decreastng res•stanoe. decreasing temperature results in increastng resistanoe. The thermistor in conjunction with a current limiting resistor In the ECA forms a voltage divider that provides a voltage signal that indicates temperature. Since the top half of the voltage divider is the current limiting resistor and Is Internal to the ECA, a thermistor sensor only has two connections, signal return and ground.

76

VBAT Battery voltage (see VPWR).

VPWR Battery voltage (see VBAT).

VSS Vehicle Spaed S.naor Normally a magnetic pickup style sensor thetis mounted on the tailshaft of the of the transmission to Indicate ground speed.

A

Air cleaner, 12

Air Induction hose, 19

Antlfoam concentrate, 47

c Cam follOwer guide, 38

Camshaft, 6

Charge air cooter

housing, 15·16

piping, 18·19

Circuit diagrams, 51, 55, 59, 63, 66-67

Crankcase, 6, 38

pressure, 10

Crankshaft, 6, 45

wear sleeve, 45

Cylinder head gasket, 39

D

Diagnostic forms. 70

Diagnostic guide, 60-61, 64·65

Dipstick, 10

E ECM pinouts, 50, 54, 58, 62

Emission label, 5

Engine harness. 8, 43

Engine mounts, 12

Engine serial number, 4

Engine torque, 5

Exhaust back pressure, 9, 13·15

Exhaust manifolds, 9

Exhaust pipe, 19

Exhaust up pipes, 8

F

Flexplate/Fiywheel, 12, 48

Front cover, 39

Fuel filter assembly

filter element, 25

heater, 24·26,36

pressure regulator, 24, 35

restriction sensor, 35

service, 25-26, 35-37

standpipe, 26

water drain, 24·25, 37

water sensor, 25, 36

Fuel inlet check valve, 27

Fuel supply tines, 27, 41

Fuel system diagram, 28

G

Glow plug relay, 43

H

High pressure oil pump, 42

Horsepower, 5

I

Injector, 21·23, 41

torque, 48

o·rings, 23

spm shot (prime), 21·22, 41

Injection control regulator, 43

<>-rings, 43

Intake cover, 16, 48

Intake hoses, 16. 47

0 Oil cooler header

filter bypass valve, 48

pressure regulator, 46

Oil fill, 10

Oilpan, 40

capacity, 48

gasket, 42

resealing, 47

011 reservoir, 23, 40

p

Pistons, 7

rings, 7

Pressure check

at pump, 29

left head, 28

right head, 28

s Sensors

camshaft position (CMP), 32, 43, 45

engine coolant temperature (ECT), 43

exhaust back pressure (ESP), 32, 43

injection control pressure (ICP), 43

manifold air temp (MAT). 31

manifold absolute pressure (MAP), 31

Snap to connect ICP lines, 29

INDEX

77

connections, 29

toots, 30

Sound Insulating material, 17

T

Thermostat, 44

Thermostat housing, 11

Torque data, 33

Turbine inlet and clamp, 10, 20

Turbo, 13-15, 20

Removal, 17-20

u Under valve oover harness (UVC), 7, 43

v Valve cover gasket, 7

Valve tXNer gasket breakout tool, 8

w Waste gate

actuator, t6

control, 15

Water pump, 11, 44

Water pump pulley, 11

78

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7. 3 D I T Power Stroke Direct Injection Turbocharged Diesel Engine

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