Posted on by

Electronic Control System Gas Plus Engines – FAULT CODE 613

Engine Misfire for Multiple Cylinders – Data Valid But Below Normal Operational Level – Most Severe Level

View Related Topic

Overview

CODE REASON EFFECT
Fault Code: 613
PID: None
SPN: 1322
FMI: 11/31
LAMP: Red
SRT: 

Engine Misfire for Multiple Cylinders – Data Valid But Below Normal Operational Level – Most Severe Level

Progressive power derate increasing in severity from time of alert. Fault will
only clear after key off event.

Ignition System Circuit
SMALL | MEDIUM | LARGE

Circuit Description

The ignition system is a coil on plug system that uses a separate ignition control module (ICM) to operate the ignition system. Spark timing is controlled by the ECM. The ECM commands the ICM to energize the ignition coil for the proper cylinder in the firing sequence over the ICM timing line in the engine harness. The ECM sends a signal to the ICM to prepare to energize the ignition coil for cylinder number 1 over the ICM reference line in the engine harness. The coils are energized by the ICM through the charge voltage and primary return lines in the ignition harness. The ICM is capable of measuring spark voltage and detecting misfire over the secondary return wire in the ignition harness. The ECM receives this information over spark voltage signal and combustion detection (misfire) signal lines.

Component Location

The ICM is located next to the ECM on the intake side of the engine near the flywheel housing. The ignition coils are located above the corresponding cylinder on the intake side of the engine.

Conditions for Running the Diagnostics

This diagnostic runs continuously when the engine is operating.

Conditions for Setting the Fault Codes

The ECM detects the engine misfire percentage for all cylinders is greater than a calibrated value.

Action Taken When the Fault Code is Active

The ECM logs this fault immediately when the diagnostic runs and fails.

Conditions for Clearing the Fault Code

To validate the repair, start the engine and operate the engine in the condition in which the misfire occurred.

  • The ECM will turn the fault inactive immediately after the ECM detects the misfire percentage for all cylinders has dropped below a calibrated value.
  • This fault code can also be cleared with INSITE™ electronic service tool.

Shop Talk

If the ECM does not receive a signal on the secondary return wire after a cylinder has been commanded to fire, the ECM will log this as a misfire. In addition to the three misfire faults for each cylinder, misfire percentages are also calculated over all six cylinders. There are three levels of severity for misfire on multiple cylinders.

Possible causes for the Fault Code 613 include:

  • Spark plugs past maintenance intervals
  • Damaged spark plugs or boots
  • Malfunctioning coils
  • Shorted or open ignition harness

In addition, misfires on multiple cylinders may be caused by low fuel pressure, EGR, voltage supply, fuel system, or oxygen sensor issues. Any fault codes for these systems should be resolved prior to troubleshooting the misfire compliant.

Misfires may
not occur under all operating conditions. Be sure to operate the engine under the conditions in which the misfire occurs when troubleshooting.

All secondary return wires in the ignition harness are tied together. This way there will be continuity through each secondary return pin of each coil to the main secondary return wire at the ignition harness connector 2. If one of the secondary return wires is found to be open, the ICM will determine that the engine is misfiring when it is not.

Physical damage to the tip of the spark plug and/or traces of aluminum can indicate a damaged piston.

Cautions and Warnings

 WARNING 

To reduce the possibility of personal injury, do not touch any ignition wires or components while the engine is operating, unless using suitably insulated tools.
 WARNING 

The ignition system produces high voltage. To reduce the possibility of personal injury from electrical shock, do not touch any ignition wires or components while the engine is operating. Always use suitably insulated tools.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fault codes.  
  STEP 1A. Check for an active fault code. Any non-ignition related fault codes?
  STEP 1B. Check for an active fault code. Fault Code 613 active?
STEP 2. Check the ignition coils and spark plugs.  
  STEP 2A. Inspect the ignition coil connector pins. Dirty or damaged pins?
  STEP 2B. Check for voltage at the coils. Steady spark observed?
  STEP 2C. Check the spark plugs. Spark plug damage or wear?
STEP 3. Check the ICM and ignition harness.  
  STEP 3A. Inspect the ICM and ignition harness connector pins. Dirty or damaged pins?
  STEP 3B. Check for an open circuit in the ignition harness. Less than 10 ohms?
  STEP 3C. Check for a pin short circuit to ground in the ignition harness. Greater than 100k ohms?
  STEP 3D. Check for a pin-to-pin short circuit in the ignition harness. Greater than 100k ohms?
  STEP 3E. Check for voltage at the coils. Steady spark observed?
  STEP 3F. Check for voltage at the coils. Steady spark observed?
STEP 4. Check ECM calibration and clear fault codes.  
  STEP 4A. Check if an ECM calibration update is available. If a calibration update for this fault code is available, does the ECM contain that revision or higher?
  STEP 4B. Disable the fault code. Fault code inactive?

