Centinel System - Repair Manual - Centinel System - Master Repair Manual

Fuel Economy Troubleshooting Tree

Symptoms

Fuel Consumption Excessive.

How To Use This Tree

This symptom tree is to be used to troubleshoot fuel economy complaints. This tree is used along with the Fuel Consumption – Customer Complaint Form and the Driveability Low Power/Excessive Fuel – Consumption Checklist to help isolate engine, chassis, or driver issues associated with excessive fuel consumption.

Shop Talk

The Fuel Consumption – General Information section of this manual and Troubleshooting Excessive Fuel Consumption, Bulletin 3666094, should be referenced prior to any troubleshooting being performed on a customer’s engine.

The cause of excessive fuel consumption is difficult to diagnose and correct because of the potential number of factors involved. Actual fuel consumption problems can be caused by any of the following factors:

Engine factors
Vehicle factors and specifications
Environmental factors
Driver technique and operating practices
Fuel system factors
Low power or driveability problems.

Before troubleshooting, it is important to determine the exact complaint. Is the complaint based on whether the problem is real or perceived, or does not meet driver expectations? The Fuel Consumption – Customer Complaint Form is a valuable list of questions that can be used to assist the service technician in determining the cause of the problem. Complete the form before troubleshooting the complaint. The following are some of the factors that must be considered when troubleshooting fuel consumption complaints.

Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle speed.
Vehicle Aerodynamics: The largest single power requirement for a truck is the power needed to overcome air resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mile per gallon.
Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and tread design have a sizeable effect on fuel economy and performance. Changing from a bias ply to a low profile radial tire can reduce rolling resistance by about 36 percent.
Environmental and Seasonal Weather Changes: There can be as much as 1 to 1.5 mile per gallon difference in fuel consumption, depending on the season and the weather conditions.
Truck Route and Terrain: East and west routes experience almost continual crosswinds and head winds. Less fuel can be used on north and south routes where parts of the trip are not only warmer, but have less wind resistance.
Driver Technique and Operating Practices: A 1 mile per hour increase in road speed equals a 0.1 mile per gallon increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss of fuel mileage of 1 mpg.
Result of a Low Power or Driveability Problem: An operator will change driving style to compensate for a low power or driveability problem. Some things the driver is likely to do are (a) shift to a higher engine rpm or (b) run on the droop curve in a lower gear instead of upshifting to drive at part-throttle conditions. These changes in driving style will increase the amount of fuel used.

Additional vehicle factors, vehicle specifications, and axle alignment can also affect fuel consumption. For additional information on troubleshooting fuel consumption complaints, refer to Troubleshooting Excessive Fuel Consumption, Bulletin 3387245.

Troubleshooting Steps

STEPS		SPECIFICATIONS
STEP 1.	Verify the complaint.
	STEP 1A. Fill out the Fuel Consumption – Customer Complaint Form.
	STEP 1B. Run VE/VMS™.
STEP 2.	Electronic checks using INSITE™.
	STEP 2A. Check for fault codes.
	STEP 2B. Confirm Features and Parameters.
	STEP 2C. Check the ECM calibration.
	STEP 2D. Monitor vehicle speed.
	STEP 2D-1. Inspect the engine and chassis grounds.
STEP 3.	Fuel system inspection.
	STEP 3A. Inspect the vehicle for fuel leaks.
	STEP 3B. Check the fuel inlet restriction.
	STEP 3C. Check the drain line restriction.
	STEP 3D. Check the fuel grade.
	STEP 3E. Perform the INSITE™ Cylinder Performance Test.
	STEP 3E-1. Interpret the results of the Cylinder Performance Test.
	STEP 3E-2. Interpret the results of the Cylinder Performance Test.
	STEP 3E-3. Measure the resistance between the actuator and the actuator base.
	STEP 3E-4. Swap the front and rear metering actuator.
	STEP 3E-5. Swap the front and rear timing actuator.
STEP 4.	Check the air handling system.
	STEP 4A. Check the air intake restriction.
	STEP 4B. Pressure test the charge air cooler.
	STEP 4C. Inspect the charge air cooler.
	STEP 4D. Check the exhaust restriction.
STEP 5.	Air handling diagnostic checks.
	STEP 5A. Start the engine and read the fault codes.
	STEP 5B. Inspect the turbocharger blades.
	STEP 5C. Determination of turbocharger type.
	STEP 5D. Check the variable geometry actuator rod for correct travel.
	STEP 5D-1. Check for air leaks and inspect air lines.
	STEP 5D-2. Check the engine and vehicle grounds.
	STEP 5D-3. Check for air pressure at the turbocharger control valve outlet.
	STEP 5D-4. Check for air pressure at the turbocharger control valve outlet.
	STEP 5D-5. Check for correct turbocharger actuator travel.
	STEP 5D-6. Check for air pressure at the turbocharger control shutoff valve outlet.
	STEP 5D-7. Check for air pressure at the turbocharger control shutoff valve inlet.
	STEP 5D-8. Check for plugged turbocharger control shutoff valve filter.
	STEP 5E. Perform the INSITE™ EGR Valve/Turbocharger Operational Test.
	STEP 5E-1. Check the engine and vehicle grounds.
	STEP 5F. Inspect the wastegate actuator hose.
	STEP 5G. Inspect the wastegate actuator rod for travel.
	STEP 5G-1. Inspect the wastegate actuator rod for travel.
	STEP 5H. Measure the resistance of the four-stage wastegate controllers, if equipped.
	STEP 5I. Inspect the four-stage wastegate controller, if equipped.
STEP 6.	Base engine checks.
	STEP 6A. Verify the overhead adjustments are correct.
	STEP 6B. Verify the dipstick calibration.
	STEP 6C. Analyze the engine oil.
	STEP 6D. Check for internal engine damage.

