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
ActionCheck for active fault codes or high counts of inactive 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. | |
---|---|
ConditionsNone. ActionThe following items must be checked or verified before continuing:
|
|
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). | |
---|---|
ConditionsNone. ActionInterview the driver and verify the complaint. |
|
Is the engine symptom low power, poor acceleration, poor response, or engine will |
|
YES | NO |
Perform the troubleshooting steps in the recommended order listed below:
|
No Repair |
Perform the troubleshooting steps suggested in the repair procedure
|
Guided Step 2B – Engine runs rough or misfires. | |
---|---|
ConditionsNone. ActionInterview 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:
|
No Repair |
Perform the troubleshooting steps suggested in the repair procedure
|
Guided Step 2C – Excessive black smoke. | |
---|---|
ConditionsNone. ActionInterview 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:
|
No Repair |
Perform the troubleshooting steps suggested in the repair procedure
|
Guided Step 2D – Excessive white smoke. | |
---|---|
ConditionsNone. ActionInterview 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:
|
No Repair |
Perform the troubleshooting steps suggested in the repair procedure
|
Guided Step 2D-1 – Excessive white smoke. | |
---|---|
ConditionsNone. ActionInterview the driver and verify the complaint. |
|
Is the engine symptom Excessive White Smoke and the engine is |
|
YES | NO |
Perform the troubleshooting steps in the recommended order listed below:
|
No Repair |
Perform the troubleshooting steps suggested in the repair procedure
|
Guided Step 2E – Engine speed surge or engine speed unstable. | |
---|---|
ConditionsNone. ActionInterview 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:
|
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. | |
---|---|
ConditionsNone. ActionInterview the driver and verify the complaint. |
|
Is the symptom Engine Difficult to Start or Will |
|
YES | NO |
Perform the troubleshooting steps in the recommended order listed below:
|
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
ActionMeasure the voltage from the fuel shutoff valve post to engine block ground. |
|
|
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
ActionDetermine if the engine is equipped with a separate fuel control module. |
|
|
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
ActionInspect the OEM harness connector and ECM pins for the following:
|
|
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:
|
No Repair |
Repair complete
|
Guided Step 3B-2 – Check the ECM keyswitch voltage. | ||
---|---|---|
Conditions
ActionCheck the ECM keyswitch voltage.
Refer to the wiring diagram or circuit diagram for connector pin identification. |
|
|
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
ActionCheck the ECM battery supply.
Refer to the wiring diagram or circuit diagram for connector pin identification. |
|
|
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
ActionInspect the engine harness or engine harness actuator connector and ECM pins for the following:
Use the following procedure for general inspection techniques. |
|
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:
|
No Repair |
Repair complete
|
Guided Step 3B-5 – Check for a pin-to-pin short circuit in the engine harness. | ||
---|---|---|
Conditions
ActionCheck for a pin-to-pin short circuit.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionCheck for a short circuit to ground.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionCheck the continuity of the fuel shutoff valve circuit.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionInspect the fuel control module and the fuel control module actuator connector pins for the following:
Use the following procedure for general inspection techniques. |
|
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
ActionCheck for a pin-to-pin short circuit.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionCheck for a short circuit to ground.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionCheck for a pin-to-pin short circuit.
Refer to the wiring diagram or circuit diagram for connector pin identification. Use the following procedure for general resistance measurement techniques. |
|
|
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
ActionCheck conditions of grounds. Check for loose, missing, or dirty ground connections at the following locations:
|
|
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
ActionCheck the shutoff valve resistance.
Use the following procedure for general resistance measurement techniques. |
|
|
Is the fuel shutoff solenoid resistance:
|
||
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
ActionCheck 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
ActionDetermine if the engine is equipped with EGR. |
|
|
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
ActionRemove 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
ActionConnect the equipment to the fuel pump as shown. |
|
|
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
ActionCheck the fuel inlet restriction. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322. |
|
|
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
ActionObserve reading on the pressure gauge. |
|
|
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
ActionRead the fuel pressure at 1200 rpm, or cranking if engine will not start. Read the fuel pressure while cranking if the engine will
|
|
|
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
ActionInspect 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. |
|
|
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. |
|
Repair complete
|
Guided Step 4F – Check fuel supply line for restrictions. | ||
---|---|---|
Conditions
ActionCheck 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. |
|
|
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
ActionIf a ReCon® cylinder head was installed, check that the plastic insert has been removed from the fuel supply inlet passage in the cylinder head. |
|
|
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. |
|
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
ActionPerform 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. |
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
ActionCheck the fault codes with the engine running.
|
|
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
ActionInspect 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. |
No Repair |
Repair complete
|
Guided Step 6C – Determination of turbocharger type. | |
---|---|
ConditionsNone. ActionDetermine 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
ActionUse INSITE™ electronic service tool to perform the turbocharger actuator test.
