ISM, ISMe, and QSM11 – ISM, ISMe, and QSM11 – Troubleshooting and Repair Manual

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Engine Performance Troubleshooting Tree

Symptoms

    • Engine Acceleration or Response Poor
    • Cranking Fuel Pressure is Low
    • Engine Operating Fuel Pressure is Low
    • Engine Difficult to Start or Will
      Not Start (Exhaust Smoke)
    • Engine Difficult to Start or Will
      Not Start (No Exhaust Smoke)
    • Engine Power Output Low
    • Engine Runs Rough at Idle
    • Engine Runs Rough or Misfires
    • Engine Speed Surges at Low or High Idle
    • Engine Speed Surges Under Load or in Operating Range
    • Smoke, Black – Excessive
    • Smoke, White – Excessive
    • Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
    • Engine Starts But Will
      Not Keep Running
    • Engine Will
      Not Reach Rated Speed (rpm)

How To Use This Tree

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing Step 1 troubleshooting. Step 2 will ask a series of questions and will provide a list of troubleshooting steps to perform, depending on the symptom.

Shop Talk

Prior to running INSITE™ electronic service tool EGR Valve and EGR Valve/Turbocharger Operational Test, the ECM Calibration Software Phase could possibly need to be updated to the latest Software Phase. The ECM Calibration Phase Software can be checked in INSITE™ electronic service tool, under ‘Features and Parameters’. Expand the selection for ‘System ID and Dataplate’ and go to ‘Calibration Information’. If the Software Phase is earlier than shown below, calibrate the ECM again using the January 2006 INCAL™ CD-ROM, or later. Engines with the Software Phase listed below or later do
not require a recalibration.

ISM engines with CM875 (engines built after January 2004) require Software Phase 06050312.

This is a warrantable calibration change.

Minimum and Maximum VGT Actuator Travel Specifications by CPL Number
CPL Minimum Actuator Travel mm [in] Maximum Actuator Travel mm [in]
8427, 8559, 8560, 8603, 8706 8 mm [0.315 in] 10 mm [0.394 in]
8271, 8272, 8273, 8274, 8503, 8504, 8505, 8506, 8556, 8557, 8561, 8562 7 mm [0.276 in] 9 mm [0.354 in]
8377, 8558, 8563, 8572 10 mm [0.394 in] 12 mm [0.472 in]