Guided Step 1 – Verify the complaint.

Guided Step 1A – Fill out the Fuel Consumption – Customer Complaint Form.

Is the problem caused by vehicle factors, environmental factors, or driver technique?
YES	NO
No Repair	No Repair
Repair complete	Go to 1B

Guided Step 1B – Run VE/VMS™.
Action Use the data gathered to run VE/VMS™ or provide the data to the appropriate support personnel to run VE/VMS™. NOTE: VE/VMS™ does not account for adverse ambient conditions.
Taking into consideration the adverse effect of ambient conditions, does the VE/VMS™ fuel economy conflict with the customer’s current fuel economy?
YES	NO
No Repair	Explain to the customer the effects of driving habits and vehicle set up on fuel consumption. See Shop Talk for specific examples of how fuel economy can be effected based on driving habits and vehicles set up.
Go to 2A	Repair complete

Guided Step 2 – Electronic checks using INSITE™.

Guided Step 2A – Check for fault codes.
Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool.
Are there any active or high counts of inactive fault codes?
YES	NO
No Repair	No Repair
Troubleshoot fault codes.	Go to 2B

Guided Step 2B – Confirm features and parameters.
Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Verify the following features and parameters: Maximum Cruise Control Speed Cruise Control Upper Droop Cruise Control Lower Droop Gear-Down Maximum Vehicle Speed (Heavy Engine Load) = (peak horsepower rpm x 60 min/hr) / (Gear Down Transmission Gear Ratio x Rear Axle Ratio x Tire Size) Gear-Down Maximum Vehicle Speed (Light Engine Load ) = (peak torque rpm x 60 min/hr) / (Top Gear Transmission Gear Ratio x Rear Axle Ratio x Tire Size) Maximum Accelerator Vehicle Speed Road Speed Governor Upper Droop Road Speed Governor Lower Droop. NOTE: Refer to the Feature Help Description in INSITE™ for additional information.
Are the features and parameters set correctly?
YES	NO
No Repair	Reset the Features and Parameters to the appropriate values.
Go to 2C	Repair complete

Guided Step 2C – Check the ECM calibration.
Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Use the calibration notes field in INSITE™ to confirm the calibration is correct for the application and CPL. Verify the calibration is not set up for STx, LBSC, or Multiplexing if the application does not require it.
Is the calibration correct?
YES	NO
No Repair	Recalibrate the ECM with the correct ECM Code.
Go to 2D	Repair complete

Guided Step 2D – Monitor vehicle speed.
Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool. Start the engine. Action
Does vehicle speed read zero when the vehicle is not moving and the engine is running?
YES	NO
No Repair	No Repair
Go to 3A	Go to 2D-1

Guided Step 2D-1 – Inspect the engine and chassis grounds.
Conditions Turn keyswitch OFF. Action Check the engine ground connection. Check the chassis ground connections. Check the battery terminal connections.
Are all grounds present, properly grounded, free of corrosion, and tight?
YES	NO
Check the VSS and the VSS circuit. Refer to Procedure 019-090, 019-091 and 019-092 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 3666259.	Replace, clean, or tighten the grounds.
Repair complete	Repair complete

Guided Step 3 – Fuel system inspection.

