Originally Posted by ctdnwakulla

Hello, I am working on a 04 F-350 4x4 6.0 for a friend.
I am using a Snap on MT 2500 scanner and have a PO 69,PO 237 and PO 132b.
The Map is reading 4 KOEO and KOER, Baro 30hg. From what I understand the Map should be at about 14.7 +/- .5 KOEO. We have replaced the Map sensor and I checked continuity from connector to computer and have .5 ohms resistance on all three circuits.We have 5 volt reference at KOEO and KOER. Readings still persist.
I am thinking PCM but wanted to see if anyone has any other suggestions on what else to pursue.
Thanks Bill

Originally Posted by vloney

<TABLE width="95%"><TBODY><TR><TD>2003 PCED On Board Diagnostics 6.0L Diesel
</TD><TD align=right>SECTION 5: Pinpoint Tests
</TD></TR><TR><TD></TD><TD align=right>Procedure revision date: 06/15/2009
</TD></TR></TBODY></TABLE>
<HR><TABLE cellSpacing=0 width="95%"><TBODY><TR><TD>KA: Turbo Charger System Performance
</TD><TD width="25%" align=right> KA: Introduction </TD></TR></TBODY></TABLE>
<HR>
KA1 PRELIMINARY DIAGNOSIS

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Are any DTCs present?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">For DTC P132B, P2262 or P2263, GO to KA2 .

For all other DTCs, REFER to Section 4 Diagnostic Trouble Code (DTC) Descriptions. </TD><TD width="50%">GO to KA2 . </TD></TR></TBODY></TABLE>
KA2 CHECK THE MANIFOLD ABSOLUTE PRESSURE (MAP) AND BAROMETRIC PRESSURE (BARO) SIGNAL ACCURACY

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Does the MGP PID match the actual gauge pressure?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">GO to KA3 . </TD><TD width="50%">GO to Pinpoint Test E . </TD></TR></TBODY></TABLE>
KA3 CHECK FOR INPUT SENSOR BIAS

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Are the BARO and MAP PIDs within specifications and is the MAP and BARO PID values within 10 kPa (1.5 psi) of each other?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">GO to KA4 . </TD><TD width="50%">REFER to the appropriate pinpoint test to continue sensor diagnostics. </TD></TR></TBODY></TABLE>
KA4 CHECK THE TURBOCHARGER OPERATION BOOST

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Is the MGP PID below 3 kPa (0.44 psi) at 0% VGT duty cycle and above 6 kPa (.87 psi) at 85% VGT duty cycle?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">GO to KA5 . </TD><TD width="50%">GO to KA6 . </TD></TR></TBODY></TABLE>
KA5 CHECK THE TURBOCHARGER OPERATION BACK PRESSURE

• Key ON, engine running.
• Using the gauge bar, access the exhaust pressure sensor port.
• Access the PCM and monitor the, EGR DC, RPM and VGTDC PIDs.
• Access the PCM and control the EGR DC, RPM, and VGTDC PIDs.
• Increase the commanded engine speed to 1,200 RPM using output state control. The calibration may limit the actual RPM between 1,150 and 1,200 RPM.
• Decrease the EGR duty cycle (EGR DC) to 0%.
• Decrease the VGT duty cycle (VGTDC) to 0%.
• Record the exhaust pressure from the gauge bar.
• Increase the VGT duty cycle to 85%.
• Record the exhaust pressure from the gauge bar.
• Decrease the VGT duty cycle to 0%.
• Record the exhaust pressure from the gauge bar.

Is the exhaust pressure gauge reading below 5 kPa (0.73 psi) at 0% VGT duty cycle and above 50 kPa (7.3 psi) at 85% VGT duty cycle?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">GO to KA7 . </TD><TD width="50%">GO to KA6 . </TD></TR></TBODY></TABLE>
KA6 CHECK THE CHARGE AIR COOLER, AIR INTAKE AND EXHAUST SYSTEMS FOR LEAKS

• Key in OFF position.
• Disconnect the exhaust pressure (EP) sensor from the tube.
• Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the EP sensor tube.
• Fill the exhaust system with smoke until smoke is present at the exhaust pipe.
• Plug the exhaust pipe.
• Pressurize the exhaust system with 20 psi regulated air.
• Disconnect the hose from the MAP sensor.
• Inspect the MAP sensor hose and manifolds for damage, leaks, restrictions, and correct routing.
• Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the MAP hose.
• Fill the air intake system with smoke.
• Plug the air filter box.
• Pressurize the air intake system with 20 psi regulated air.
• Check the air intake and exhaust systems for leaks.

Are any leaks present?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">REPAIR the leaks. REFER to Section 4, Performance Diagnostic Procedures if a driveability concern exists.

CLEAR the DTCs. REPEAT the self-test. </TD><TD width="50%">GO to KA8 . </TD></TR></TBODY></TABLE>
KA7 CHECK THE VGT ACTUATOR STABILITY

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Do the VGTDC and MGP PIDs remain steady at all of the RPMs?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">The turbocharger system is operating correctly. REFER to Section 4, Performance Diagnostic Procedures.

CLEAR the DTCs. REPEAT the self-test. </TD><TD width="50%">GO to AK7 . </TD></TR></TBODY></TABLE>
KA8 CHECK THE OPERATION OF THE VGT ACTUATOR

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Is any internal valve cam follower movement present when the VGT duty cycle is increased?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">GO to KA9 . </TD><TD width="50%">GO to AK2 . </TD></TR></TBODY></TABLE>
KA9 CHECK THE VGT VANE OPERATION

• Key in OFF position.
• Install the VGT actuator in the turbocharger assembly.
• Remove the pipe plug from the top of the VGT actuator housing, located near the oil supply tube.
• Apply an index mark on the internal valve cam follower (tip of the actuator).
• Key ON, engine running.
• Access the PCM and control the VGTDC PID.
• Increase the VGT duty cycle from 20% to 85%.
• Check the internal valve cam follower for movement at each step while increasing the duty cycle.

Is any internal valve cam follower movement present in each step when the VGT duty cycle is increased?
<TABLE border=1 cellSpacing=0 cellPadding=3 width="92%"><TBODY><TR><TH width="50%">Yes </TH><TH width="50%">No </TH></TR><TR><TD width="50%">The turbocharger system is operating correctly. REFER to Section 4, Performance Diagnostic Procedures.

CLEAR the DTCs. REPEAT the self-test. </TD><TD width="50%">CARRY OUT the Turbocharger Reconditioning General Procedure. REFER to the Workshop Manual Section 303-04D Fuel Charging and Controls — Turbocharger. </TD></TR></TBODY></TABLE>


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Originally Posted by mustang_309

Did you make sure the MAP hose and hose nipple at the intake are clear?

Originally Posted by ctdnwakulla

Finally got time to do further testing and discovered I had a defective Map sensor out of the box doing the same thing as the original one. Just goes to show that you can't take anything for granted.
Bill

Originally Posted by ctdnwakulla

Finally got time to do further testing and discovered I had a defective Map sensor out of the box doing the same thing as the original one. Just goes to show that you can't take anything for granted.
Bill

Originally Posted by npccpartsman

Did that fix your issue?

Originally Posted by acf6

sorry to derail but Tim, are those diagnostic flow charts available to the public? ive been using a few for my failing pedal and was wondering if i could find the whole file. its a very helpful diagnostic tool