TSB 97-15A-1


TSB 97-15A-1	7.3L DI TURBO POWERSTROKE DIESEL ENGINE
Publication Date: AUGUST 4, 1997

FORD:
1994-1996 F-47
1994-1997 F SUPER DUTY, F-250, F-350
1995-1996 F-250 CREW CAB, F-350 CREW CAB
1995-1997 ECONOLINE, E-250, E-350

Introduction

This 7.3L DIT Powerstroke Diagnostic Aide is being published in order to assist the dealer service technician with diagnosing driveability concerns. TSBs and OASIS messages have been included addressing several diagnostic procedures for driveability symptoms. The diagnostic aide is intended to condense TSBs and OASIS messages into one comprehensive manual for the technician. It is also intended to be a reference guide and a supplement to the PC/ED Manual (Powertrain Control/Emissions Diagnosis).

Using the flowcharts and recommendations in this manual should provide clear direction to the service technician, and should also assist in diagnosis, reduce repair time, repeat field repairs, and reduce owner down time.

This TSB is not a substitute for attending a comprehensive training class.

MECHANICAL DIAGNOSTIC FORM INFORMATION

HARD START/NO START DIAGNOSTIC PROCEDURES

PERFORMANCE DIAGNOSTIC PROCEDURES

ELECTRONIC CONTROL SYSTEM DIAGNOSTICS

SUPPLEMENTAL DIAGNOSTIC PROCEDURES

SYMPTOM FLOWCHARTS

7.3L DIT TECHNICAL SERVICE BULLETIN (TSB) ARTICLES

94-23-15

LOSS OF POWER — 7.3L DIRECT INJECTION TURBO DIESEL — INCORRECT MAP SENSOR
MIL — CODES 128 AND 845 (94MY) OR P0236 AND P0238 (95-97MY) — 7.3L DIRECT INJECTION TURBO DIESEL — INCORRECT MAP SENSOR

95-5-19

HESITATION — STUMBLE — LACK OF POWER — IMPROPER OIL DIPSTICK —VEHICLES WITH 7.3L DI TURBO DIESEL BUILT FROM 2/9/94
IDLE — ROUGH — POOR PERFORMANCE — IMPROPER OIL DIPSTICK —VEHICLES WITH 7.3L DI TURBO DIESEL BUILT FROM 2/9/94
OIL — IMPROPER OIL DIPSTICK CAUSES DRIVEABILITY CONCERNS ON VEHICLES WITH 7.3L DI TURBO DIESEL BUILT FROM 2/9/94

95-6-13

NO START — 7.3L DI TURBO — IDM MODULE — NO DIAGNOSTIC TROUBLE CODES
REDUCED POWER — 7.3L DI TURBO — IDM MODULE — NO DIAGNOSTIC TROUBLE CODES

95-10-7

LOW OUTPUT — DAMAGED OIL PICK-UP OR DAMAGED/MISSING O-RING SEAL — VEHICLES WITH 7.3L DI TURBO DIESEL
ROUGH IDLE — DAMAGED OIL PICK-UP OR DAMAGED O-RING SEAL — VEHICLES WITH 7.3L DI TURBO DIESEL

95-10-8

HARD STARTING AFTER INJECTOR REPLACEMENT — DIPPING INJECTORS IN OIL BEFORE INSTALLATION — 7.3L DI TURBO DIESEL ENGINE — SERVICE TIP
ENGINE — 7.3L DI TURBO DIESEL — DIPPING INJECTORS IN OIL BEFORE INSTALLATION —SERVICE TIP

95-10-10

ACCELERATOR PEDAL — POOR OR NO ENGINE RESPONSE —7.3L DIT
ENGINE — 7.3L DIT — LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION

95-14-12

ENGINE — 7.3L DIT — MANUAL TRANSMISSION — OIL LEAK —TRANSMISSION COVER PLATE RUBS ON ENGINE OIL PAN
ENGINE OIL LEAK — 7.3L DIT — MANUAL TRANSMISSION — TRANSMISSION COVER PLATE RUBS ON ENGINE OIL PAN

