Hoping Ron will chime in here.

3 litre 2006 with new heads and 180 psi avg. across all cylinders.
New O2 sensrors.
Remaned heads.
New IAC.
New injectors.
New MAF.
New plugs and wires.
New fuel filter
New fuel pump.
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Problem engine has no power past 2k rpms. Have reset PCM/ECU more than once with Forscan and by headlights on pull positive on battery cable.
New injectors toss rich both bank codes, originals did not.
New injects full trim 2ms, old injectors 4ms. New injectors likely e-85 and all negative trims attributed to that..... arrrgh. Anyway, put originals back in and normal pulse idle widths are correct.
Serious amount of pinging past 2k rpms.\
Plugs look fine, a bit of white them which looks lean,
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Suspect bad PCM/ECU unit.
Injector pulse at 10ms max about 2.5k rpm, after that no increase in pulse width.... Hold gas pedal to floor and no way will it rev higher.

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It really looks like bad ECU, do you have any other ideas for me to check?

thanks,
Jeff

 

So I tried a force factory tables. Pulled connector on MAF/IAT which in theory put ECU into default tables. Only getting 15ms on injectors and same result, feels like just not enough fuel. And this is with the likely e-85 injectors installed.
Also measured vacuum at 2.5k steady for a minute. No loss, so that suggests not plugged cats or muffler. Damn, running out of ideas..?

 

Also, TPS voltage is correct. 4.95v at full pedal.

 

Oh forgot to mention that there is new cam positioner sensor as well. Problem did not occur after that installation. Much later.

 

Yes, larger injectors will cause Rich codes

Computer does have a REV Limiter, but thats for 3,000rpms, when speed is 0mph or transmission shows park/neutral(or clutch pedal down)

2006 expects 55-65psi fuel pressure, thats done by the fuel pressure regulator in the gas tank, its on the fuel pump assembly with fuel pump
There should be a fuel pressure test port on the engine, looks like a tires air valve

 

Thanks Ron for reply,

Confirmed 65 psi fluttering at idle and same under load.
But what should I be looking for? Was and A.M.E before a lifetime of computer stuff. No slouch here. I can follow the dots.
Were is next test, as I'm at a loss now. There should be something I can try before replacing ECU?


thanks,
Jeff

 

Check if computer "thinks" its in Neutral all the time

I assume speedometer works, should be able to see that on OBD, in a 2006 the engine computer gets speed from OSS sensor then converts it and sends it out to speedometer

 

Sorry for late reply, work gets in the way somedays. Well and first crack at replying timed out with expired token and deleted everything when trying to attach file...

The VSS and OSS data is good. Your comment on "Neutral" got me thinking. I checked the clutch pedal position switch / neutral safety switch and it is physically floppy. More than I would think is a pass.
I cable tied it for now to hold it more stable on shaft for now, will order up replacement anyway.

I've attached a 450 second Forscan log file that can be replayed. The file is compressed with WinRar and Zip types, as uploads won't accept Forscan file type .fsl
The file monitors 22 PIDs that I thought would be of interest. Unfortunately, Forscan oscilloscope view only shows first 10 PIDs. It would be nice if they fixed that and included display only "xyz" PIDs or a scroll bar to see rest. Feature request I bet has been made many times :-)

I'm going to do another short drive and log the only 10 PIDs that I think are mostly relevant, especially in oscilloscope view.

RPM, CPP/NDS, CPP/PNP, IAC, MAF, TPMODE, VSS, FUELPW1/2, SPARKADV <- edited to remove TP_V as it looks correct in all positions and thought ignition timing was something that should be on monitor list.

If you have other PIDs you think should be logged let me know, will do another test drive with them.

thanks,
Jeff

 

Sorry I won't download and open those types of files but maybe someone else could

I think you are over thinking this problem
You can't do a board level repair on any engine computer that I an aware of

If the computer is sending out what looks like good data on all PIDs/sensors then and its control data looks OK except for the calculated open time for injectors then I would say it is a computer issue
Could just be a software glitch/loop and most Ford dealers can reload factory software, although 2006 is just a 15 years old so they might not do it

The computer KNOWS its running a 3 LITER engine, so it knows exactly how much air is coming in at any RPM and throttle position, its just MATH and thats why its called a Computer, it calculates/computes large numbers easily

14.7:1 air:fuel mix for gasoline is a WEIGHT RATIO, not volume
14.7 pounds of air to 1 pound of gasoline
14.7 grams of air to 1 gram of gasoline

This is why fuel injectors are rated in Pounds(lbs) per hour, 14lb injector can pass 14 pounds of gasoline per hour, 19lb, 19 pounds an hour
Gasoline weighs pretty much the same whether its -50deg or 120deg outside

Air on the other hand changes weight every few degrees and also changes weight by height above sea level, elevation
"hot air rises", because its Lighter than cooler air
This is where the MAF(mass air flow) sensor comes in, it WEIGHS the incoming air, well 10 to 15% of it
Computer knows how many liters of air are coming in, the MAF tell it how much each liter weighs so it can calculate the 14.7:1 ratio
There is also an Air Temp sensor, in a 2006 its in with the MAF sensor

What you are describing is a computer error
Rich codes and then PINGING at higher RPMs, which means LEAN running
So the O2 sensor are telling the computer there was too little oxygen in the exhaust, Rich exhaust, so computer reduces the open time of injectors, - STFT, but in reality the exhaust has too much air, lean, so engine starts to PING as its fuel starved

You could have two brand new BAD O2 sensors, long shot, lol
Or the O2 sensor wires are shorted to Heater wire so bad higher voltage
O2 sensors generate their own voltage
0.1 volt is lean, too much oxygen
0.9v is rich. too little oxygen

The computer tries to keep these upstream O2 sensors in the 0.4v average
Downstream O2 should stay around 0.7 to 0.8v as the Cats burn up most of the oxygen when cleaning the exhaust emissions

So your computer is calculating a correct mix but for some reason its "seeing" 0.9v feed back from O2s so Rich code but as it sends STFT into -10 fuel trims its actually making mix too lean causing the pinging

If it was just one one bank of the engine then bad O2, new or not
But both would be an extreme long shot
MAF and air temp sensors are tested against each other and MAF is also Range compared to RPMs and throttle position
So there are several checks and balances with most engine sensors, and codes are set if a sensor is out of range compared to other sensors
The O2s have no compare, but 2 banks are the compare in this case

Computer is mad I tell you mad, lol

 

I agree Ron, the computer may very well have gone mad indeed. lol It might be too much provoking from the clutch pedal switch data.

Hopefully the attached pic is in decent resolution. I used the clutch 20 times during this road test. The CPP/NDS cycles like crazy, like an intermittent/bad connection. Well and the CCP/PNP only once registers "drive" state. Definitely something amiss inside that switch.


Jeff
June-20-10-PIDs


thanks,
Jeff

 

Yes, that's odd its showing neutral all the time, if clutch pedal was up all the way thats wrong

Also is TP Mode the throttle position?
There is no middle ground, reading WOT or Closed

 

It's just the resolution at 430 secs. Zooming in or switching to table mode shows CT, PT, WOT clearly.

thanks,
Jeff