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Perform basic troubleshooting procedures.  
  STEP 1A. Check for active fault codes or high counts of inactive fault codes. Active fault codes or high counts of inactive fault codes?
  STEP 1B. Perform basic troubleshooting checks. All steps have been verified to be correct?
STEP 2. Determination of engine symptom.  
  STEP 2A. Low power, poor acceleration, poor response, or engine will not reach rated speed (rpm). Is the engine symptom low power, poor acceleration, poor response, or engine will
not reach rated speed (rpm)?
  STEP 2B. Engine runs rough or misfires. Is the engine symptom Engine Runs Rough or Misfires?
  STEP 2C. Excessive black smoke. Is the engine symptom Excessive Black Smoke?
  STEP 2D. Excessive white smoke. Is the engine symptom Excessive White Smoke and the engine is using coolant?
  STEP 2D-1. Excessive white smoke.
  STEP 2E. Engine speed surge or engine speed unstable. Is the engine symptom Engine Speed Surge or Engine Speed Unstable?
  STEP 2F. Engine will not start or difficult to start, engine shuts off unexpectedly. Is the symptom Engine Difficult to Start or Will Not Start, or Engine Shuts Off Unexpectedly?
STEP 3. No-start troubleshooting procedures.  
  STEP 3A. Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage greater than 11-VDC?
  STEP 3B. Determine if engine is equipped with a fuel control module. Is the engine equipped with a separate fuel control module?
  STEP 3B-1. Check the ECM connector and pins.
  STEP 3B-2. Check the ECM keyswitch voltage.
  STEP 3B-3. Check the ECM battery supply voltage.
  STEP 3B-4. Check the ECM actuator connector and pins.
  STEP 3B-5. Check for a pin-to-pin short circuit in the engine harness.
  STEP 3B-6. Check for a short circuit to ground in the engine harness.
  STEP 3B-7. Check the continuity of the fuel shutoff valve circuit.
  STEP 3C. Check the fuel control module and fuel control module power connector pins. Dirty or damaged pins?
  STEP 3D. Check for a pin-to-pin short circuit at the fuel control module. Greater than 100k ohms?
  STEP 3E. Check for a short circuit to ground in the engine harness. Greater than 100k ohms?
  STEP 3F. Check for a pin-to-pin short circuit in the engine harness. Greater than 100k ohms?
  STEP 3G. Check ground connections. Ground connections clean and tight?
  STEP 3H. Check the fuel shutoff valve resistance. Is the fuel shutoff solenoid resistance 1 to 5 ohms for 6-VDC solenoids, 6 to 15 ohms for 12-VDC solenoids, 24 to 50 ohms for 24-VDC solenoids, 42 to 80 ohms for 32-VDC solenoids, 46 to 87 ohms for 36-VDC solenoids, 92 to 145 ohms for 48-VDC solenoids, 315 to 375 ohms for 74-VDC solenoids, 645 to 735 ohms for 115-VAC solenoids?
  STEP 3I. Check the engine position sensor installation. Is the engine position sensor installed correctly?
  STEP 3J. Determine if engine is equipped with EGR. Is the engine equipped with a separate fuel control module?
  STEP 3K. Check for coolant in the EGR transfer tube. Is coolant present in the crossover tube?
STEP 4. Fuel system checks.  
  STEP 4A. Check for air in the fuel. Are air bubbles visible in the sight glass?
  STEP 4B. Check fuel inlet restriction. Is fuel inlet restriction less than the specifications?
  STEP 4C. Check drain line restriction. Is fuel drain line restriction less than 89 mm Hg [3.5 in Hg]?
  STEP 4D. Check pump output pressure. Does the fuel pressure meet the specification?
  STEP 4E. Check fuel gear pump check valve. Is check valve installed and operating correctly?
  STEP 4F. Check fuel supply line for restrictions. Are fuel lines free from restrictions?
  STEP 4G. Check for plugged fuel drillings in the cylinder head. Has plastic insert been removed from the fuel supply passage in the cylinder head?
STEP 5. Injector diagnostics.  
  STEP 5A. Perform INSITE™ electronic service tool cylinder cutout test. Do all cylinders pass the cylinder cutout test?
STEP 6. Air handling diagnostic checks.  
  STEP 6A. Start engine and read fault codes. Active fault codes?
  STEP 6B. Inspect the turbocharger blades for damage. Damage found on turbocharger fins?
  STEP 6C. Determination of turbocharger type. Is the turbocharger a variable geometry turbocharger?
  STEP 6D. Check the variable geometry actuator rod for correct travel. Does the turbocharger actuator rod extend between the minimum and maximum actuator travel specification found in the CPL table in the Shop Talk section?
  STEP 6D-1. Check for air leaks and inspect air lines.
  STEP 6D-2. Check the engine and vehicle grounds.
  STEP 6D-3. Check for air pressure at the turbocharger control valve outlet.
  STEP 6D-4. Check for air pressure at the turbocharger control valve outlet.
  STEP 6D-5. Check for correct turbocharger actuator travel.
  STEP 6D-6. Determine if the engine is equipped with a turbocharger control shutoff valve.
  STEP 6D-7. Check for air pressure at the turbocharger control shutoff valve outlet.
  STEP 6D-8. Check for air pressure at the turbocharger control shutoff valve inlet.
  STEP 6D-9. Check for plugged turbocharger control shutoff valve filter.
  STEP 6D-10. Verify the OEM air supply line is connected to the correct port on the turbocharger control valve.
  STEP 6E. Perform INSITE™ electronic service tool EGR Valve/Turbocharger Operational Test. Does the Turbocharger Operational Test pass?
  STEP 6E-1. Check the engine and vehicle grounds.
  STEP 6F. Inspect the wastegate actuator hose. Holes or cracks found in the wastegate actuator hose?
  STEP 6G. Inspect the wastegate actuator rod for travel. Does the wastegate actuator rod move?
  STEP 6G-1. Inspect wastegate actuator rod for travel.
  STEP 6H. Measure resistance of the four-stage wastegate controllers, if equipped. Are the wastegate controller solenoid resistances between 7.0 and 8.0 ohms?
  STEP 6I. Inspect four-stage wastegate controller, if equipped. Damage or debris found on the valve disc, valve seat, or actuator disc?
STEP 7. Check EGR valve for proper operation.  
  STEP 7A. Check for air leaks in the EGR system. Air leaks found in the EGR connection tubing?
  STEP 7B. Check repair history. Is there any record of the poppet head missing?
  STEP 7C. Perform the EGR Valve Test. Does the EGR Valve Test pass?
STEP 8. Verify electronic features are operating correctly.  
  STEP 8A. Verify accelerator pedal travel. Does the Percent Accelerator read 0 when the accelerator is released and 100 percent when the accelerator is depressed?
  STEP 8B. Monitor vehicle speed. Does the vehicle speed read 0 when the vehicle is not moving?
  STEP 8C. Verify electronic feature settings are correct. Are the electronic features set correctly?
  STEP 8D. Check barometric pressure sensor reading. Is the barometric pressure sensor reading in INSITE™ electronic service tool within 5 percent of the present local barometric pressure reading?
STEP 9. Perform base engine mechanical checks.  
  STEP 9A. Verify overhead adjustments are correct. Are the overhead settings within the reset limits?
  STEP 9B. Check air intake restriction. Is air intake restriction greater than 635 mm H
2O [25 in H
2O]?
  STEP 9C. Check exhaust restriction. Is exhaust restriction within specification as listed in the Service Manual?
  STEP 9D. Inspect the charge air cooler. Is the pressure drop 34 kPa [5 psi] or less in 15 seconds?
  STEP 9E. Verify engine brake adjustment. Are the engine brake settings within the reset limits?
  STEP 9F. Measure turbocharger axial and radial clearance. Are the axial and radial clearances within specification?
  STEP 9G. Verify engine blowby is within specification. Are the engine blowby measurements within specification?
  STEP 9G-1. Verify turbocharger contribution to engine blowby.
  STEP 9H. Check the static injection timing. Is the static injection timing correct?
STEP 10. Check the EGR differential pressure sensor and exhaust gas pressure sensor  
  STEP 10A. Check the EGR differential pressure tubes for cracks, restrictions, or leaks. Are cracks, restrictions, or leaks present?
  STEP 10B. Check the exhaust gas pressure tubes for cracks, restrictions, or leaks. Are cracks, restrictions, or leaks present?


Guided Step 1 – Perform basic troubleshooting procedures.

Guided Step 1A – Check for active fault codes or high counts of inactive fault codes.

Conditions

  • Connect INSITE™ electronic service tool
  • Turn keyswitch ON.

Action

Check for active fault codes or high counts of inactive fault codes.

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

Active fault codes or high counts of inactive fault codes?

YES NO

See one of the following manuals:

No Repair
Go to appropriate fault code troubleshooting tree

Guided Step 1B – Perform basic troubleshooting checks.

Conditions

None.

Action

The following items must be checked or verified before continuing:

  • Verify the fuel level in the tanks
  • Verify there have
    not been any changes to CPL components on the engine
  • Verify fuel grade is correct for the application
  • Verify the engine is operating within the recommended altitude
  • Verify engine oil is at the correct level
  • Verify engine parasitics have
    not changed
  • Verify engine duty cycle has
    not changed
  • Verify engine cranking speed is greater than 150 rpm.

All steps have been verified to be correct?

YES NO
No Repair

Correct the condition and verify complaint is no longer present after repair.

Repair complete


Guided Step 2 – Determination of engine symptom.

Guided Step 2A – Low power, poor acceleration, poor response, or engine will not reach rated speed (rpm).