Guided Step 3A – Inspect the vehicle for fuel leaks.
Conditions Turn keyswitch OFF. Action With EGR Check for pressure-side fuel filter, fittings and hoses to and from the ECM, cooling plate, fuel pump, IFSM, and actuators for leaks. NOTE: Dye can be placed in the fuel to assist in finding fuel system leaks.
Are any leaks present?
YES	NO
Repair or replace the failed component.	No Repair
Repair complete	Go to 3B

Guided Step 3B – Check the fuel inlet restriction.

Conditions

Connect vacuum gauge to the suction-side Compucheck® fitting.
Turn keyswitch ON.
Engine running at high idle.

SMALL | MEDIUM | LARGE

Is fuel inlet restriction less than the specifications listed below?

Dirty: 305 mm Hg [12 in Hg]
New: 203 mm Hg [8 in Hg].

YES

No Repair

Locate the cause of high fuel inlet restriction. Check the suction-side fuel filter and fuel supply lines.

Go to 3C

Repair complete

Guided Step 3C – Check the drain line restriction.

Conditions

Connect pressure gauge, Part Number 3375278.
Turn keyswitch ON.
Engine running at high idle.

SMALL | MEDIUM | LARGE

Is fuel drain line restriction less than 229 mm Hg [9 in Hg]?

YES

No Repair

Locate the cause of the high fuel drain line restriction in the OEM fuel return line.

Go to 3D

Repair complete

Guided Step 3D – Check the fuel grade.
Conditions Turn keyswitch OFF. Action Run the engine on an alternate, known good fuel source and verify engine performance if the fuel can not be tested appropriately. NOTE: Refer to Fuel for Cummins Engines, Bulletin 3379001.
Is the fuel grade used and the quality acceptable?
YES	NO
No Repair	Instruct the driver or owner to refuel with acceptable fuel.
Go to 3E	Repair complete

Guided Step 3E – Perform the INSITE™ Cylinder Performance Test.
Conditions Connect INSITE™ electronic service tool. Engine running at low idle. Action NOTE: Do not run the engine above 900 rpm when performing the Cylinder Performance Test.
Do all injectors and both banks pass the Cylinder Performance Test?
YES	NO
No Repair	No Repair
Go to 4A	Go to 3E-1

Guided Step 3E-1 – Interpret the results of the Cylinder Performance Test.
Action If the Cylinder Performance Test displays bar graphs for each cylinder’s contribution, use the INSITE™ help file to interpret the results. If the Cylinder Performance Test displays pass or fail for each cylinder, run the test at least 3 times to verify the results. Read the Test Results under the Results section of the test.
Did the Cylinder Performance Test find an individual failed cylinder?
YES	NO
Replace the failed injector. Refer to Procedure 006-026.	No Repair
Repair complete	Go to 3E-2

Guided Step 3E-2 – Interpret the results of the Cylinder Performance Test.
Action If the Cylinder Performance Test displays bar graphs for each bank’s contribution, use the INSITE™ help file to interpret the results. If the Cylinder Performance Test displays pass or fail for each bank, run the test at least 3 times to verify the results. Read the Test Results under the Results section of the test.
Did the Cylinder Performance Test find an individual failed bank?
YES	NO
No Repair	No Repair
Go to 3E-3	Go to 4A

Guided Step 3E-3 – Measure the resistance between the actuator and the actuator base.

Conditions

Turn keyswitch OFF.
Disconnect the engine harness from the timing and fueling actuators.

SMALL | MEDIUM | LARGE

Greater than 100k ohms?

YES

No Repair

Replace the failed fueling or timing actuator.

Refer to Procedure 019-110 or 019-111 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.

Go to 3E-4

Repair complete

Guided Step 3E-4 – Swap the front and rear fueling actuator.
Action Refer to Procedure 019-110 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334 for removal and installation. Perform the INSITE™ Cylinder Performance Test.
Does the failed bank follow the metering actuator?
YES	NO
Replace the failed fueling actuator. Refer to Procedure 019-110 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.	No Repair
Repair complete	Go to 3E-5

Guided Step 3E-5 – Swap the front and rear timing actuator.
Action Refer to Procedure 019-111 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334 for removal and installation. Perform the INSITE™ Cylinder Performance Test.
Does the failed bank follow the timing actuator?
YES	NO
Replace the failed timing actuator. Refer to Procedure 019-111 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.	Troubleshooting procedures need to be repeated from the beginning. A failed injector or actuator should have been detected.
Repair complete	Go to 3A

Guided Step 4 – Check the air handling system.