95-23-9

HESITATION/STUMBLE — POOR SEAL ON INJECTOR O-RINGS — 7.3L DI TURBO — ENGINES BUILT BEFORE 1/3/95 OR BEFORE ENGINE NUMBER 93602
IDLE — ROUGH — POOR SEAL ON INJECTOR O-RINGS — 7.3L DI TURBO — ENGINES BUILT BEFORE 1/3/95 OR BEFORE ENGINE NUMBER 93602
LACK OF POWER/POOR PERFORMANCE — POOR SEAL ON INJECTOR O-RINGS — 7.3L DI TURBO — ENGINES BUILT BEFORE 1/3/95 OR BEFORE ENGINE NUMBER 93602
STALLS — POOR SEAL ON INJECTOR O-RINGS — 7.3L DI TURBO — ENGINES BUILT BEFORE 1/3/95 OR BEFORE ENGINE NUMBER 93602
OIL — EXCESSIVE OIL CONSUMPTION — POOR SEAL ON INJECTOR O-RINGS — 7.3L DI TURBO — ENGINES BUILT BEFORE 1/3/95 OR BEFORE ENGINE NUMBER 93602

95-25-12

FUEL — FUEL DOES NOT DRAIN OR DRAINS SLOWLY WHEN FUEL DRAIN VALVE IS OPENED — WATER-IN FUEL LAMP ON — VEHICLES WITH 7.3L DI TURBO —SERVICE TIP
WATER-IN FUEL LAMP — LAMP ILLUMINATED CONSTANTLY — FUEL DOES NOT DRAIN WHEN VALVE IS OPENED — VEHICLES WITH 7.3L DI TURBO —SERVICE TIP

96-1-8

ENGINE — 7.3L DI TURBO —SEALANT — RTV — AVAILABILITY OF NEW SEALANT FOR SERVICING 7.3L DI TURBO ENGINE
SEALANT — RTV — AVAILABILITY OF NEW SEALANT FOR SERVICING 7.3L DI TURBO ENGINE

96-3-18

HARD OR NO START — 7.3L DI TURBO — 1994-95 CALIBRATION
HESITATION — 7.3L DI TURBO — 1994-95 CALIBRATION
IDLE — ROUGH — 7.3L DI TURBO — 1994-95 CALIBRATION
LOW POWER — 7.3L DI TURBO — 1994-95 CALIBRATION
MISSES — 7.3L DI TURBO — 1994-95 CALIBRATION
STALLS — 7.3L DI TURBO — 1994-95 CALIBRATION

96-6-7

HARD START/NO START/LONG CRANK TIME — F-SERIES BUILT FROM 2/9/94 AND ECONOLINES BUILT FROM 8/94 WITH 7.3L DI TURBO DIESEL

96-6-10

ELECTRICAL PARTS — WEATHER PACK CONNECTOR SEALS —VEHICLES WITH 7.3L DI TURBO — SERVICE TIP
WIRING — ELECTRICAL PARTS — WEATHER PACK CONNECTOR SEALS —VEHICLES WITH 7.3L DI TURBO — SERVICE TIP

96-10-14

STALL — WHEN REVERSE AND/OR MANUAL LOW ARE SELECTED — VEHICLES WITH E4OD TRANSMISSION BUILT PRIOR TO 9/20/95
STALL — WHEN REVERSE AND/OR MANUAL LOW ARE SELECTED, OVERDRIVE CANCEL LAMP ILLUMINATED, AND DIAGNOSTIC TROUBLE CODE (DTC) P1728 — VEHICLES WITH E4OD TRANSMISSION BUILT PRIOR TO 9/20/95
TRANSMISSION — E4OD — 7.3L DIT ENGINE — OVERDRIVE CANCEL LAMP ILLUMINATED, AND DIAGNOSTIC TROUBLE CODE (DTC) P1728 — VEHICLES WITH E4OD TRANSMISSION BUILT PRIOR TO 9/20/95
TRANSMISSION — E4OD — 7.3L DIT ENGINE — OVERDRIVE CANCEL LAMP ILLUMINATED, AND DIAGNOSTIC TROUBLE CODE (DTC) P1728, AND WHEN REVERSE AND/OR MANUAL LOW ARE SELECTED — VEHICLES WITH E4OD TRANSMISSION BUILT PRIOR TO 9/20/95

