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

Engine Performance Troubleshooting Tree – ISM with CM876

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

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM.
Refer to Procedure 019-032 in Section 19.

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 1C. Perform INSITE™ electronic service tool Monitor Test. Is ‘Engine Operating State’ reading a value that can cause an engine derate?
STEP 2. Determination of engine symptom.  
  STEP 2A. Low power, poor acceleration, or poor response. Is the engine symptom low power, poor acceleration, or poor response?
  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 2G. Engine run on, or will not shut down. Is the engine symptom Engine Run On or Slow to Shut Down after operated at high idle for 1 minute then keyed OFF?
STEP 3. No-start troubleshooting procedures.  
  STEP 3A. Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage greater than 11-VDC?
  STEP 3A-1. Check ECM keyswitch voltage.
  STEP 3A-2. Check the fuel shutoff valve wire.
  STEP 3B. Check 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 3C. Check fuel shutoff valve actuator disk. Debris or damage found on the valve disc, valve seat, or actuator disc?
  STEP 3D. Check for an engine equipped with a priming pump. Does the engine use a priming pump?
  STEP 3D-1. Check for correct priming pump operation.
  STEP 3D-2. Check priming pump pressure.
  STEP 3E. 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. 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 7. Check EGR system for proper operation.  
  STEP 7A. Check for EGR related fault codes. EGR related fault codes present?
  STEP 7B. Check for inactive EGR Differential Pressure Sensor fault codes. Fault Code 1866, 2273, or 2274 active?
  STEP 7C. Check the EGR differential pressure tubes for leaks. Leaks detected at either the low or high EGR differential pressure tubes?
  STEP 7D. Check the EGR differential pressure sensor adapter for leaks. Leaks detected at the EGR differential pressure sensor adapter?
  STEP 7E. Check the EGR differential pressure tubes for plugging. Debris or soot found in either EGR differential pressure tube?
  STEP 7F. Check for air leaks in the EGR system. Air leaks found in the EGR connection tubing?
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 ambient air 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 8E. Check the intake manifold pressure sensor accuracy. INSITE™ electronic service tool reading within 17 kPa [2.5 psi] of mechanical gauge 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. Verify engine brake adjustment. Are the engine brake settings within the reset limits?
  STEP 9C. Check air intake restriction. Is air intake restriction greater than 635 mm-H
20 [25 in-H
20] for a used air filter or 254 mm-H
20 [10 in-H
20); for a new filter?
  STEP 9D. Check exhaust restriction. Is exhaust restriction greater than 304.8 mm-Hg [12.0 in-Hg]?
  STEP 9E. Inspect the charge-air cooler. Is the pressure drop 34 kPa [5 psi] or less in 15 seconds?
  STEP 9F. Verify engine blowby is within specification. Are the engine blowby measurements within specification?
  STEP 9F-1. Verify turbocharger contribution to engine blowby.
STEP 10. Aftertreatment Checks  
  STEP 10A. Check for aftertreatment related fault codes. Fault codes related to the aftertreatment system are found to be active?
  STEP 10B. Perform basic aftertreatment troubleshooting checks. All parts have been visually inspected, and appear to be functioning properly?
  STEP 10C. Check for signs of internal damage to the aftertreatment system. Any visible smoke (black or white) is present during the snap throttle acceleration?
  STEP 10D. Check exhaust restriction. Is exhaust restriction greater than 304.8 mm-Hg [12.0 in-Hg]?


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.

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

Active fault codes or high counts of inactive fault codes?

YES NO
No Repair 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.
  • Verify battery voltage is adequate

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 1C – Perform INSITE™ electronic service tool Monitor Test.

Conditions

  • Correct INSITE™ electronic service tool
  • Engine running at the speed and load where the symptom occurs.

Action

Use INSITE™ electronic service tool to monitor the parameter ‘Engine Operating State’ at the same engine operating conditions where the symptom occurs.

Refer to Advanced Engine Performance Troubleshooting Techniques, Bulletin
4021686, for a description of what “User Fueling States” or “Engine Operating State” can cause engine derates.

Is ‘Engine Operating State’ reading a value that can cause an engine derate?

YES NO

Determine if the engine derate is being caused by normal engine operation or by actual engine damage.

Continue following troubleshooting steps as outlined in step 2 if engine damage is suspected.

No Repair


Guided Step 2 – Determination of engine symptom.

Guided Step 2A – Low power, poor acceleration, or poor response.

Conditions

None.

Action

Interview the driver and verify the complaint.

Is the engine symptom low power, poor acceleration, or poor response?

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
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
  • Step 7 – EGR 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.