Guided Step 4A – Check the air intake restriction.
Conditions Run the engine at advertised horsepower and rpm. Action Refer to Procedure 010-031.
Is air intake restriction greater than 635 mm H₂O [25 in H₂O] for a used filter or 254 in H₂O [10 in H₂O] for a new filter?
YES	NO
Correct the cause of high intake air restriction. Check for plugged air filter or restricted air intake piping.	No Repair
Repair complete	Go to 4B

Guided Step 4B – Pressure test the charge air cooler.
Conditions Turn keyswitch OFF. Action Refer to Procedure 010-027.
Is the pressure drop 5 psi or less in 15 seconds?
YES	NO
No Repair	Repair the charge air cooler.
Go to 4C	Repair complete

Guided Step 4C – Inspect the charge air cooler.
Conditions Turn keyswitch OFF. Action Bent or plugged fins will force the temperature of the air exiting the cooler to raise and force the engine to work harder to obtain the desired charge flow. A harder working engine will use more fuel.
Is the charge air cooler free from bent or plugged fins?
YES	NO
No Repair	Clean the charge air cooler.
Go to 4D	Repair complete

Guided Step 4D – Check the exhaust restriction.
Conditions Run engine at advertised horsepower and rpm. Action Refer to Procedure 011-009.
Is exhaust restriction less than 76 mm Hg [3 in Hg]?
YES	NO
No Repair	Repair the exhaust for source of high restriction.
Go to 5A	Repair complete

Guided Step 5 – Air handling diagnostic checks.

Guided Step 5A – Start the engine and read the fault codes.
Conditions Connect INSITE™ electronic service tool. Engine running at low idle. Action Use INSITE™ to read the fault codes.
Are Fault Codes 2355 or 2356 active?
YES	NO
No Repair	No Repair
Go to appropriate Fault Code troubleshooting tree.	Go to 5B

Guided Step 5B – Inspect the turbocharger blades.
Conditions Engine OFF. Remove intake and exhaust connections for turbocharger. Action Measure the turbocharger wheel axial movement. Check the radial movement of the turbocharger wheel. Refer to Procedure 010-033.
Was damage found on turbocharger fins or was axial or radial movement out of specification?
YES	NO
Replace the turbocharger. Refer to Procedure 010-033.	No Repair
Repair complete	Go to 5C

Guided Step 5C – Determination of turbocharger type.

Is the turbocharger a variable geometry turbocharger?
YES	NO
No Repair	No Repair
Go to 5D	Go to 5F

Guided Step 5D – Check the variable geometry actuator rod for correct travel.

Conditions

Engine OFF.
Turn keyswitch ON.
Connect INSITE™ electronic service tool.
Verify air tanks are fully charged.

Action

Adjust the delay timer in the Turbocharger Actuator Test so rod movement can be observed.
Select the Retract Actuator position with INSITE™.
Mark or scribe the VG™ actuator rod at the base of the actuator.
Select the Extend Actuator position with INSITE™.
Measure the rod travel by measuring the distance from the base of the turbocharger actuator to the scribe mark.

NOTE: The turbocharger actuator should move quickly and crisply. If the actuator rod movement is slow, there could be a problem with the air supply, a faulty ground connection on the engine or chassis, or mechanical problems with the variable geometry turbocharger assembly.

SMALL | MEDIUM | LARGE

Does the turbocharger actuator rod extend between 10.2 and 11.8 mm [0.402 and 0.465 in]?

YES

No Repair

Go to 5E

Go to 5D-1

Guided Step 5D-1 – Check for air leaks and inspect air lines.
Conditions Engine OFF. Turn keyswitch ON. Connect INSITE™ electronic service tool. Verify vehicle air tanks are fully charged. Action Listen for air leaks at the following components: Turbocharger control valve Turbocharger control shutoff valve inlet connection Turbocharger control shutoff valve outlet connection Turbocharger control valve inlet connection Turbocharger control valve outlet connection Turbocharger actuator All air lines, including the OEM supply line to the turbocharger control shutoff valve, turbocharger control shutoff valve to the turbocharger control valve, and turbocharger control valve to the turbocharger actuator.
Air leaks found in the system?
YES	NO
Repair air leaks.	No Repair
Repair complete	Go to 5D-2

Guided Step 5D-2 – Check the engine and vehicle grounds.