96-11-13

ENGINE — 7.3L DIT — 1996 ENGINE CONTENT REVISIONS — SERVICE TIP

96-16-7

NOISE — "KNOCKING" SOUND — VEHICLES WITH 7.3L DIT ENGINE — CALIFORNIA EMISSION VEHICLES ONLY

96-17-19

FEAD BELT — WEARS, SHREDS, AND/OR COMES OFF — VEHICLES WITH 7.3L DIT ENGINE BUILT 8/94 THROUGH 5/96

96-19-9

MISS — VEHICLE MAY STALL AND NOT RESTART — DIAGNOSTIC TROUBLE CODE (DTC) 1298 MAY BE STORED IN MEMORY — 7.3L VEHICLES ONLY — VEHICLES BUILT BEFORE 4/11/96
NO START — VEHICLE MAY STALL AND NOT RESTART — DIAGNOSTIC TROUBLE CODE (DTC) 1298 MAY BE STORED IN MEMORY — 7.3L VEHICLES ONLY — VEHICLES BUILT BEFORE 4/11/96
STALL — VEHICLE MAY STALL AND NOT RESTART — DIAGNOSTIC TROUBLE CODE (DTC) 1298 MAY BE STORED IN MEMORY — 7.3L VEHICLES ONLY — VEHICLES BUILT BEFORE 4/11/96

96-21-16

TRANSMISSION — E4OD — HARSH SHIFTS — F-250-350, E-350, AND CUTAWAY EQUIPPED WITH 7.3L DIESEL ENGINE BUILT BETWEEN 5/15/96 AND 7/8/96 — CALIFORNIA CALIBRATION 6-90P-R11 ONLY

96-22-11

AIR CLEANER — DAMAGED AIR FILTER IN SEVERE DUTY CONDITIONS — VEHICLES WITH 7.3L DIT DIESEL ENGINE BUILT THROUGH 5/8/98 — SERVICE TIP

96-26-21

VIBRATION — DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS — VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13)
TRANSMISSION — E4OD — DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS — VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13)

97-1-13

ENGINE — 7.3L DI — "MOANING" NOISE HEARD AT 2600-3000 RPM — VEHICLES WITH 4X4
ENGINE — 7.3L DI — VIBRATION AT 2600-3000 RPM — VEHICLES WITH 4X4
NOISE — "MOANING" AT 2600-3000 RPM — VEHICLES WITH 7.3L DI AND 4X4
VIBRATION — AT 2600-3000 RPM — VEHICLES WITH 7.3L DI AND 4X4

97-2-14

ENGINE — 7.3L DIT — GLOW PLUG START-UP ON-TIME DURING COLD TEMPERATURE — SERVICE TIP

97-2-16

LEAK — OIL LEAK AT ENGINE VALLEY PAN AND/OR HIGH PRESSURE OIL PUMP — VEHICLES EQUIPPED WITH 7.3L DIESEL ENGINE

97-5-12

IDLE — ROLLING IDLE — SURGE — VEHICLES BUILT 8/96 THROUGH 12/96 WITH 7.3L ENGINE
SURGE — ROLLING IDLE — VEHICLES BUILT 8/96 THROUGH 12/96 WITH 7.3L ENGINE