Progressive damage to the aftertreatment system has occurred if black smoke is visible. Remove the exhaust aftertreatment system from the vehicle and inspect for reuse. Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 011-050 in Section 11.

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
  • Step 7 – EGR 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 10 -Aftertreatment 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 7 – EGR 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 Will
Not Start or Difficult to Start, 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

Guided Step 2G – Engine run on, or will not shut down

Action

Interview the driver and verify the complaint.

None

Is the engine symptom Engine Run On or Slow to Shut Down after operated at high idle for 1 minute then keyed OFF?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

Step 5 – Injector Check

Step 4 – Fuel System Checks

Step 9 – Base Engine Checks

No Repair
Perform the troubleshooting steps suggested in the repair procedure.

Return to correct symptom trees.


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 3A-1 – Check ECM Keyswitch Voltage

Conditions

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

Action

Measure the voltage from the keyswitch input SIGNAL wire of the OEM harness to engine block ground.

Is the keyswitch voltage equal to battery voltage?

YES NO
No Repair

Repair or replace the OEM power harness, keyswitch, or check the battery connections. Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-064 in Section 19.

Repair complete

Guided Step 3A-2 – Check the fuel shutoff valve wire.

Conditions

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

Action

Measure the resistance from the fuel shutoff valve SIGNAL pin in the ECM connector to the fuel shutoff valve eyelet.

SMALL | MEDIUM | LARGE

Less than 10 ohms?

YES NO

Call for pre-authorization to replace the ECM. Upon receipt of authorization, replace the ECM. Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-031 in Section 19.

Repair or replace the engine harness. Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-043 in Section 19.

Repair complete

Guided Step 3B – Check fuel shutoff valve resistance

Conditions

  • Turn keyswitch OFF
  • Disconnect the fuel shutoff valve signal wire from the fuel shutoff solenoid
  • Fuel shutoff valve temperature between 20 – 25°C [68 – 77°F].

Action

Measure the resistance from the fuel shutoff solenaoid post to engine block ground.

The fuel shutoff solenoid must be between 20 – 25°C [68 – 77°F] before the use of the resistance specifications listed.

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 solenoid. Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-050 in Section 19.

Guided Step 3C – Check fuel shutoff valve actuator disk

Conditions

  • Turn keyswitch OFF
  • Remove the fuel shutoff valve solenoid, valve disc, valve seat, and actuator disk.

Action

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

SMALL | MEDIUM | LARGE

Debris or damage found on the valve disc, valve seat, or actuator disc?

YES NO

Replace the damaged fuel shutoff valve component. Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 402156
Refer to Procedure 019-050 in Section 19.

No Repair
Repair complete

Guided Step 3D – Check for an engine equipped with a priming pump.

Conditions

  • Turn keyswitch OFF
  • Assemble fuel shutoff valve components
  • Turn keyswitch ON

Action

Listen for the lift pump operation.

Listen for the priming pump operation after the keyswitch is turned to the ON position. If priming pump operation is not heard, inspect the unit to verify that is not equipped with a priming pump.

Not all ISM engines use a priming pump and
not all ISM engines use a priming pump that actuates at keyswitch ON. Understand which system is present on this engine before beginning this step.

Does the engine use a priming pump?

YES NO
No Repair No Repair

Guided Step 3D-1 – Check for correct priming pump operation.

Conditions

  • Turn keyswitch OFF
  • Turn keyswitch ON.

Action

Listen for priming pump operation.

Listen for the priming pump operation after the keyswitch is turned to the ON position.

Not all ISM engines use a priming pump and
not all ISM engines use a priming pump that actuates at keyswitch ON. Understand which system is present on this engine before beginning this step.

Does the priming pump operate after turning the keyswitch ON?

YES NO
No Repair

Check the priming pump operation. Replace the priming pump as necessary.

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

Repair complete

Guided Step 3D-2 – Check priming pump pressure.

Conditions

  • Turn keyswitch OFF
  • Turn keyswitch ON.

Action

Measure the pressure.

Measure the priming pump pressure at the quick connect fitting located on the top of the fuel pump.

Does the pressure meet the 69 kPa [10 psi]?

YES NO
No Repair

Replace the priming pump.

NOTE: ISM engines are
not equipped with a lift pump from the factory. Reference the chassis manufacturer’s repair procedure for priming pump replacement.

Repair complete

Guided Step 3E – 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

Air bubbles visible in the sight glass?

YES NO

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

Check the ECM cooling plate, associated plumbing, and o-ring seals for failures that can cause air ingestion. Repair or replace the malfunctioned component. Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 006-006 in Section 6.

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 (engine cranking if troubleshooting No-Start).