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. |
|
|
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
ActionUse INSITE™ electronic service tool to perform the Turbocharger Actuator Test. Select the Extend Actuator position. Listen for air leaks at the following components:
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 |
|
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
ActionCheck for loose or corroded engine, chassis, or battery ground connections.
|
|
|
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
ActionPerform 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
ActionPerform the Turbocharger Actuator Test, use INSITE™ electronic service tool. Select the Retract Actuator position.
|
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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
ActionNOTE: Damage to the turbocharger can result if the proper removal procedure is not followed.
|
|
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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. |
Replace the turbocharger actuator. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322. |
|
Repair complete
|
Repair complete
|
Guided Step 6D-6 – Determine if the engine is equipped with a turbocharger control shutoff valve. | ||
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ConditionsNone. ActionDetermine if the engine is equipped with a turbocharger control shutoff valve. |
|
|
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
ActionUse INSITE™ electronic service to perform the Turbocharger Actuator Test.
|
|
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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
ActionVerify the OEM air supply line is connected to the correct port on the turbocharger control shutoff valve.
|
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Can air be heard escaping from the turbocharger control shutoff valve inlet? |
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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
ActionUse INSITE™ electronic service tool to perform the Turbocharger Actuator Test.
|
|
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. |
Replace the turbocharger control shutoff valve. Use the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System, ISM Engines, Bulletin 4021381. |
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
ActionVerify 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? |
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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
ActionSelect 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 ISM engines with CM875 (engines built after January 2004) require Software Phase 06050312. This is a warrantable calibration change.
|
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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
ActionCheck for loose or corroded engine, chassis, or battery ground connections.
|
|
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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. |
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
ActionInspect the integral wastegate actuator hose for cracks or holes. |
|
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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
ActionApply a regulated air supply of 310 kPa [45 psi] to the actuator and check for actuator movement. |
|
|
Does the wastegate actuator rod move? |
||
YES | NO | |
No Repair | No Repair | |
Guided Step 6G-1 – Inspect wastegate actuator rod for travel. | ||
---|---|---|
Conditions
ActionApply a regulated air supply of 310 kPa [45 psi] to the actuator and check for actuator movement. |
|
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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 . |
Replace the wastegate actuator. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322. |
|
Repair complete
|
Repair complete
|
Guided Step 6H – Measure resistance of the four-stage wastegate controllers, if equipped. | |
---|---|
Conditions
ActionMeasure the resistance from the wastegate controller post to engine block ground. The wastegate controller solenoids Use the following procedure for general resistance measurement techniques. |
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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. |
Repair complete
|
Guided Step 6I – Inspect four-stage wastegate controller, if equipped. | ||
---|---|---|
Conditions
ActionCheck the valve disc, valve seat, and actuator disc for dirt, metal parts, bonding separation, corrosion, cracks, or wear. |
|
|
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. | |
---|---|
ConditionsNone. ActionCheck 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. | |
---|---|
ActionCheck 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
ActionPerform 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 ISM engines with CM875 (engines built after January 2004) require Software Phase 06050312. This is a warrantable calibration change.
|
|
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. |
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
ActionUse 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
ActionUse INSITE™ electronic service tool to monitor Vehicle Speed while the vehicle is not moving. |
|
Does the vehicle speed read 0 when the vehicle is |
|
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
ActionUse INSITE™ electronic service tool to verify the following adjustable parameters are correctly set:
|
|
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
ActionCheck 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. |
|
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
ActionMeasure 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. |
Repair complete
|
Guided Step 9B – Check air intake restriction. | ||
---|---|---|
Conditions
ActionCheck 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. |
|
|
Is air intake restriction greater than 635 mm H |
||
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
ActionCheck 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. |
|
|
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
ActionPressure test the charge air cooler.
|
|
|
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
ActionVerify 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. |
Repair complete
|
Guided Step 9F – Measure turbocharger axial and radial clearance. | |
---|---|
Conditions
ActionMeasure the axial and radial clearances of the turbocharger. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322. |
|
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. |
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
ActionLoad 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. |
|
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
ActionLoad 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. |
|
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. |
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
ActionCheck for the correct static injection timing. Use the following procedure in the Service Manual, ISM, ISMe, and QSM11 Engines, Bulletin 3666322. |
|
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. |
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
ActionInspect 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. |
No Repair |
Repair complete
|
Repair complete
|
Guided Step 10B – Check the exhaust gas pressure tubes for cracks, restrictions, or leaks. | |
---|---|
Conditions
ActionInspect 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. |
No Repair |
Repair complete
|
Perform the next troubleshooting procedure as outlined in Step 2
|