Conditions

Turn keyswitch OFF.

Action

Check the engine ground connection.
Check the chassis ground connections.
Check the battery terminal connections.

SMALL | MEDIUM | LARGE

Are all grounds present, properly grounded, free of corrosion, and tight?

YES

No Repair

Replace, clean, or tighten the ground.

Go to 5D-3

Repair complete

Guided Step 5D-3 – Check for air pressure at the turbocharger control valve outlet.
Conditions Engine OFF. Turn keyswitch ON. Connect INSITE™ electronic service tool. Verify vehicle air tanks are fully charged. Action Remove the air line connection at the outlet of the turbocharger control valve. Install an M12 Compucheck® fitting, Part Number 3824843, at the outlet of the turbocharger control valve. Install an air pressure gauge that is capable of reading at least 1034 kPa [150 psi] Perform the Turbocharger Actuator Test using the INSITE™ electronic service tool. Select the Extend Actuator position.
Is vehicle air tank pressure present at the turbocharger control valve outlet?
YES	NO
No Repair	No Repair
Go to 5D-4	Go to 5D-6

Guided Step 5D-4 – Check for air pressure at the turbocharger control valve outlet.
Conditions Engine OFF. Turn keyswitch ON. Connect INSITE™ electronic service tool. Verify vehicle air tanks are fully charged. Action Remove the air line connection at the outlet of the turbocharger control valve. Install an M12 Compucheck® fitting at the outlet of the turbocharger control valve. Install an air pressure gauge that is capable of reading at least 1034 kPa [150 psi].
Does the pressure gauge read more than 15 psi after 5 minutes?
YES	NO
Replace the turbocharger control valve. Refer to Procedure 019-388 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.	No Repair
Repair complete	Go to 5D-5

Guided Step 5D-5 – Check for correct turbocharger actuator travel.

Conditions

Engine OFF.
Turn keyswitch ON.
Connect INSITE™ electronic service tool.
Verify vehicle air tanks are fully charged.

Action

Refer to Procedure 010-113.

NOTE: Damage to the turbocharger may result if the proper removal procedure is not followed.

Perform the Turbocharger Actuator Test using the INSITE™ electronic service tool. Select the Extend Actuator position.

SMALL | MEDIUM | LARGE

Does the turbocharger actuator rod travel at least 12 mm [0.472 in]?

YES

Replace the turbocharger assembly.

Refer to Procedure 010-033.

Replace the turbocharger actuator.

Refer to Procedure 010-113.

Repair complete

Guided Step 5D-6 – Check for air pressure at the turbocharger control shutoff valve outlet.

Conditions

Engine OFF.
Turn keyswitch ON.
Verify vehicle air tanks are fully charged.
Connect INSITE™ electronic service tool.

Action

Loosen the air line connection at the turbocharger control shutoff valve outlet.

SMALL | MEDIUM | LARGE

Can air be heard escaping from the turbocharger control shutoff valve outlet?

YES

Replace the turbocharger control valve.

Refer to Procedure 019-388 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.

No Repair

Repair complete

Go to 5D-7

Guided Step 5D-7 – Check for air pressure at the turbocharger control shutoff valve inlet.
Conditions Engine OFF. Turn keyswitch ON. Verify vehicle air tanks are fully charged. Action Loosen the air line connection at the turbocharger control shutoff inlet.
Can air be heard escaping from the turbocharger control shutoff valve inlet?
YES	NO
No Repair	Repair the air supply from the OEM air tanks.
Go to 5D-8	Repair complete

Guided Step 5D-8 – Check for plugged turbocharger control shutoff valve filter.
Conditions Remove the turbocharger control shutoff valve filter. Turn keyswitch ON. Verify vehicle air tanks are fully charged. Connect the INSITE™ electronic service tool. Action Listen for an air leak at the turbocharger control shutoff valve filter head.
Is an air leak present at the turbocharger control shutoff valve filter head?
YES	NO
Replace the turbocharger control shutoff valve filter. Refer to Procedure 010-114.	Replace the turbocharger control shutoff valve. Refer to Procedure 019-386 in the Troubleshooting Manual, Signature Fuel System, Signature Engines, Bulletin 4021334.
Repair complete	Repair complete

Guided Step 5E – Perform the INSITE™ EGR Valve/Turbocharger Operational Test.
Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool. Engine running at low idle. Action Choose the Turbocharger Actuator option under Test Choices.
Does the Turbocharger Operational Test pass?
YES	NO
No Repair	No Repair
Go to 6A	Go to 5E-1

Guided Step 5E-1 – Check the engine and vehicle grounds.