Action

Check the fuel inlet restriction.

Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, 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 (engine cranking if troubleshooting No-Start).

Action

Observe the reading on the pressure gauge.

SMALL | MEDIUM | LARGE

Is fuel drain line restriction less than 89 mm-Hg [3.5 in-Hg]?

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

Observe the reading on the pressure gauge.

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

  • Engine cranking at minimum of 150 rpm for 10 seconds: 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

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

SMALL | MEDIUM | LARGE

Is check valve installed and operating correctly?

YES NO

Replace the fuel pump.

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

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

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

Repair complete

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

Perform the next troubleshooting procedure as outlined in Step 2

Repair complete


Guided Step 5 – Injector diagnostics.

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

Conditions

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

Action

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

No Repair
Repair complete

Perform the next troubleshooting procedure as outlined in Step 2.


Guided Step 7 – Check EGR system for proper operation.

Guided Step 7A – Check for EGR related fault codes.

Conditions

  • Turn keyswitch OFF.
  • Wait 30 seconds
  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Check for any EGR related fault codes.

EGR related fault codes present?

YES NO

Troubleshoot electronic fault codes.

No Repair
Appropriate fault code troubleshooting trees

Guided Step 7B – Check for inactive EGR Differential Pressure Sensor fault codes.

Conditions

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

Action

Check for active fault codes.

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

Fault Code 1866, 2273, or 2274 active?

YES NO
No Repair No Repair
Appropriate fault code troubleshooting tree.

Guided Step 7C – Check the EGR differential pressure tubes for leaks.

Conditions

  • Turn keyswitch OFF.

Action

Check the lines for leaks.

  • Leaks will be easily noted by traces of soot.

Leaks detected at either the low or high EGR differential pressure tubes?

YES NO

Tighten the fittings, or replace the EGR differential pressure tube.

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

No Repair
Repair complete

Guided Step 7D – Check the EGR differential pressure sensor adapter for leaks.

Conditions

  • Turn keyswitch OFF.

Action

Inspect the EGR differential pressure sensor adaptor for leaks.

  • Leaks will be easily noted by traces of soot; however, the sensor can be removed to inspect the o-rings between the EGR differential pressure sensor and the adapter for proper sealing. Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
    Refer to Procedure 011-028 in Section 11.

Leaks detected at the EGR differential pressure sensor adapter?

YES NO

Replace the EGR differential pressure sensor adapter.

Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 011-028 in Section 11.

No Repair
Repair complete

Guided Step 7E – Check the EGR differential pressure tubes for plugging.

Conditions

  • Turn keyswitch OFF.
  • Remove the EGR differential pressure tubes. Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
    Refer to Procedure 011-026 in Section 11.

Action

Inspect the EGR differential pressure tubes for restrictions, soot plugging and plugging.

Debris or soot found in either EGR differential pressure tube?

YES NO

Clear the debris or replace the EGR differential pressure tube.

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

No Repair
Repair complete

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

Action

Check for leaks in the EGR connection tubing and connections.

Soot streaks are 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

Perform next troubleshooting procedure as outlined in Step 2


Guided Step 8 – Verify electronic features are operating correctly.

Guided Step 8A – Verify accelerator pedal travel.

Conditions

  • Turn keyswitch ON.
  • Connect the 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 the 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.

Repair complete

Guided Step 8D – Check ambient air pressure sensor accuracy

Conditions

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

Action

Check for correct barometric pressure reading.

Compare the barometric pressure sensor reading on INSITE™ electronic service tool data monitor/logger to the current local barometric pressure.

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

YES NO
No Repair

Replace the ambient air pressure sensor.

Use the following procedure in the ISX CM871 and ISM CM876 Electronic Control Systems, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-004 in Section 19.

Repair complete

Guided Step 8E – Check the intake manifold pressure sensor accuracy.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Start and operate the engine at high idle after connecting the mechanical intake manifold pressure gauge.

Action

Connect a mechanical intake manifold pressure gauge to the engine, as close to the intake manifold pressure sensor as possible.

  • Start INSITE™ electronic service tool Data Monitor/Logger and compare INSITE™ electronic service tool reading for intake manifold pressure to the mechanical gauge.

INSITE™ electronic service tool reading within 17 kPa [2.5 psi] of mechanical gauge reading?

YES NO
No Repair

Remove and clean the intake manifold pressure sensor.

Use the following procedure found in the ISX CM871 and ISM CM876 Electronic Control System, Bulletin 4021560.
Refer to Procedure 019-159 in Section 19.

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

Repair complete

Guided Step 9B – Verify engine brake adjustment.