97-6-18

LOW RPM — 7.3L DIT ENGINE FAILS TO START —CODE 340 STORED IN MEMORY AND/OR ENGINE FAILS TO ACHIEVE RATED SPEED FOR 2-3 MINUTES AFTER EXTENDED COLD SOAK — F-SERIES BUILT THROUGH 2/9/96 AND ALL ECONOLINES
NO START — 7.3L DIT ENGINE FAILS TO START AFTER EXTENDED COLD SOAK
RUNS POORLY — ENGINE TEMPERATURE COLD —RUNS OK WARM — 7.3L DIT ENGINE
STALL — ENGINE TEMPERATURE WARM —WILL NOT RESTART UNTIL COOL — 7.3L DIT ENGINE
STALL ON DECELERATION — DURING COLD AMBIENT TEMPERATURES — 7.3L DIT ENGINE

97-7-7

HARD START — EXTREME COLD AMBIENT TEMPERATURE — VEHICLES WITH 7.3L DIESEL ENGINE
NO START — EXTREME COLD AMBIENT TEMPERATURE — VEHICLES WITH 7.3L DIESEL ENGINE

97-7-9

WIRING — AFTERMARKET WIRING ALTERATIONS — SERVICE TIP

97-9-20

NOISE — "MOANING" AT 1500-2000 RPM — 4X4 VEHICLES WITH 7.3L DIT ENGINE

97-11-18

FUEL SYSTEM — 7.3L DIRECT INJECTOR (DI) TURBO DIESEL — NO RETURN FUEL FLOW TO FUEL TANK — BEGINNING WITH VEHICLES BUILT 2/9/94
LOW PERFORMANCE/LACK OF POWER — 7.3L DIRECT INJECTION (DI) TURBO DIESEL — NO RETURN FUEL FLOW TO FUEL TANK — BEGINNING WITH VEHICLES BUILT 2/9/94

97-12-11

COOLING SYSTEM — COOLANT LEAK AT REAR OIL COOLER HEADER — VEHICLES WITH 7.3L DIT ENGINE — VEHICLES BUILT FROM 9/1/95 THROUGH 10/31/95
ENGINE — 7.3L DIT — COOLANT LEAK AT REAR OIL COOLER HEADER — VEHICLES BUILT FROM 9/1/95 THROUGH 10/31/95

OASIS SPECIAL SERVICE MESSAGES

OASIS

ONLINE AUTOMOTIVE SERVICE INFORMATION SYSTEM SPECIAL SERVICE MESSAGES

SSM NUMBER: 4102

EBP solenoid serviced separately from turbo

If you encounter a 1994-95 7.3L DIT engine with an rpm/speed limitation associated with black exhaust smoke, and possibly a Code 478, check the EBP Solenoid (F5TZ-6C673-A). Replace the solenoid rather than the entire turbo assembly. It is serviced separately.

SSM NUMBER: 4249

Oil filter torque

The torque specification for the 7.3L DIT oil filter has been revised to 27 N-m (20 lb-ft).

SSM NUMBER: 4293

Check clamps and connections at turbo

If you have a report of an exhaust smell in the cab of the 7.3L DIT, check the clamp on the turbo down pipe to turbocharger. Also, check inlet pipes to turbocharger and mainfold for loose connections or exhaust leaks. Tighten as necessary. Be sure not to position the clamp to crease a grounding issue.

SSM NUMBER: 4301

Normal condition — blue smoke on restart after idling

For 7.3L DIT engines, blue smoke on start up following extended idling with the blue smoke disappearing after a short drive at normal operating temperatures is considered normal and no service action is to be performed. White smoke on cold start up on 7.3L DIT engines is a normal characteristic. This condition is common to diesel engines and does not call for service action.

SSM NUMBER: 4418

Film of oil/dust normal — If not dripping, do not service

Seepage of oil between the halves of the turbo and the small amount of oil in the intake deposited by the positive crankcase ventilation system arefrequently misdiagnosed as oil leaks on the 7.3L DIT engine. The seal on the turbo allows a small amount of oil to weep through and this may attract a film of dust. If the seal is not dripping, DO NOT ATTEMPT TO SERVICE IT.