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom low power, poor acceleration, poor response, or engine will
not reach rated speed (rpm)?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 4 – Fuel System Checks
  • Step 6 – Air Handling Checks
  • With EGR – Step 7 – EGR Checks
  • Step 8 – Electronic Checks
  • Step 5 – Injector Checks
  • Step 9 – Base Engine Checks
  • With EGR – Step 10 – EGR Differential Pressure and Exhaust Gas Pressure Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2B – Engine runs rough or misfires.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Runs Rough or Misfires?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 5 – Injector Checks
  • Step 4 – Fuel System Checks
  • Step 9 – Base Engine Checks
  • With EGR – Step 10 – EGR Differential Pressure and Exhaust Gas Pressure Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2C – Excessive black smoke.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom Excessive Black Smoke?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 6 – Air Handling Checks
  • Step 4 – Fuel System Checks
  • With EGR – Step 7 – EGR Checks
  • With EGR – Step 10 – EGR Differential Pressure and Exhaust Gas Pressure Checks
  • Step 9 – Base Engine Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2D – Excessive white smoke.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom Excessive White Smoke and the engine is using coolant?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • See the Coolant Loss – Internal symptom tree.
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2D-1 – Excessive white smoke.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom Excessive White Smoke and the engine is
not using coolant?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 4 – Fuel System Checks
  • Step 5 – Injector Checks
  • Step 6 – Air handling checks
  • Step 9 – Base Engine Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2E – Engine speed surge or engine speed unstable.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Speed Surge or Engine Speed Unstable?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 4 – Fuel System Checks
  • Step 5 – Injector Checks
  • Step 10 – EGR Differential Pressure and Exhaust Gas Pressure Checks
  • Step 6 – Air Handling Checks
  • Step 8 – Electronics Checks
  • Step 9 – Base Engine Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Guided Step 2F – Engine will not start or difficult to start, engine shuts off unexpectedly.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the symptom Engine Difficult to Start or Will
Not Start, or Engine Shuts Off Unexpectedly?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

  • Step 3 – No Start Checks
  • Step 4 – Fuel System Checks
  • Step 5 – Injector Checks
  • Step 6 – Air Handling Checks
  • Step 8 – Electronics Checks
  • Step 9 – Base Engine Checks
No Repair
Perform the troubleshooting steps suggested in the repair procedure

Return to correct symptom tree


Guided Step 3 – No-start troubleshooting procedures.

Guided Step 3A – Check fuel shutoff valve voltage.

Conditions

  • Turn keyswitch ON.

Action

Measure the voltage from the fuel shutoff valve post to engine block ground.

SMALL | MEDIUM | LARGE

Is the fuel shutoff valve voltage greater than 11-VDC?

YES NO
No Repair No Repair

Guided Step 3B – Determine if engine is equipped with a fuel control module.

Conditions

  • Connect all components.

Action

Determine if the engine is equipped with a separate fuel control module.

SMALL | MEDIUM | LARGE

Is the engine equipped with a separate fuel control module?

YES NO
No Repair No Repair

Guided Step 3B-1 – Check the ECM connector and pins.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the OEM harness connector from the ECM.

Action

Inspect the OEM harness connector and ECM pins 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 damaged
  • Damaged connector locking tab.

For general inspection techniques, refer to Procedure 019-361 (Component Connector and Pin Inspection) in Section 19.

Dirty or damaged pins?

YES NO

Clean the connector and pins.

Repair the damaged harness, connector, or pins if possible.

See one of the following procedures:

  • Flush the dirt, debris, or moisture from the connector pins. Use electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Replace the engine harness. Use one of the following procedures:
  • Troubleshooting and Repair Manual, Electronic Control System, ISM and QSM11 Engines, Bulletin 3666266.
    Refer to Procedure 019-043 in Section 19.
  • Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines Bulletin 4021381.
    Refer to Procedure 019-043 in Section 19.
  • Troubleshooting and Repair Manual, CM875 Electronic Control System, ISM Engines, Bulletin 4021477.
    Refer to Procedure 019-043 in Section 19.
  • Replace the OEM harness. Refer to the OEM service manual.
  • Call for authorization to replace the ECM. Upon receipt of authorization, replace the ECM. Use one of the following procedures:
  • Troubleshooting and Repair Manual, Electronic Control System, ISM and QSM11 Engines, Bulletin 3666266.
    Refer to Procedure 019-031 in Section 19.
  • Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines Bulletin 4021381.
    Refer to Procedure 019-031 in Section 19.
  • Troubleshooting and Repair Manual, CM875 Electronic Control System, ISM Engines, Bulletin 4021477.
    Refer to Procedure 019-031 in Section 19.
No Repair
Repair complete

Guided Step 3B-2 – Check the ECM keyswitch voltage.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the OEM harness connector from the ECM.
  • Turn keyswitch ON.

Action

Check the ECM keyswitch voltage.

  • Measure the voltage from the keyswitch input SIGNAL pin of the OEM connector to ground.

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

SMALL | MEDIUM | LARGE

Keyswitch voltage equal to battery voltage?

YES NO
No Repair

Repair the OEM keyswitch circuit.

Use one of the following procedures:

Repair complete

Guided Step 3B-3 – Check the ECM battery supply voltage.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the OEM or 4-pin power harness connector from the ECM.

Action

Check the ECM battery supply.

  • Measure the voltage from the battery SUPPLY (+) pins of the OEM or 4-pin power harness connector to the battery SUPPLY (-) pins of the connector.

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

SMALL | MEDIUM | LARGE

Voltage equal to battery voltage?

YES NO
No Repair

Repair the OEM battery supply or keyswitch circuit.

Repair complete

Guided Step 3B-4 – Check the ECM actuator connector and pins.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the engine harness or engine harness actuator connector from the ECM.

Action

Inspect the engine harness or engine harness actuator connector and ECM pins 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 damaged
  • Damaged connector locking tab.

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

Dirty or damaged pins?

YES NO

Clean the connector and pins.

Repair the damaged harness, connector, or pins if possible.

