Autoenginuity

AutoEnginuity (AE) software offers the average mechanic a great resource to troubleshoot OBD II vehicles. AE is offered in a generic OBD II version, or versions specific to manufactures. To perform tests on a Powerstroke, you will need to get AE with the Ford Enhanced Bundle. This will allow you to run vehicle specific tests and retrieve manufacture specific codes.

AE is available from many different vendors, but I get most all of my stuff from Riffraff Diesel Performance. Take a look at their site for your needs. Here is their AE Ford Enhanced Bundle

1998 Powertrain Control and Emissions Manual

IPR Troubleshooting

Scroll to the bottom of this page for files I have attached to help use AE

7.3L Powerstroke Cylinder Arrangement

Test Descriptions

Quick Test Operation

Quick Test is performed by retrieving KOEO, KOER, and Continuous DTCs.

Special Notes

Before running Quick Test, always perform the necessary visual checks and safety precautions listed below.

Visual Check

• Inspect the air cleaner and inlet ducting.
• Check system wiring harness for proper connections, bent or broken pins, corrosion, loose wires, proper routing, etc.
• Check the PCM, sensors and actuators for physical damage.
• Check the engine coolant for proper level and mixture.
• Check the transmission fluid level and quality.
• Make all necessary repairs before continuing with Quick Test.

Vehicle Preparation

• Perform ALL safety steps required to start and run vehicle tests. Apply parking brake, place shift lever firmly into PARK position (NEUTRAL on manual transmission and all F650/750), block drive wheels, etc.
• Turn off ALL electrical loads-radios, lights, A/C, blower, fans, etc.
• Start engine and bring up to normal operating temperature before running Quick Test.

Key On Engine Off (KOEO) On-Demand Self Test

Key On Engine Off (KOEO) On-Demand Self Test is a functional test of the PCM performed on demand with the key on and the engine off. This test will check that all inputs and outputs (circuits, sensors, regulators, relays and solenoids) connected to the PCM are electrically operating without fault, with the exception of the Injector Driver Module DTCs. The IDM stores both historical and hard IDM fault codes; to ensure that IDM DTC is a hard fault, you must first clear continuous DTCs (be sure to record all fault codes before clearing). After clearing, rerun self test; a fault must be present at the time of testing for the KOEO On Demand Self Test to detect the fault. If a fault is detected, a Diagnostic Trouble Code (DTC) will be the output on the data link at the end of the test when requested by a scan tool. Only a hard fault code (DTC) will be displayed.

Key On Engine Off (KOEO) Injector Electrical Self Test

Key On Engine Off (KOEO) Injector Electrical Self Test is a functional test of the PCM performed on demand with the key on and the engine off. This test determines if the injector circuits and solenoids are electrically operating without fault. All injectors will first buzz (audible feedback of the injector solenoids energizing the injector valves) together for approximately 2 seconds, then each injector will buzz for approximately 1 second in numerical order (1 through 8). The IDM stores all historical IDM fault codes; to ensure that the DTC is a hard fault, you must first clear continuous DTCs (be sure to record all IDM fault codes before clearing). After clearing, rerun self test; a fault must be present at the time of testing for the KOEO Injector Electrical Self Test to detect the fault. If a fault is detected, a Diagnostic Trouble Code (DTC) will be the output on the data link at the end of the test when requested by a scan tool. Only a hard fault code (DTC) will be displayed.

Key On Engine Off (KOEO) Output State Self Test

Key On Engine Off (KOEO) Output State Self Test is a functional test of the PCM performed on demand with the key on and the engine off. This test is designed to cycle outputs high and low. After pressing the trigger to start the test, you must then depress and release the accelerator pedal to cycle the outputs high: solenoids, wait to start lamp, IDM relay, TCIL, FDCS, CID and EF. The second time the accelerator pedal is depressed and released the outputs are cycled low, with the exception of the glow plug relay, which is cycled on for 5 seconds the first time only that the accelerator is pressed and released. This Self Test does not set any codes.

Key On Engine Running (KOER) Switch (SW) Self Test

Key On Engine Running (KOER) Switch Self Test is a functional test of the PCM performed on demand with the engine running. This test is designed to set DTC(s) if the test does not detect a transition on one or more of the switches. After pressing the trigger to start the test, wait 5 seconds before running through the driver-operated controls to eliminate the chance of setting a false IVS code. The accelerator pedal must first be depressed and released to begin test, then the Parking Brake, Speed Control ON, OFF, SET, RESUME, COAST, Transmission Control or Clutch. The last to be depressed and released must be the brake pedal, which will test both the brake pressure applied (BPA) switch and the brake ON/OFF (BOO) switch.

Key On Engine Running (KOER) On-Demand Self Test

Note: On F-Series 650/750, only the injection control pressure (ICP) check is performed.

Key On Engine Running (KOER) On-Demand Self Test is a functional test of the PCM performed on demand with the engine running. Temperature is not a factor, but A/C must be turned off. A check is made on the injection control pressure (ICP), exhaust back pressure (EBP), and manifold intake air heater (MIAH) systems. During this test, engine rpm will increase; the PCM will first command ICP high and low, then command EBP high and low. A fault must be present at the time of testing for the KOER On Demand Self Test to detect a fault. If a fault is detected, a Diagnostic Trouble Code (DTC) will be the output on the data link at the end of the test when requested by a scan tool. Only a hard fault code (DTC) will be displayed.

Key On Engine Running (KOER) Cylinder Contribution Self Test

Key On Engine Running (KOER) Cylinder Contribution Self Test is a functional test of the PCM performed on-demand with the engine running, A/C off and engine oil temperature above 21°C (70 °F). This test will determine if all cylinders are contributing equally to engine performance. The PCM will test all 8 cylinders continuously during the test; there is no change in engine speed or operation that can be detected by the technician. The test checks for cylinder-to-cylinder changes in engine rpm, and sets a code if the rpm change is not within a pre-calibrated range. The test checks for weak injectors or low compression cylinders. A fault must be present at the time of testing for the KOER Cylinder Contribution Self Test to detect a fault, so the engine operating condition at which the idle is the worst will produce the best test results. For automatic transmission vehicles, the best results are reached with the parking brake set and the transmission in DRIVE. If a fault is detected, a Diagnostic Trouble Code (DTC) will be output on the data link at the end of the test when requested by a scan tool. Only a hard fault code (DTC) will be displayed.

Key On Engine Running (KOER) Glow Plug Monitor Self Test

Note: This test is not performed on F-Series 650/750.

Key On Engine Running (KOER) Glow Plug Monitor Self Test (California F-Series and Excursion) is a functional test of the glow plug system performed on demand with the engine running and the A/C off. Battery voltage must be maintained at 10-14 volts during this test. If necessary, press the accelerator pedal to increase voltage to the specified level. The PCM will activate the Glow Plug Control Module (GPCM) and monitor the glow plug circuits. A fault must be present at the time of testing for the test to detect a fault. The trouble codes will be sent to the PCM on the diagnostic line and then output to the NGS.

7.3L PCM Pinout and Expected Values (Click to link to the page)

Strictly Diesel's AE Help Page

How to Set-Up AE for 94.5-95 OBS trucks.

Videos from AE

These attachments are not all my doing, they are a collection of other AE users helping others out!