SSM NUMBER: 4774

Install quality fuel and operate at speed to clean up catalytic converter

Investigation of a plugged catalytic converter on a 7.3L DIT engine indicated that a very low grade diesel fuel, probably not intended for highway use, was being used by the fleet. The concern was resolved by draining the tank. purchasing known quality fuel from a local service station and operating vehicle at highway speeds for about 15-20 minutes while the plugged condition cleared. The low power complaint cleared as the converter self-cleaned.

SSM NUMBER: 4808

Check for missing oil filter relief valve

A missing oil filter relief valve in the rear oil cooler header is a possible cause of a start/stall with no oil noted in the reservoir, rough idle, or irregular oil pressure gauge readings. The three pieces of of the valve (spring, fiber washer, and steel washer) can fall out of the rear oil cooler header while removing the oil filter due to the lack of enough retaining stake. If all pieces fall out and are recovered, the proper order to reinstall these pieces is: spring, fiber washer, and steel washer. Stake them back in place. The valve is not serviced separately. If any one piece is missing, the rear oil cooler header must be replaced.

SSM NUMBER: 5005

Check for short in circuit #16 — replace fuel heater

Some vehicles may come in with Fuse #22 (30 amp) being open. Other symptoms may include stalling, no start, or a "wait to start" lamp that will not come on. If so, check for short to ground in Circuit #16 from Connector C138 (42-pin) to C188 at the fuel line heater assembly with both connectors disconnected. If the circuit checks OK, replace the fuel heater element.

SSM NUMBER: 5011

Remove trapped air after repair

The cause of codes 1211 or 1212 can be internal or external leaks, a faulty IPR, a faulty ICP, injectors, high pressure oil system concerns, low or improper oil, trapped air, loss of oil pump pressure, or PCM or wiring issues. Make sure trapped air is purged from the high pressure system by running the vehicle hard for 20 minutes after a repair to avoid false codes. Use 1996 PC/ED symptom flowcharts 3, 10, or 17 and record results of checks on the 11x17 Diagnostic Guide. Only run pinpoint tests when directed by the symptom flowcharts.

SSM NUMBER: 10389

Aftermarket products may cause severe engine damage

There are various manufacturers offering devices to increase turbocharger boost or otherwise increase the power/torque of the 7.3L DIT engine. Many owner's past experience with products of this type has been very poor. Severe powertrain damage may result form use of these aftermarket products, which will not be covered by the Ford warranty.

SSM NUMBER: 10614

Acceptable smoke levels and factors explained

White smoke from the exhaust on start up in cool to cold temperatures on the 7.3L DIT and other diesel engines is normal. Acceptable levels could be described as a puff of smoke followed by very light white smoke for the first kilometer (mile) or so. Some factors which will affect the smoke are fuel quality, fuel range (1D, 2D and winterized 2D), temperature, oil quality API rating, and oil viscosity. All engines are now shipped year-around with 10W30 oil from the factory.

AUXILIARY POWERTRAIN CONTROL MODULE (APCM) TSBs

94-19-18

PCM (POWERTRAIN CONTROL MODULE) — REPLACEMENT PCM ALLOW FOR SELECTABLE RPM CONTROL — 7.3L DI (TURBO) DIESEL — VEHICLES BUILT FROM 2/9/94 THROUGH 8/29/94
STALLS — 7.3L DI (TURBO) DIESEL —WHEN OPERATING PTO AT IDLE — VEHICLES BUILT FROM 2/9/94 THROUGH 8/29/94

95-15-12

AUXILIARY POWERTRAIN CONTROL MODULE (APCM) —7.3L DIT — AVAILABLE FOR AMBULANCES, TOW TRUCKS, AND OTHER VEHICLES REQUIRING MANUAL THROTTLE CONTROL

95-15-13

AUXILIARY POWERTRAIN CONTROL SYSTEM (APCS) —ENGINE IDLE SPEED DOES NOT ADJUST — 7.3L DI TURBO
ENGINE IDLE SPEED DOES NOT ADJUST — 7.3L DI TURBO — SHORTED OR OPEN CIRCUIT TO AUXILIARY POWERTRAIN CONTROL SYSTEM (APCS)