See one of the following procedures:

  • Flush the dirt, debris, or moisture from the connector pins. Use electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Replace the engine harness. Use one of the following procedures:
  • Troubleshooting and Repair Manual, Electronic Control System, ISM and QSM11 Engines, Bulletin 3666266.
    Refer to Procedure 019-043 in Section 19.
  • Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines Bulletin 4021381.
    Refer to Procedure 019-043 in Section 19.
  • Troubleshooting and Repair Manual, CM875 Electronic Control System, ISM Engines, Bulletin 4021477.
    Refer to Procedure 019-043 in Section 19.
  • Replace the OEM harness. Refer to the OEM service manual.
  • Call for authorization to replace the ECM. Upon receipt of authorization, replace the ECM.
  • Use one of the following procedures:
  • Troubleshooting and Repair Manual, Electronic Control System, ISM and QSM11 Engines, Bulletin 3666266.
    Refer to Procedure 019-031 in Section 19.
  • Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines Bulletin 4021381.
    Refer to Procedure 019-031 in Section 19.
  • Troubleshooting and Repair Manual, CM875 Electronic Control System, ISM Engines, Bulletin 4021477.
    Refer to Procedure 019-031 in Section 19.
No Repair
Repair complete

Guided Step 3B-5 – Check for a pin-to-pin short circuit in the engine harness.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the engine harness or engine harness actuator connector from the ECM.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check for a pin-to-pin short circuit.

  • Measure the resistance between the fuel shutoff valve SIGNAL pin of the engine harness or engine harness actuator connector, and all pins in the connector.

Refer to the wiring diagram or circuit 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

Greater than 100k ohms?

YES NO
No Repair

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

Guided Step 3B-6 – Check for a short circuit to ground in the engine harness.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the engine harness or engine harness actuator connector from the ECM.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check for a short circuit to ground.

  • Measure the resistance between the fuel shutoff valve SIGNAL pin of the engine harness or engine harness actuator connector and ground.

Refer to the wiring diagram or circuit 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

Greater than 100k ohms?

YES NO
No Repair

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

Guided Step 3B-7 – Check the continuity of the fuel shutoff valve circuit.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the engine harness or engine harness actuator connector from the ECM.
  • Disconnect the fuel shutoff valve wire from the valve terminal post.

Action

Check the continuity of the fuel shutoff valve circuit.

  • Measure the resistance of the fuel shutoff valve SIGNAL circuit between the engine harness or engine harness actuator connector and the fuel shutoff valve eyelet.

Refer to the wiring diagram or circuit 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

Call for authorization to replace the ECM. Upon receipt of authorization, replace the ECM.

See one of the following procedures:

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

Repair complete

Guided Step 3C – Check the fuel control module and fuel control module power connector pins.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the fuel control module actuator connector from the fuel control module.

Action

Inspect the fuel control module and the fuel control module actuator connector pins 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 damaged
  • Damaged connector locking tab.

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

Dirty or damaged pins?

YES NO

Clean the connector and pins.

Repair the damaged harness, connector, or pins if possible.

Repair or replace the fuel control module harness.

See one of the following procedures:

No Repair
Repair complete

Guided Step 3D – Check for a pin-to-pin short circuit at the fuel control module.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the fuel control module actuator connector from the fuel control module.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check for a pin-to-pin short circuit.

  • Measure the resistance between the fuel shutoff valve SIGNAL pin of the fuel control module actuator connector, and all other pins in the connector.

Refer to the wiring diagram or circuit 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

Greater than 100k ohms?

YES NO
No Repair

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

Guided Step 3E – Check for a short circuit to ground in the engine harness.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the fuel control module actuator connector from the fuel control module.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check for a short circuit to ground.

  • Measure the resistance between the fuel shutoff valve SIGNAL pin of the engine harness fuel control module actuator connector and engine block ground.

Refer to the wiring diagram or circuit 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

Greater than 100k ohms?

YES NO
No Repair

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

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

Conditions

  • Turn keyswitch OFF.
  • Disconnect the fuel control module actuator connector from the fuel control module.
  • Disconnect the engine harness from the ECM.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check for a pin-to-pin short circuit.

  • Measure the resistance between the fuel shutoff valve SIGNAL pin of the engine harness fuel control module actuator connector and all pins in the engine harness engine control module connector.

Refer to the wiring diagram or circuit 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

Greater than 100k ohms?

YES NO
No Repair

Repair or replace the engine harness.

See one of the following procedures:

Repair complete

Guided Step 3G – Check ground connections.

Conditions

  • Connect all components.

Action

Check conditions of grounds. Check for loose, missing, or dirty ground connections at the following locations:

  • Engine harness ground at block stud
  • Starter to block ground strap and battery negative
  • Chassis to engine block or battery negative.

Ground connections clean and tight?

YES NO

Replace the fuel control module.

See one of the following procedures:

Tighten and clean ground connections as needed.

Repair complete

Repair complete

Guided Step 3H – Check the fuel shutoff valve resistance.

Conditions

  • Turn keyswitch OFF.
  • Remove the engine harness ring terminal from the fuel shutoff valve.

Action

Check the shutoff valve resistance.

  • Measure the resistance between the fuel shutoff valve ring terminal stud and engine block ground.

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

SMALL | MEDIUM | LARGE

Is the fuel shutoff solenoid resistance:

  • 1 to 5 ohms for 6-VDC solenoids
  • 6 to 15 ohms for 12-VDC solenoids
  • 24 to 50 ohms for 24-VDC solenoids
  • 42 to 80 ohms for 32-VDC solenoids
  • 46 to 87 ohms for 36-VDC solenoids
  • 92 to 145 ohms for 48-VDC solenoids
  • 315 to 375 ohms for 74-VDC solenoids
  • 645 to 735 ohms for 115-VAC solenoids?
YES NO
No Repair

Replace the fuel shutoff valve.

See one of the following procedures:

Repair complete

Guided Step 3I – Check the engine position sensor installation.

Conditions

  • Turn keyswitch OFF.

Action

Check the engine position sensor for proper installation. Excessive air gap between the sensor and camshaft can cause incorrect speed sensor readings.

Is the engine position sensor installed correctly?

YES NO
No Repair

Install the engine position sensor correctly. Replace the engine position sensor, if necessary.

See one of the following procedures:

Repair complete.

Guided Step 3J – Determine if engine is equipped with exhaust gas recirculation (EGR).

Conditions

  • Connect all components.

Action

Determine if the engine is equipped with EGR.

SMALL | MEDIUM | LARGE

Is the engine equipped with EGR?

YES NO
No Repair No Repair

Perform next troubleshooting procedure as outlined in Step 2

Guided Step 3K – Check for coolant in the EGR transfer tube.

