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Home >> Ford Truck >> 2003 >> F 550 2WD Super Duty V8-6.0L DSL Turbo VIN P >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Reading and Clearing Diagnostic Trouble Codes >> Reading Diagnostic Trouble Codes >> With Manufacturer's Scan Tool >> Performance Diagnostic Procedures >> Steps 14 - 16

Steps 14 - 16



14. Crankcase Pressure Test

Purpose:
The purpose of this test is to measure the crankcase pressure. Crankcase pressure is a measure of how well the cylinders are sealing.

Crankcase Pressure Test

- Measure the pressure at the oil fill tube with 6.0L Crankcase Pressure Tester p/n 303-758, with engine at 70°C (158°F) minimum.
- Block the breather tube on the left valve cover.
- Measure at 3,000 RPM with no load in PARK/NEUTRAL.

Crankcase Pressure Test:










If greater than 15 mm Hg (8 H2O), refer to the base engine.

Recommended Procedure:

NOTE: Do not plug hole on Crankcase Pressure Test Adapter 303-758.

Make sure the engine is at operating temperature. A cold engine will give higher readings. Remove the ducting to the turbocharger inlet pipe and remove the inlet pipe and elbow that connects to the breather box. Block the outlet at the valve cover with the cap provided in Pressure Test Adapter kit 014-00761 or equivalent. Install a protective screen over the turbocharger inlet.

Screw the Crankcase Pressure Test Adapter 303-758 in the oil fill cap hole. Plumb to the Magnehelic (R) gauge in the gauge block. Make sure the Magnehelic (R) gauge has been zeroed.

Start the engine and operate at 3,000 rpm. Hold for 30 seconds minimum and take a stabilized reading. Do not block the hole at the top of the restrictor tool.

Possible Causes:
- Broken or worn compression rings
- Polished cylinder bores
- Leaking or bent valves

Inspect the air induction system. If the air induction system allows dirt to enter the cylinders, it will quickly "dust" the engine causing high crankcase pressure.

Tools Required:
- Crankcase Pressure Test Adapter 303-758 or equivalent
- Magnehelic (R) gauge (part of Pressure Test Kit 014-00761)
- Protective screen

15. Oil Aeration Test

Purpose:
The purpose of this test is to determine if the engine lube oil is aerated and causing poor idle quality.

Oil Aeration Test

Oil Aeration Test:






- Run engine at 3000 RPM for 1 minute.
- Take an oil sample from the engine oil temperature(EOT) sensor port at idle.
- Inspect the sample for presence of air bubbles.
- Excessive oil aeration can be caused by depleted oil additives, pick-up tube leak, front cover seal leak, or upper pan seal leak.

Recommended Procedure:

NOTE: The engine must be at operating temperature.

1. Remove the EOT sensor. For additional information, refer to Electronic Engine Controls.

2. Install the High Pressure Pump Test Adapter 303-765 or equivalent and Gauge 0-1,100 kPa (0-160 psi) Bar 014-00761 or equivalent.
3. Increase the engine speed to 3,000 RPM and maintain for 1 minute.
4. Return the engine speed to idle.
5. Obtain an oil sample with the engine at idle.

Possible Causes:
- Extended oil drain intervals - the anti-foam additives in the oil may be depleted from severe use or extended intervals.
- Air may be present due to recent engine repair on injection control pressure system. It may be necessary to run the vehicle aggressively for 24-32 kilometers (15-20 miles) to remove excess air.
- Incorrect type or grade of oil.

Tools Required:
Clear container - approximately 0.95L (1-quart)
Gauge 0-1,100 kPa (0-160 psi) Bar 014-00761 or equivalent
High Pressure Pump Test Adapter 303-765 or equivalent

16. Combustion Gas In The Fuel Rail Test

Purpose:
The purpose of this test is to check if any combustion gas leaks past the injector's needle and seat or past the copper combustion gasket.






Carry out the Combustion Gas In The Fuel Rail Test to verify the repair.
When the repair is verified carry out the Electric Fuel System Delivery test in this section.

Recommend Procedure:

Note: The compression pulses indicate the combustion gas is leaking into the fuel rail.

- Disconnect bank 1 and bank 2 fuel lines from the secondary fuel filter.
- Install a latex balloon over each fuel line and secure with the tie strap.
- Disconnect the fuel pump and the fuel injection control module (FICM) relays.
- Crank the engine and observe latex balloons for compression pulses. Identify which bank is a cause of the concern.
- Remove all but 1 glow plugs from the bank that leaks the combustion gas in the rail. Crank engine and observe latex balloon for compression pulses. Repeat this procedure for the 3 remaining cylinders on the same bank.
- For cylinders that leak combustion gas into the fuel rail, remove the injector and inspect the lower O-ring. Replace if necessary. Refer to Fuel Charging and Controls. Carry out the Combustion Gas In The Fuel Rail Test to verify the repair. When the repair is verified carry out the Electric Fuel System Delivery test.

If the lower O-ring is OK, install a new fuel injector copper gasket, then remove the injector to inspect the copper gasket for an even circular crush pattern. If the crush pattern is visible install a new copper gasket. Refer to Fuel Charging and Controls. Carry out test Combustion Gas In The Fuel Rail Test to verify the repair. When the repair is verified carry out the Electric Fuel System Delivery test.

If the lower O-ring and the copper gasket are OK, install a new fuel injector. Refer to Fuel Charging and Controls. Carry out the Combustion Gas In The Fuel Rail Test to verify the repair. When the repair is verified carry out test the Electric Fuel System Delivery test.

Possible Causes:
- Fuel injector
- Fuel injector lower O-ring
- Fuel injector copper gasket

Tools Required:
- latex balloons
- tie straps
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