Guided Step 1 – Check the fault codes.

Guided Step 1A – Check for an active fault code.

Conditions

  • Turn keyswitch ON
  • Connect the INSITE™ electronic service tool.
  • Start the engine.

Action

Operate the engine under the conditions in which the misfire occured.

  • Use INSITE™ electronic service tool to read the fault codes.

Any non-ignition related fault codes?
YES NO
No Repair No Repair
Troubleshoot the non-ignition related fault codes.

Guided Step 1B – Check for an active fault code.

Conditions

  • Turn keyswitch ON.
  • Connect the INSITE™ electronic service tool.
  • Start the engine.

Action

Operate the engine under the conditions in which the misfire occured.

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 613 active?
YES NO
No Repair No Repair

Guided Step 2 – Check the ignition coils and spark plugs.

Guided Step 2A – Inspect the ignition coil connector pins.

Conditions

  • Turn keyswitch OFF
  • Disconnect ICM connector C1 from the ICM
  • Disconnect ignition harness from all of the ignition coils.

Action

Inspect the ignition harness and ignition coil connector pins of the misfiring cylinders for the following:

  • Loose connector
  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Moisture in or on the connector
  • Missing or damaged connector seals
  • Dirt or debris in or on the connector pins
  • Connector shell broken
  • Wire insulation damage
  • Damaged connector locking tab.

Use the following procedure for general inspection techniques.
Refer to Procedure 019-361 in Section 19.

Dirty or damaged pins?
YES NO

A damaged connection has been detected in the ignition coil or ignition harness connectors.

Repair or replace the harness, or replace the ignition coil, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins using electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Repair the harness.
    Refer to Procedure 019-202 in Section 19.
  • Replace the harness. Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-037 in Section 13.
  • Replace the ignition coil. Replace the harness. Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-012 in Section 13.
No Repair

Guided Step 2B – Check for voltage at the coils.

Conditions

  • Turn keyswitch ON

Action

Check the ignition coils of the misfiring cylinders.

  • Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-012 in Section 13.
  • Test the misfiring cylinders to determine if the plugs are receiving voltage.
  • Use the Ignition Coil Test Kit, Part Number 4918343, to observe the spark in the observation window.

NOTE: The coils
must be tested in the vertical position or damage to the coils can result.

Steady spark observed?
YES NO
No Repair No Repair

Guided Step 2C – Check the spark plugs.

Conditions

  • Turn keyswitch OFF.
  • Remove all of the spark plugs.

Action

Inspect the spark plugs for the following.

  • Insulation flashover
  • Electrode deposits or fouling
  • Worn or missing electrode
  • Cracked insulator
  • Electrode misalignment.
  • Correct spark plug gap. Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-016 in Section 13.

Spark plug damage or wear?
YES NO
No Repair

Guided Step 3 – Check the ICM and ignition harness.

Guided Step 3A – Inspect the ICM and ignition harness connector pins.

Conditions

  • Turn keyswitch OFF.
  • Disconnect engine harness from the ECM.

Action

Inspect the Iignition harness and ICM connector pins of the misfiring cylinders for the following:

  • Loose connector
  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Moisture in or on the connector
  • Missing or damaged connector seals
  • Dirt or debris in or on the connector pins
  • Connector shell broken
  • Wire insulation damage
  • Damaged connector locking tab.

Do
not spray contact cleaner directly into the ECM ports as damage may result. Do
not blow compressed air in the ECM ports or connector. Compressed air can contain moisture due to condensation.

Use the following procedure for general inspection techniques.
Refer to Procedure 019-361 in Section 19.

Dirty or damaged pins?
YES NO

A damaged connection has been detected in the ICM or ignition harness connector.

Repair the harness, whichever has the damaged pins.

 No Repair

Guided Step 3B – Check for an open circuit in the ignition harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect ignition harness from the ICM connector 2.
  • Disconnect the ignition harness from all of the coils.

Action

Check for an open circuit in the ignition harness.

  • Measure the resistance between the ignition harness ICM connector C2 primary return pins and the ignition harness coil connector primary return pins.
  • Measure the resistance between the ignition harness ICM connector C2 charge voltage pin and the ignition harness coil connector charge voltage pins.
  • Measure the resistance between the ignition harness ICM connector C2 secondary return pin and the ignition harness coil connector secondary return pins.