Conditions

  • Turn keyswitch OFF.

Action

Remove the EGR transfer hose from the EGR cooler outlet.

Is coolant present in the crossover tube?

YES NO

See the Coolant Loss – Internal symptom tree.

No Repair
Repair complete

Perform next troubleshooting procedure as outlined in Step 2


Guided Step 4 – Fuel system checks.

Guided Step 4A – Check for air in the fuel.

Conditions

  • Engine running at low idle (engine cranking if troubleshooting No-Start).

Action

Connect the equipment to the fuel pump as shown.

SMALL | MEDIUM | LARGE

Are air bubbles visible in the sight glass?

YES NO

Locate and correct cause of air ingestion in the OEM fuel supply system or damaged fuel filter sealing ring.

No Repair
Repair complete

Guided Step 4B – Check fuel inlet restriction.

Conditions

  • Connect a manometer, Part Number ST-1111-3, to the fuel pump supply hose.
  • Turn keyswitch ON.
  • Engine running at rated speed.

Action

Check the fuel inlet restriction.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 006-020 in Section 6.

SMALL | MEDIUM | LARGE

Is fuel inlet restriction less than the specifications listed below?

Dirty – 254 mm Hg [10 in Hg]; New – 152 mm Hg [6 in Hg]

YES NO
No Repair

Locate the cause of high fuel inlet restriction. Check the prefilter and fuel supply lines.

Repair complete

Guided Step 4C – Check drain line restriction.

Conditions

  • Connect a manometer, Part Number ST-1111-3, to the fuel drain line.
  • Turn keyswitch ON.
  • Engine running at rated speed.

Action

Observe reading on the pressure gauge.

SMALL | MEDIUM | LARGE

Is fuel drain line restriction less than 89 mm Hg [3.5 in Hg] for Automotive Applications or less than 63.5 mm Hg [2.5 in Hg] for Industrial/Generator Applications?

YES NO
No Repair

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

Repair complete

Guided Step 4D – Check pump output pressure.

Conditions

  • Connect pressure gauge on the Compuchek™ fitting of the fuel pump.
  • Turn keyswitch ON.
  • Engine running at 1200 rpm (engine cranking if troubleshooting No-Start).

Action

Read the fuel pressure at 1200 rpm, or cranking if engine will not start.

Read the fuel pressure while cranking if the engine will
not start.

  • Cranking: minimum of 172 kPa [25 psi]
  • Engine running at 1200 rpm: minimum of 827 kPa [120 psi]
SMALL | MEDIUM | LARGE

Does the fuel pressure meet the specification?

YES NO
No Repair No Repair
Perform next troubleshooting procedure as outlined in Step 2

Guided Step 4E – Check fuel gear pump check valve.

Conditions

  • Disconnect fuel drain line from fuel gear pump housing.

Action

Inspect the fuel gear pump check valve for correct installation and operation.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 005-026 in Section 5

SMALL | MEDIUM | LARGE

Is check valve installed and operating correctly?

YES NO
No Repair

Install the check valve correctly or replace the fuel gear pump check valve, if necessary.

Use the following procedure in the Service Manual, ISM, ISMe and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 005-026 in Section 5.

Repair complete

Guided Step 4F – Check fuel supply line for restrictions.

Conditions

  • Connect all components.

Action

Check the fuel line between the fuel pump and cylinder head for obstructions. Check the fuel line for sharp bends or kinks that could cause a restriction.

SMALL | MEDIUM | LARGE

Are fuel lines free from restrictions?

YES NO
No Repair

Remove obstructions from fuel lines. Replace kinked or restricted lines as necessary.

Repair complete

Guided Step 4G – Check for plugged fuel drillings in the cylinder head.

Conditions

  • Turn keyswitch OFF.

Action

If a ReCon® cylinder head was installed, check that the plastic insert has been removed from the fuel supply inlet passage in the cylinder head.

SMALL | MEDIUM | LARGE

Has plastic insert been removed from the fuel supply passage in the cylinder head?

YES NO
No Repair

Remove the plastic insert from the fuel supply passage in the cylinder head.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 002-004 in Section 2.

Replace the fuel pump. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 005-016 in Section 5.

Repair complete


Guided Step 5 – Injector diagnostics.

Guided Step 5A – Perform INSITE™ electronic service tool cylinder cutout test.

Conditions

  • Connect INSITE™ electronic service tool
  • Engine running at low idle

Action

Perform the INSITE™ electronic service tool cylinder cutout test.

Do all cylinders pass the cylinder cutout test?

YES NO
No Repair

Replace the injectors as needed.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 006-026 in Section 6.

Perform next troubleshooting procedure as outlined in Step 2

Repair complete


Guided Step 6 – Air handling diagnostic checks.

Guided Step 6A – Start engine and read fault codes.

Conditions

  • Connect INSITE™ electronic service tool.
  • Engine running at low idle.

Action

Check the fault codes with the engine running.

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

Active fault codes?

YES NO
No Repair No Repair
Go to appropriate fault code troubleshooting tree

Guided Step 6B – Inspect the turbocharger blades for damage.

Conditions

  • Engine OFF.
  • Remove intake and exhaust connections for turbocharger.

Action

Inspect the compressor and turbine fins for damage or wear.

Damage found on turbocharger fins?

YES NO

Replace the turbocharger.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

No Repair
Repair complete

Guided Step 6C – Determination of turbocharger type.

Conditions

None.

Action

Determine if the turbocharger is a variable geometry turbocharger

Is the turbocharger a variable geometry turbocharger?

YES NO
No Repair No Repair

Guided Step 6D – Check the variable geometry actuator rod for correct travel.

Conditions

  • Engine OFF.
  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action

Use INSITE™ electronic service tool to perform the turbocharger actuator test.

  • Adjust the delay timer in the Turbocharger Actuator Test so that the rod movement can be observed.
  • Select the Retract Actuator position with INSITE™ electronic service tool.
  • Mark or scribe the variable geometry actuator rod at the base of the actuator.
  • Select the Extend Actuator position with INSITE™ electronic service tool.
  • Measure the rod travel by measuring the distance from the base of the turbocharger actuator to the scribe mark.
  • Use a straight edge steel ruler.
  • Retract and extend the turbocharger actuator at least 10 times.
  • Examine the engine dataplate to identify the CPL number. Use the CPL number from the dataplate to identify the proper actuator travel from the CPL table in the Shop Talk section.

