F8059 Force SPRING LOCKWASHER

Illustration 1 g00725749
HEUI fuel system components (typical example)Test Step 1. SymptomsThe following symptoms may occur if there is a problem with the HEUI fuel system:
The engine cranks but the engine will not start.
The engine runs rough.
The engine is erratic or unstable at idle or running.
Low power
The following fault codes might be currently active codes or logged event codes: 164-00, 164-02 and 164-11.Complete the following test steps. Circle the appropiate answers in the Results section of each test step and return with the fuel system component.
Connect the electronic service tool to the service tool connector.
Turn the ignition keyswitch to the ON position but do not start the engine.
Print the "Lifetime Totals" and the "Configuration" screen.
Check for active diagnostic codes.Expected Result:There are no active diagnostic codes with the keyswitch in the ON position and the engine off.Results:
OK - There are no active codes. Proceed to Test Step 2.
Not OK - Active codes are present with the keyswitch in the ON position and the engine off.Repair: Refer to Troubleshooting, "Injection Actuation Pressure Sensor - Test" if 164-03 or 164-04 is active.Call technical support if 164-00, 164-02, or 164-11 is active.STOPTest Step 2. Check the Engine Oil Level
Check the engine oil level.
If the engine oil level is low add oil to the engine.
Try to start the engine.Expected Result:The engine starts.Results:
Yes - The engine starts. Proceed to Test Step 9.
No - The engine does not start. Proceed to Test Step 3.Test Step 3. Engine Cranks but Will not StartYour answers indicated that your engine oil level is satisfactory. Do not replace the Injection Actuation Pressure Sensor (IAP Sensor) at this time.
Connect the electronic service tool to the engine. Observe the "Injection Actuation Pressure" and "Engine RPM" when the engine is cranking.________ Record the actual Injection Actuation Pressure.________ Record the observed engine speed.Expected Result:The injection actuation pressure is above 6 MPa (870 psi).Results:
Yes - The injection actuation pressure is above 6 MPa (870 psi).Repair: The HEUI system is functioning correctly. Refer to Troubleshooting, "Engine Cranks but Will Not Start" which is located in the "Troubleshooting without a Diagnostic Code" section.STOP
No - The injection actuation pressure is below 6 MPa (870 psi). Proceed to Test Step 4.Test Step 4. Check the Oil PressureDisconnect the high pressure oil line from the cylinder head and install the 8T-0852 Pressure Gauge. Crank the engine and record the oil pressure.Note: The pressure readings may vary between gauges. ________ Observed pressure reading________ Observed RPM________ Observed "Injection Actuation Output Percent"Expected Result:The oil pressure is above 27.5 MPa (4000 psi).Results:
Yes - The oil pressure is above 27.5 MPa (4000 psi). Proceed to Test Step 8.
No - The oil pressure is below 27.5 MPa (4000 psi). Proceed to Test Step 5.Test Step 5. Install a Test Plug and Check the Oil Pressure
Remove the Injection Actuation Pressure Control Valve (IAPCV).
Install a 219-2368 Plug and 9X-1484 Seal Kit and perform the pressure test.________ Observed pressure readingNote: If the 219-2368 Plug is not available, proceed to Test Step 6.Expected Result:The oil pressure is above 27.5 MPa (4000 psi).Results:
Yes - The oil pressure is above 27.5 MPa (4000 psi). The HEUI pump is OK.Repair: Replace the IAPCV and check the oil pressure. If the problem continues contact technical support.STOP
No - The oil pressure is below 27.5 MPa (4000 psi). Proceed to Test Step 7.Test Step 6. Install a New IAPCV and Check the Oil PressureNote: Use this Test Step ONLY if the 219-2368 Plug is not available.
Remove the IAPCV.
Install a new IAPCV and check the oil pressure.________ Observed pressure readingExpected Result:The oil pressure is above 27.5 MPa (4000 psi).Results:
Yes - The problem has been resolved.STOP
No - Remove the new IAPCV and reinstall the original IAPCV. Proceed to Test Step 7.Test Step 7. Check the Drive Gear
Remove the high pressure oil pump.
Check for any physical damage to the drive gear. Replace the drive gear, if necessary.
Verify that the drive gear and the retaining bolt are properly tightened. Also verify that the pump shaft rotates freely.Expected Result:The drive gear and the retaining bolt for the high pressure oil pump are tight. The pump shaft rotates freely.Results:
Yes - The drive gear bolt is properly tightened and the pump shaft rotates freely. Repair: Replace the high pressure oil pump. If this does not fix the problem, contact technical support.STOP
No - The pump shaft does not rotate freely. Repair: Replace the high pressure oil pump. If this does not fix the problem, contact technical support.STOP
No - The drive gear bolt is loose. The pump shaft rotates freely and there is no obvious mechanical damage that would indicate a different failure.Repair: Tighten the drive gear bolt to a torque of 110 14 N m (80 10 lb ft). Check the pressure in order to ensure that the problem has been resolved. If this does not fix the problem, replace the high pressure oil pump.STOPTest Step 8. Check the High Pressure Oil System for Leaks.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Remove the valve cover and inspect the high pressure oil system for oil leaks.
While the engine is being cranked, look around the injector bores for any signs of oil leakage. Inspect the injector spill ports for excessive oil. All six injectors should spill the same amount of oil.Expected Result:No leaks are apparent.Results:
OK - Call technical support for assistance.STOP
Not OK - Repair: Replace the O-ring on the injector or replace the damaged injector.STOPTest Step 9. Engine Starts
Connect the electronic service tool to the engine and start the engine.
Check for the following codes:
164-00 Injection Actuation Pr Out of Range
164-02 Injection Actuation Pr Sensor Erratic
164-11 Injection Actuation Pressure SystemExpected Result:164-00 or 164-11 is active or logged.Place a check beside the codes that are active or logged.
________ 164-00
________ 164-02
________ 164-11Results:
Yes - 164-00 or 164-11 is active or logged. 164-02 may also be active or logged. Proceed to Test Step 10.
No - 164-02 is active or logged, but 164-00 and 164-11 are not active or logged.Repair: Refer to Troubleshooting, "Injection Actuation Pressure Sensor - Test" for information on