Conditions

  • Turn keyswitch OFF.
  • Remove rocker lever 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 brakes settings.

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

Repair complete

Guided Step 9C – Check air intake restriction.

Conditions

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

Action

Check the intake system restriction by installintg a vacuum gauge or water manometer into the air intake system.

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

Is air intake restriction greater than 635 mm-H
20 [25 in-H
2O] for a used air filter or 254 mm-H
2O [10 in-H
2O] for a new filter?

YES NO

Correct the cause of high intake air restriction.

Check for plugged air filter or restricted air intake piping.

No Repair
Repair compete

Guided Step 9D – 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 ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 011-009 in Section 11.

SMALL | MEDIUM | LARGE

Is exhaust restriction greater than 304.8 mm-Hg [12.0 in-Hg]?

YES NO

Remove the exhaust aftertreatment system from the vehicle and inspect for reuse.

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

Inspect the aftertreatment system for a potential malfunction.

No Repair
Repair complete

Guided Step 9E – Inspect charge-air cooler

Conditions

  • Turn keyswitch OFF.

Action

Pressure test the charge-air cooler.

Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 010-027 in Section 1.

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

YES NO
No Repair

Repair or replace the charge air cooler assembly.

Repair complete

Guided Step 9F – 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.

Are the engine blowby measurements within specification?

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

Guided Step 9F-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 the turbocharger oil drain line form 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

Did the total engine blowby drop more than 30 percent?

YES NO

Replace the turbocharger assembly.

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

Engine rebuild is possible.

See the engine rebuild specifications.

Repair complete

Repair complete


Guided Step 10 – Aftertreatment Checks

Guided Step 10A – Check for aftertreatment related fault codes.

Conditions

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

Action

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

Check for any aftertreatment fault codes. Specifically fault codes related to high soot in the aftertreatment diesel particulate filter, face plugging of the aftertreatment diesel oxidation catalyst, and aftertreatment diesel oxidation catalyst efficiency.

Fault codes related to the aftertreatment system are found to be active?

YES NO
No Repair

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

Appropriate fault code troubleshooting tree

Guided Step 10B – Perform basic aftertreatment troubleshooting checks

Conditions

None

Action

The following items must be checked or verified before continuing:

  • Check to make sure that Ultra Low Sulfur Diesel (ULSD) fuel is being used in the vehicle.
  • Check for any fuel leaks around the aftertreatment fuel shutoff valve or aftertreatment injector components.
  • Check for any noticeable exhaust leaks around any aftertreatment components.
  • Check the exhaust pipes for restrictions that can create high exhaust back pressure.
  • Check the aftertreatment sensors, wires, connectors, and harnesses for proper connections.
  • Check the exhaust gas filter differential pressure sensor tubes for proper connections.

All parts have been inspected, and appear to be functioning properly?

YES NO
No Repair

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

Repair complete

Guided Step 10C – Check for signs of internal damage to the aftertreatment system.

Conditions

  • Engine warmed up to normal operating temperature
  • Vehicle
    must be stationary.

Action

Quickly snap the throttle pedal accelerating the engine from low idle to high idle while checking for smoke at the exhaust outlet.

Inspect the following during the snap throttle acceleration:

  • Smoke (any color) coming out of the vehicle tailpipe
  • Soot or signs of fuel, coolant, or oil inside the tailpipe.

If the aftertreatment system is operating correctly, no visible smoke will be present during the snap throttle acceleration. Any visible smoke is an indication of a possible malfunction in the aftertreatment system.

Any visible smoke (black or white) is present during the snap throttle acceleration?

YES NO

Any malfunction in the aftertreatment system:

Remove the exhaust gas aftertreatment system form the vehicle and inspect for reuse.

Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 011-050 in Section 11.

Inspect the aftertreatment system for a potential malfunction.

No Repair
Repair complete, troubleshoot the smoke complaint , use the proper TT tree steps

Guided Step 10D – 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.

If a port is not found in the exhaust system, remove the exhaust gas temperature 1 sensor and install the pressure gauge in the temperature sensor port.

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

SMALL | MEDIUM | LARGE

Is exhaust restriction greater than 304.8 mm-Hg [12.0 in-Hg]?

YES NO

Remove the exhaust aftertreatment system from the vehicle and inspect for reuse.

Use the following procedure in the ISM, ISMe, and QSM11 Engines, Service Manual, Bulletin 3666322.
Refer to Procedure 011-050 in Section 11.

Inspect the aftertreatment system for a potential malfunction.

No Repair
Repair complete

Perform the next troubleshooting procedure as outlined in Step 2.

Last Modified:  10-Aug-2010