07-8-9 6.4l Diesel Engine - Lacks Power, Leaks Fluid From Exhaust Pipe, Abnormal Tail - Diesel Truck Forum - TheDieselGarage.com
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07-8-9 6.4l Diesel Engine - Lacks Power, Leaks Fluid From Exhaust Pipe, Abnormal Tail

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07-8-9 6.4L DIESEL ENGINE - LACKS POWER, LEAKS FLUID FROM EXHAUST PIPE, ABNORMAL TAILPIPE SEDIMENT, WHITE SMOKE, EXHAUST SMELL, AND MIL ON

Publication Date: April 13, 2007

FORD: 2008 F-Super Duty


ISSUE:
Some F-Super Duty vehicles equipped with the 6.4L diesel may exhibit one or more of the following concerns: lacks power, leaks oil, fuel or coolant from the tail pipe, abnormal tailpipe sediment, white smoke or ash, exhaust smell, knock or rattle, elevated idle, surge, crankcase oil level over-full, MIL On, DTC's P0087, P2291, P0263-P0284, P0300-P0308, P1336, P132B, P2262, P2263, P244C or P244D.

ACTION:
To diagnose and correct the concern, refer to the following Service Procedure.

SERVICE PROCEDURE

NOTE: DO NOT START ENGINE



Evaluation, Inspections, And Checks

Retrieve KOEO diagnostic trouble codes (DTCs).
Check oil level. Remove and clean dipstick. Reinsert into dipstick tube only until dipstick handle reaches top of dipstick tube (Figure 1).
NOTE: FIGURE 1 DEMONSTRATES DIPSTICK POSITIONING FOR OVER-FULL CHECK. KEEP DIPSTICK HANDLE OFFSET OF CENTER TO PREVENT IT FROM FULLY SEATING. IF OIL LEVEL IS BELOW THE MAX MARK, OIL IS NOT OVER-FULL.





Figure 1 - Article 07-8-9



Check coolant level.
Check fuel quality.
Inspect tailpipes for abnormal sediment; for example black soot, white ash, oil, coolant, or fuel.
Inspect vehicle for coolant, oil and fuel leaks at the following locations:
Tailpipes
Up-pipe joints
Exhaust manifolds to cylinder heads
Exhaust manifolds to up-pipes
Charge air cooler system and air inlet system
Oil separator
Inside air filter housing
NOTE: PROCEED ONLY IF ENGINE OIL TEMPERATURE (EOT) IS LESS THAN 150 F (66 C).



NOTE: VALIDATE INTEGRITY OF ALL EXHAUST GAS TEMPERATURE (EGT) SENSORS WITH POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) PINPOINT TEST (PPT) RC5 AND RC6 BEFORE PROCEEDING.



NOTE: IF REPAIRS ARE PERFORMED AS A RESULT OF THIS TSB, CHECK DIESEL PARTICULATE FILTER OPERATION. SEE PC/ED, SYMPTOM CHARTS, NO DTCS, CHART 8.



Repair Directions

Section A - If the following DTCs are present P0087, P2291, P0263-0284, P0300-P0308, or P1336 or if observation of external fuel leaks, for example, wetness around exhaust manifolds or over-full oil level indication.
Section B - If the following DTCs are present P132B, P2262, or P2263 or observation of oil leaks (aside from over-full oil level) or oil level is low.
Section C - If coolant low or observation of coolant leaks.
Sections A, B, and C - If only abnormal sediment in tailpipes.
SECTION - A

Fuel System Diagnostics

NOTE: IN CASES WHERE ENGINE OIL HAS BEEN DILUTED WITH DIESEL FUEL AND ALL REPAIRS ARE COMPLETE, RELEASE THE OIL FILTER CAP ALLOWING OIL TO DRAIN TO OIL PAN AND KEEP FILTER, DRAIN THE OIL FROM OIL PAN AND FILL WITH NEW OIL. TIGHTEN OIL FILTER CAP AND RUN ENGINE FOR 10 MINUTES. FINALLY, CHANGE OIL FILTER AND OIL AGAIN.



If oil is not over-full - go to Step 9.
If oil is over full, drain and fill crankcase with new oil setting the level to the middle of the hash marks.
Remove valve covers; refer to Workshop Manual (WSM), Section 303-01.
Remove lower charged air cooler CAC hose. Inspect for fuel and oil contamination. Clean as required and reinstall.
Start engine and use caution when looking for fuel leaks around supply tubes and injectors.
If no leak is found run the IDS high pressure fuel system test and inspect for a leak during the test.
If no leak is found turn the engine off and use a hand held mirror to inspect for cracks on the underside of the fitting boss. (Figure 2)


Figure 2 - Article 07-8-9


Replace any leaking components and verify leak has been repaired while running IDS high pressure fuel system test - KOER.
Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check.
If fuel quality is poor, drain all fuel and replace with known good ultra-low sulfur diesel fuel.
If no DTCs were stored in pending or continuous memory go to Step 13.
Is there abnormal sediment in tailpipes or fuel evident?
No - Complete PC/ED worksheet and applicable PPT tests for the codes retrieved.
Yes - Go to Step 13.
Is there abnormal sediment in the tailpipes?
No - See WSM for diagnosis.
Yes - Go to Step 14.
Perform IDS Relative Compression Test.
Problem Identified - Repair as required.
No Problem - Go to Step 15.
Perform fuel supply system pressure check (low pressure system) - KOEO.
Problem Identified - Repair as required.
No Problem - Go to Step 16.
Observe IDS injector fuel trim.
NOTE: FUEL TRIM WILL DEFAULT TO ZERO WHILE EXHAUST AFTER TREATMENT SYSTEM REGENERATION IS ACTIVE. (Figure 3)



Observe IDS Power Balance. (Figure 3)
Perform Enhanced Power Balance. (Figure 3)
Compare results in Steps 16-18.
Low fuel trim may indicate leaking injector.
High contribution may indicate leaking injector.
Elevated contribution in comparison to other cylinders while cancelled may indicate leaking injector.
Excessive pull-up by subsequent injector may indicate leaking injector.
An engine knock that is lessened when a cylinder is cancelled may indicate a leaking injector.
If no root cause is determined in Steps 1-18, perform IDS high-pressure fuel system check and repeat Steps 1-18.
If no root cause is determined, replace horizontal fuel conditioning module (HFCM) and on-engine fuel filters.
SECTION - B

Do not crank engine. Perform KOEO and observe turbocharger actuator. Does the actuator move at key on?
No - Ensure turbocharger is above 32 F (0 C). Move truck to a warm location and repeat test. If turbocharger actuator does not move and is above 32 F (0 C), perform PC/ED diagnostics.
Yes - Step 2.
If no DTCs are present, go to Step 4.
Is oil or abnormal sediment evident in tailpipes?
No - Complete PC/ED worksheet and applicable PPT tests for the codes retrieved.
Yes - Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check and repair as required.
Is oil or abnormal sediment evident in tailpipes?
No - Perform WSM, Section 100-04 - Noise Diagnostics.
Yes - Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check and repair as required.
Remove lower CAC hose. Inspect for fuel and oil contamination. Clean as required and reinstall.
SECTION - C

Perform WSM, Section 303-03 - Diagnostics for EGR cooler and engine internal coolant leaks.


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION DESCRIPTION TIME
MT070809 Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual Time. Actual Time

DEALER CODING
BASIC PART NO. CONDITION CODE
9e527 42



Figure 3 - Article 07-8-9


--------------------------------------------------------------------------------

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright 2007 Ford Motor Company

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