The turbocharger actuator moves 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 the minimum and maximum actuator travel specification found in the CPL table in the Shop Talk section?

YES NO
No Repair No Repair

Guided Step 6D-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 charged to at least 586 kPa [85 psi] air pressure.

Action

Use INSITE™ electronic service tool to perform the Turbocharger Actuator Test.

Select the Extend Actuator position. Listen for air leaks at the following components:

  • Turbocharger control valve
  • Turbocharger control shutoff valve inlet connection (if equipped)
  • Turbocharger control shutoff valve outlet connection (if equipped)
  • Turbocharger control valve inlet connection
  • Turbocharger control valve outlet connection
  • Turbocharger actuator inlet connection
  • Turbocharger actuator
  • All air lines including the OEM supply line to turbocharger control shutoff valve, turbocharger control shutoff valve to turbocharger control valve, and turbocharger control valve to turbocharger actuator.

A small amount of air could possibly be heard escaping from the turbocharger control valve during the turbocharger actuator test. This is a normal condition for the valve to achieve output regulation pressure. Do
not replace the turbocharger control valve for this condition.

Air leaks found in the system?

YES NO

Repair air leaks.

No Repair
Repair complete

Guided Step 6D-2 – Check the engine and vehicle grounds.

Conditions

  • Turn keyswitch OFF.

Action

Check for loose or corroded engine, chassis, or battery ground connections.

  • Check the engine ground connection.
  • Check the chassis ground connections.
  • Check the battery terminal connections.
SMALL | MEDIUM | LARGE

Connections tight and corrosion free?

YES NO
No Repair

Tighten the connections.

Tighten the loose connections and clean the terminals.

Refer to the OEM troubleshooting and repair manual.

Repair complete

Guided Step 6D-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 charged to at least 586 kPa [85 psi] air pressure.

Action

Perform the Turbocharger Actuator Test, use INSITE™ electronic service tool. Select Retract Actuator position.

Remove the air line connection at the outlet of the turbocharger control valve.

Install an M12 Compuchek™ 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].

Use INSITE™ electronic service tool to perform the Turbocharger Actuator Test. Select the Extend Actuator position.

Is vehicle air tank pressure present at the turbocharger control valve outlet?

YES NO
No Repair No Repair

Guided Step 6D-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 charged to at least 586 kPa [85 psi] air pressure.

Action

Perform the Turbocharger Actuator Test, use INSITE™ electronic service tool. Select the Retract Actuator position.

  • Remove the air line connection at the outlet of the turbocharger control valve.
  • Install an M12 Compuchek™ fitting at the outlet of the turbocharger control valve.
  • Install an air pressure gauge capable of reading at least 1034 kPa [150 psi].

Does the pressure gauge read more than 103 kPa [15 psi] after 5 minutes?

YES NO

Replace the turbocharger control valve.

See one of the following procedures:

No Repair
Repair complete

Guided Step 6D-5 – Check for correct turbocharger actuator travel.

Conditions

  • Engine OFF.
  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action

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

  • Remove the variable geometry actuator from the turbocharger. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
    Refer to Procedure 010-033 in Section 10.
  • Use INSITE™ electronic service tool to perform the Turbocharger Actuator Test. Select the Extend Actuator position.
SMALL | MEDIUM | LARGE

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

YES NO

Replace the turbocharger assembly.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

Replace the turbocharger actuator.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-113 in Section 10.

Repair complete

Repair complete

Guided Step 6D-6 – Determine if the engine is equipped with a turbocharger control shutoff valve.

Conditions

None.

Action

Determine if the engine is equipped with a turbocharger control shutoff valve.

SMALL | MEDIUM | LARGE

Is the engine equipped with a turbocharger control shutoff valve?

YES NO
No Repair No Repair

Guided Step 6D-7 – Check for air pressure at the turbocharger control shutoff valve outlet.

Conditions

  • Engine OFF.
  • Turn keyswitch ON.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
  • Connect INSITE™ electronic service tool.

Action

Use INSITE™ electronic service to perform the Turbocharger Actuator Test.

  • Select the Extend Actuator position.
  • 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 NO

Replace the turbocharger control shutoff valve.

See one of the following procedures:

No Repair
Repair complete

Guided Step 6D-8 – Check for air pressure at the turbocharger control shutoff valve inlet.

Conditions

  • Engine OFF.
  • Turn keyswitch ON.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action

Verify the OEM air supply line is connected to the correct port on the turbocharger control shutoff valve.

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

Repair complete

Guided Step 6D-9 – Check for plugged turbocharger control shutoff valve filter.

Conditions

  • Remove the turbocharger control shutoff valve filter.
  • Turn keyswitch ON.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
  • Connect INSITE™ electronic service tool.

Action

Use INSITE™ electronic service tool to perform the Turbocharger Actuator Test.

  • Select the Extend Actuator position.
  • 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.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-114 in Section 10.

Replace the turbocharger control shutoff valve.

Use the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines, Bulletin 4021381.
Refer to Procedure 019-386 in Section 19.

Repair complete

Repair complete

Guided Step 6D-10 – Verify the OEM air supply line is connected to the correct port on the turbocharger control valve.

Conditions

  • Engine OFF.
  • Turn keyswitch ON.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action

Verify the OEM air supply line is connected to the correct port on the turbocharger control valve.

Loosen the air line connection at the turbocharger control valve inlet.

Can air be heard escaping form the turbocharger control valve inlet?

YES NO

Replace the turbocharger control valve.

See one of the following procedures:

Repair the air supply from the OEM air tanks.

Repair Complete

Repair Complete

Guided Step 6E – Perform INSITE™ electronic service tool EGR Valve/Turbocharger Operational Test.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
  • Start the engine and run at low idle.

Action

Select the INSITE™ electronic service tool EGR/Variable Geometry Turbocharger Operational Test.