Conditions

Turn keyswitch OFF.

Action

Check the engine ground connection.
Check the chassis ground connections.
Check the battery terminal connections.

SMALL | MEDIUM | LARGE

Are all grounds present, properly grounded, free of corrosion, and tight?

YES

Replace the variable geometry turbocharger.

Refer to Procedure 010-033.

Replace, clean, or tighten the ground.

Repair complete

Guided Step 5F – Inspect the wastegate actuator hose.

Conditions

Engine OFF.
Remove the turbocharger if wastegate actuator is inaccessible.

SMALL | MEDIUM | LARGE

Are holes or cracks found in the wastegate actuator hose?

YES

Replace the wastegate actuator hose.

No Repair

Repair complete

Go to 5G

Guided Step 5G – Inspect the wastegate actuator rod for travel.

Conditions

Engine OFF.
Remove the wastegate actuator hose from the wastegate actuator.

SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?

YES

No Repair

Go to 5H

Go to 5G-1

Guided Step 5G-1 – Inspect the wastegate actuator rod for travel.

Conditions

Engine OFF.
Remove the e-clip from the wastegate pin and disconnect the actuator rod.

SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?

YES

Move the wastegate lever on the turbocharger back and forth and check for smooth operation. Replace the turbocharger assembly if the wastegate is seized.

Refer to Procedure 010-033.

Replace the wastegate actuator.

Refer to Procedure 010-050.

Repair complete

Guided Step 5H – Measure the resistance of the four-stage wastegate controllers, if equipped.
Conditions Engine OFF. Disconnect the ring terminals from the four-stage wastegate controllers, if equipped. Action NOTE: The wastegate controller solenoids must be between 20°C and 26°C [68°F and 78°F] before using the resistance specifications listed.
Are the wastegate controller solenoid resistances between 7.0 and 8.0 ohms?
YES	NO
No Repair	Replace the failed wastegate controller. Refer to Procedure 010-109.
Go to 5I	Repair complete

Guided Step 5I – Inspect the four-stage wastegate controller, if equipped.

Conditions

Engine OFF.
Remove the four-stage wastegate controllers.

SMALL | MEDIUM | LARGE

Damage or debris found on the valve disc, valve seat, or actuator disc?

YES

Replace or clean failed components.

No Repair

Repair complete

Go to 6A

Guided Step 6 – Base engine checks.

Guided Step 6A – Verify the overhead adjustments are correct.
Conditions Turn keyswitch OFF. Remove valve cover. Action Valve Lash Reuse Limits: Intake valve lash: 0.102 mm [0.004 in] to 0.483 mm [0.019 in] Exhaust valve lash: 0.508 mm [0.020 in] to 0.813 mm [0.032 in].
Are the overhead settings within the reuse limits?
YES	NO
No Repair	Adjust the overhead settings. Refer to Procedure 003-004.
Go to 6B	Repair complete

Guided Step 6B – Verify the dipstick calibration.
Conditions Turn keyswitch OFF. Action Drain, remove, clean, and install the lubricating oil pan. Refer to Procedure 007-025. Check the calibration of the lubricating oil dipstick. Refer to Procedure 007-009.
Is the dipstick calibrated properly?
YES	NO
No Repair	Calibrate the lubricating oil dipstick. Refer to Procedure 007-009.
Go to 6C	Repair complete

Guided Step 6C – Analyze the engine oil.
Conditions Turn keyswitch OFF.
Does the engine oil analysis show any signs of wear metals or contaminates?
YES	NO
No Repair	Locate and replace the worn component or remove the source of contaminate and repair the engine as necessary.
Repair complete	Go to 6D

Guided Step 6D – Check for internal engine damage.
Conditions Turn keyswitch OFF. Action Refer to Procedure 007-013. Inspect the oil filter for foreign material. Refer to Procedure 007-002.
Is any foreign material found in the oil filter?
YES	NO
Locate the source of foreign material and repair the engine as necessary.	No Repair
Repair complete	Return to the troubleshooting steps or contact a local Cummins Authorized Repair Location, if all steps have been completed and checked again.

Last Modified: 18-Mar-2004

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