Refer to the circuit diagram or wiring diagram for connector pin identification.

Use the following procedure for general resistance measurement techniques.
Refer to Procedure 019-360 in Section 19.

SMALL | MEDIUM | LARGE

Less than 10 ohms?
YES NO
No Repair

A pin to ground short circuit has been detected in the ignition harness.

Repair or replace the ignition harness.

Guided Step 3C – Check for a pin short circuit to ground in the ignition harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect ignition harness connector C2 from the ICM.
  • Disconnect ignition harness from all of the coils.

Action

Check for an open circuit in the ignition harness.

  • Measure the resistance between the charge voltage pins at the coil connectors and engine block ground.
  • Measure the resistance between the secondary return pin at the coil connectors and engine block ground.
  • Measure the resistance between the primary return pin at the coil connectors and engine block ground.

Refer to the circuit diagram or wiring diagram for connector pin identification.

Use the following procedure for general resistance measurement techniques.
Refer to Procedure 019-360 in Section 19.

Greater than 100k ohms?
YES NO
No Repair

A pin-to-ground short circuit has been detected in the ignition harness.

Repair or replace the ignition harness, with the damaged pins.

Guided Step 3D – Check for a pin-to-pin short circuit in the ignition harness.

Conditions

  • Turn keyswitch OFF.
  • Disconnect ignition harness connector C2 from the ICM.
  • Disconnect ignition harness from the ignition coils.

Action

Check for a pin-to-pin short.

  • Measure the resistance between the charge voltage pin in the ignition harness ICM connector 2 and all other pins in the ignition harness connector 2.
  • Measure the resistance between the secondary return pin in the ignition harness ICM connector 2 and all other pins in the ignition harness connector 2.
  • Measure the resistance the primary return pins in the ignition harness ICM connector 2 and all other pins in the ignition harness connector 2.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general resistance measurement techniques, refer to Resistance Measurements Using a Multimeter and Wiring Diagram,
Refer to Procedure 019-360 in Section 19.

Less than 10 ohms?
YES NO
No Repair

A pin-to-pin short circuit has been identified in the ignition harness.

Repair or replace the ignition harness.

Guided Step 3E – Check for voltage at the coils.

Conditions

  • Turn keyswitch ON

Action

Check the ignition coils of the misfiring cylinders.

  • Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-012 in Section 13.
  • Test the misfiring cylinders to determine if the plugs are receiving voltage.
  • Use the Ignition Coil Test Kit, Part Number 4918343, to observe the spark in the observation window.

NOTE: The coils
must be tested in the vertical position or damage to the coils can result.

Steady spark observed?
YES NO
No Repair

Guided Step 3F – Check for voltage at the coils.

Conditions

  • Turn keyswitch ON

Action

Check the ignition coils of the misfiring cylinders.

  • Use the following procedure found in the C8.3G C Gas Plus Troubleshooting and Repair manual, Bulletin 3666206.
    Refer to Procedure 013-012 in Section 13.
  • Test the misfiring cylinders to determine if the plugs are receiving voltage.
  • Use the Ignition Coil Test Kit, Part Number 4918343, to observe the spark in the observation window.

NOTE: The coils
must be tested in the vertical position or damage to the coils can result.
SMALL | MEDIUM | LARGE

Steady spark observed?
YES NO
No Repair

Guided Step 4 – Check ECM calibration and clear the fault codes.

Guided Step 4A – Check if an ECM calibration update is available.

Conditions

  • Connect all components
  • Connect the INSITE™ electronic service tool.

Action

Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History for applicable changes related to this fault code.

  • Use INSITE™ electronic service tool to find the present ECM code and revision number in the ECM. The ECM code and revision number are found in the Calibration Information section of System ID and Dataplate in Features and Parameters.

If a calibration update for this fault code is available, does the ECM contain that revision or higher?
YES NO
No Repair

If necessary, calibrate the ECM.
Refer to Procedure 019-032 in Section 19.

Guided Step 4B – Disable the fault code.

Conditions

  • Connect all components
  • Connect the INSITE™ electronic service tool.

Action

Disable and clear the fault code.

Fault code inactive?
YES NO
No Repair

Return to the troubleshooting steps or contact a Cummins® Authorized Repair Location if all steps have been completed and checked again.
Repair complete

Last Modified:  24-Mar-2010
Avatar photo

Published by Jack

Hello, I'm Jack, a diesel engine fan and a blogger. I write about how to fix and improve diesel engines, from cars to trucks to generators. I also review the newest models and innovations in the diesel market. If you are interested in learning more about diesel engines, check out my blog and leave your feedback.