Prior to running INSITE™ electronic service tool EGR Valve and EGR Valve/Turbocharger Operational Test, the ECM Calibration Software Phase could possibly need to be updated to the latest Software Phase. The ECM Calibration Phase Software can be checked in INSITE™ electronic service tool, under ‘Features and Parameters’. Expand the selection for ‘System ID and Dataplate’ and go to ‘Calibration Information’. If the Software Phase is earlier than shown below, recalibrate the ECM using the January 2006 INCAL™ CD-ROM, or later. Engines with the Software Phase listed below or later do
not require a recalibration.

ISM engines with CM875 (engines built after January 2004) require Software Phase 06050312.

This is a warrantable calibration change.

  • Choose the Turbocharger actuator option under Test Choices.

Does the Turbocharger Operational Test pass?

YES NO
No Repair No Repair
Perform next troubleshooting procedure as outlined in Step 2

Guided Step 6E-1 – Check the engine and vehicle grounds.

Conditions

  • Turn keyswitch OFF.

Action

Check for loose or corroded engine, chassis, or battery ground connections.

  • Check the engine ground connection.
  • Check the chassis ground connections.
  • Check the battery terminal connections.
SMALL | MEDIUM | LARGE

Connections tight and corrosion free?

YES NO

Replace the variable geometry turbocharger.

Use tthe following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

Tighten the connections.

Tighten the loose connections and clean the terminals.

Refer to the OEM troubleshooting and repair manual.

Repair complete

Verify repair
Repair complete

Guided Step 6F – Inspect the wastegate actuator hose.

Conditions

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

Action

Inspect the integral wastegate actuator hose for cracks or holes.

SMALL | MEDIUM | LARGE

Holes or cracks found in the wastegate actuator hose?

YES NO

Replace wastegate actuator hose.

No Repair
Repair complete

Guided Step 6G – Inspect the wastegate actuator rod for travel.

Conditions

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

Action

Apply a regulated air supply of 310 kPa [45 psi] to the actuator and check for actuator movement.

SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?

YES NO
No Repair No Repair

Guided Step 6G-1 – Inspect wastegate actuator rod for travel.

Conditions

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

Action

Apply a regulated air supply of 310 kPa [45 psi] to the actuator and check for actuator movement.

SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?

YES NO

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

Use the following procedure in the Troubleshooting and Repair Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322 .
Refer to Procedure 010-033 in Section 10.

Replace the wastegate actuator.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-050 in Section 10.

Repair complete

Repair complete

Guided Step 6H – Measure 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

Measure the resistance from the wastegate controller post to engine block ground.

The wastegate controller solenoids
must be between 20°C and 26°C [68°F and 78°F] before using the resistance specifications listed.

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

Are the wastegate controller solenoid resistances between 7.0 and 8.0 ohms?

YES NO
No Repair

Replace the failed wastegate controller.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-109 in Section 10.

Repair complete

Guided Step 6I – Inspect four-stage wastegate controller, if equipped.

Conditions

  • Engine OFF.
  • Remove the four-stage wastegate controllers.

Action

Check the valve disc, valve seat, and actuator disc for dirt, metal parts, bonding separation, corrosion, cracks, or wear.

SMALL | MEDIUM | LARGE

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

YES NO

Replace failed components. Clean dirty components

No Repair
Repair complete

Perform next troubleshooting procedure as outlined in Step 2


Guided Step 7 – Check EGR valve for proper operation.

Guided Step 7A – Check for air leaks in the EGR system.

Conditions

None.

Action

Check for leaks in the EGR connection tubing and connections.

Soot streaks can be noticeable where leaks are present.

Air leaks found in the EGR connection tubing?

YES NO

Repair any leaks in the EGR system.

No Repair
Repair complete

Guided Step 7B – Check repair history.

Action

Check with the customer for a recent EGR valve replacement.

Is there any record of the poppet head missing?

YES NO

Remove the exhaust manifold and run a wire through every port to check for the missing poppet head.

No Repair

Guided Step 7C – Perform the EGR Valve Test.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Perform INSITE™ electronic service tool EGR Valve Test.

Prior to running INSITE™ electronic service tool EGR Valve and EGR Valve/Turbocharger Operational Test, the ECM Calibration Software Phase could possibly need to be updated to the latest Software Phase. The ECM Calibration Phase Software can be checked in INSITE™ electronic service tool, under ‘Features and Parameters’. Expand the selection for ‘System ID and Dataplate’ and go to ‘Calibration Information’. If the Software Phase is earlier than shown below, recalibrate the ECM using the January 2006 INCAL™ CD-ROM, or later. Engines with the Software Phase listed below or later do
not require a recalibration.

ISM engines with CM875 (engines built after January 2004) require Software Phase 06050312.

This is a warrantable calibration change.

  • Check for complete travel of the EGR valve by selecting Open Valve and verifying the EGR Valve opens 100 percent.

Does the EGR Valve Test pass?

YES NO
No Repair

Replace the EGR valve.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 011-022 in Section 11.

Perform next troubleshooting procedure as outlined in Step 2

Repair complete


Guided Step 8 – Verify electronic features are operating correctly.

Guided Step 8A – Verify accelerator pedal travel.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Use INSITE™ electronic service tool to monitor Percent Accelerator while fully depressing and releasing the accelerator pedal.

Does the Percent Accelerator read 0 when the accelerator is released and 100 percent when the accelerator is depressed?

YES NO
No Repair

Determine and correct cause of accelerator pedal restriction.

Repair complete

Guided Step 8B – Monitor vehicle speed.

Conditions

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

Action

Use INSITE™ electronic service tool to monitor Vehicle Speed while the vehicle is not moving.

Does the vehicle speed read 0 when the vehicle is
not moving?

YES NO
No Repair

Check the vehicle speed sensor and circuit or locate the cause of the vehicle speed interference.

Repair complete

Guided Step 8C – Verify electronic feature settings are correct.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Use INSITE™ electronic service tool to verify the following adjustable parameters are correctly set:

  • Maximum vehicle speed
  • Powertrain protection
  • Rear axle ratio
  • Number of transmission tailshaft gear teeth
  • Tire revolutions per mile
  • Gear-down protection
  • Cruise control droop settings
  • Cruise control maximum vehicle speed.

Are the electronic features set correctly?

YES NO
No Repair

Correct programmable features.

Perform next troubleshooting procedure as outlined in Step 2

Repair complete

Guided Step 8D – Check barometric pressure sensor reading.

Conditions

  • Connect all components.
  • Connect INSITE electronic service tool.
  • Turn keyswitch ON.

Action

Check for correct barometric pressure sensor reading.

Compare the barometric pressure sensor reading on INSITE™ electronic service tool data monitor/logger to the present local barometric pressure.
Refer to Procedure 018-028 in Section V.

Is the barometric pressure sensor reading in INSITE™ electronic service tool within 5 percent of the present local barometric pressure reading?

YES NO
No Repair

Replace the barometric pressure sensor.

See one of the following procedures:

Perform next troubleshooting procedure as outlined in Step 2

Repair complete


Guided Step 9 – Perform base engine mechanical checks.

Guided Step 9A – Verify overhead adjustments are correct.

Conditions

  • Turn keyswitch OFF.
  • Remove valve cover.

Action

Measure the overhead settings.

Are the overhead settings within the reset limits?

YES NO
No Repair

Adjust the overhead settings.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 003-004 in Section 3.

Repair complete

Guided Step 9B – Check air intake restriction.

Conditions

  • Turn keyswitch ON.
  • Run engine at advertised horsepower and rpm.

Action

Check the intake system restriction by installing a manometer gauge into the air intake system.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-031 in Section 10.

SMALL | MEDIUM | LARGE

Is air intake restriction greater than 635 mm H
2O [25 in H
2O]?

YES NO

Correct the cause of high intake air restriction.

Check for plugged air filter or restricted air intake piping.

No Repair
Repair complete

Guided Step 9C – Check exhaust restriction.

Conditions

  • Install a pressure gauge into the exhaust system.
  • Turn keyswitch ON.
  • Run engine at advertised horsepower and rpm.

Action

Check exhaust restriction by installing a pressure gauge into the exhaust system just past the turbocharger outlet.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 011-009 in Section 11.

SMALL | MEDIUM | LARGE

Is exhaust restriction within specification listed in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322?

YES NO
No Repair

Repair exhaust system for source of high restriction.

Repair complete

Guided Step 9D – Inspect the charge air cooler.

Conditions

  • Turn keyswitch OFF.

Action

Pressure test the charge air cooler.

SMALL | MEDIUM | LARGE

Is the pressure drop 34 kPa [5 psi] or less in 15 seconds?

YES NO
No Repair

Repair the charge air cooler.

Repair complete

Guided Step 9E – Verify engine brake adjustment.

Conditions

  • Turn keyswitch OFF.
  • Remove valve cover.

Action

Verify the engine brakes are operating correctly.

Are the engine brake settings within the reset limits?

YES NO
No Repair

Adjust the engine brake settings.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 020-024 in Section 20.

Repair complete

Guided Step 9F – Measure turbocharger axial and radial clearance.

Conditions

  • Engine OFF.
  • Disconnect exhaust and intake connections from the turbocharger.

Action

Measure the axial and radial clearances of the turbocharger.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

Are the axial and radial clearances within specification?

YES NO
No Repair

Replace the turbocharger assembly.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

Repair complete

 WARNING 

Do not run the engine for more than one minute. Severe engine damage can occur if the engine is run too long with the turbocharger oil drain line disconnected from the block.
Guided Step 9G – Verify engine blowby is within specification.

Conditions

  • Turn keyswitch OFF.
  • Connect the appropriate orifice to the end of the blowby draft tube.
  • Start engine.

Action

Load engine to rated rpm on a chassis dynamometer.

Measure the engine blowby.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 014-002 in Section 14.

Are the engine blowby measurements within specification?

YES NO
No Repair No Repair

 WARNING 

Do not run the engine for more than one minute. Severe engine damage can occur if the engine is run too long with the turbocharger oil drain line disconnected from the block.
Guided Step 9G-1 – Verify turbocharger contribution to engine blowby.

Conditions

  • Turn keyswitch OFF.
  • Verify oil level is full.
  • Connect the appropriate orifice to the end of the blowby draft tube.
  • Remove turbocharger oil drain line from the block and drain into a bucket.
  • Make sure the turbocharger oil drain port in the block is plugged so no crankcase gases escape.
  • Start engine.

Action

Load engine to rated rpm on a chassis dynamometer.

Measure the engine blowby.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 014-002 in Section 14.

Did the total engine blowby drop more than 30 percent?

YES NO

Replace the turbocharger assembly.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 010-033 in Section 10.

Engine could possibly need to be rebuilt.

See the engine rebuild specifications.

Repair complete

Repair complete

Guided Step 9H – Check the static injection timing.

Conditions

  • Turn keyswitch OFF.

Action

Check for the correct static injection timing.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 006-025 in Section 6.

Is the static injection timing correct?

YES NO
No Repair

Set the static injection timing to specification.

Use the following procedure in the Troubleshooting and Repair Manual, ISM, ISMe and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 006-025 in Section 6.

Perform the next troubleshooting procedure as outlined in Step 2

Repair complete


Guided Step 10 – Check the EGR differential pressure sensor and exhaust gas pressure sensor

Guided Step 10A – Check the EGR differential pressure tubes for cracks, restrictions, or leaks.

Conditions

  • Turn keyswitch OFF.

Action

Inspect the EGR differential pressure tubes for cracks, restrictions, or leaks.

Soot streaks can indicate that the line is loose or cracked.

Are cracks, restrictions, or leaks present?

YES NO

Tighten or replace the EGR differential pressure tubes.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 011-026 in Section 11.

No Repair
Repair complete

Repair complete

Guided Step 10B – Check the exhaust gas pressure tubes for cracks, restrictions, or leaks.

Conditions

  • Turn keyswitch OFF.

Action

Inspect the exhaust gas pressure tubes for cracks, restrictions, or leaks.

Soot streaks can indicate that the line is loose or cracked.

Are cracks, restrictions, or leaks present?

YES NO

Tighten or replace the exhaust gas pressure tubes.

Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322.
Refer to Procedure 011-027 in Section 11.

No Repair
Repair complete

Perform the next troubleshooting procedure as outlined in Step 2

Last Modified:  20-Aug-2009