Verify Customer's Concern
Locate the correct symptom table. Inspect the items indicated under that symptom from the following symptom tables
- «Hard Start»(ref-238231-S23482400822006072400000)
- «Surges/Chuggles»(ref-238231-S29641846772006072400000)
- «Lack of Power, Sluggishness, or Sponginess»(ref-238231-S03831821752006072400000)
- «Fuel Knock/Combustion Noise»(ref-238231-S01368633482006072400000)
- «Hesitation, Sag, Stumble»(ref-238231-S12157747992006072400000)
- «Cuts Out, Misses»(ref-238231-S41778804002006072400000)
- «Poor Fuel Economy»(ref-238231-S20882870592006072400000)
- «Rough, Unstable, or Incorrect Idle and Stalling»(ref-238231-S25344876452006072400000)
- «Excessive Smoke (Black)»(ref-238231-S36658030962006072400000) or «Excessive Smoke (Gray or Blue)»(ref-238231-S06829585052006072400000) or «Excessive Smoke (White)»(ref-238231-S21838357482006072400000)
Hard Start
| Inspection | Action |
|---|---|
| DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Ensure the driver is using the correct starting procedure. |
| Sensor Inspection | Inspect the engine coolant temperature (ECT) sensor. Use the scan tool to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself. Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure with a scan tool. The actual fuel rail pressure (FRP) should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . Inspect the crankshaft position (CKP) sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Fuel System Inspection | Inspect the fuel pressure regulator 12-volt circuit for an intermittent short to ground. Observe the FRP Command percent while cranking. A range of 85-95 percent indicates a possible short to ground condition. Inspect the fuel supply to the fuel injection pump. Refer to Fuel System Diagnosis . Inspect for a restricted fuel filter. Refer to Fuel System Diagnosis . Inspect for air in the fuel system. Refer to Fuel System Diagnosis . Inspect for external fuel leaks. Refer to Fuel Leaks . Inspect for high engine oil level. Refer to Fuel in Engine Oil . Inspect for low fuel pressure. Command the fuel pressure to 160 MPa with a scan tool while the engine is at idle. If 160 MPa is not achieved, perform Fuel System Diagnosis - High Pressure Side . At idle observe the FRP Regulator Fuel Flow Command parameter with a scan tool. If the FRP Regulator Fuel Flow Command is more than 2700 mm 3 , perform the Fuel System Diagnosis - High Pressure Side . Inspect the fuel tank cap vent for proper operation. |
| Electrical System Inspection | Inspect for a slow cranking speed. Refer to Symptoms - Engine Electrical . |
| Air Intake System Inspection | Inspect the air cleaner and air intake ducts for a restrictions or leaks. Inspect for a restriction in turbocharger inlet duct. Inspect for a restriction or a leak in the intake manifolds. |
| Exhaust System Inspection | Inspect the exhaust system for a possible restriction. Refer to Restricted Exhaust . |
| Engine Mechanical Inspection | Inspect the engine for the following conditions: Improper valve timing Bent pushrods Worn rocker arms-Refer to Valve Rocker Arm and Shaft Cleaning and Inspection . Low engine compression-Refer to Engine Compression Test . Broken or weak valve springs Worn camshaft lobes-Refer to Camshaft and Bearings Cleaning and Inspection . |
| Additional Inspection | Inspect for an intermittent CKP signal. Refer to Testing for Intermittent Conditions and Poor Connections . Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . Inspect the Service Bulletins for control module software updates. |
Hard Start
Surges/Chuggles
| Inspection | Action |
|---|---|
| DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down with no change in the accelerator pedal. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Ensure the driver understands the torque converter clutch (TCC) operation. Ensure the driver understands the A/C compressor operation. Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . Use the scan tool to ensure the vehicle speed sensor (VSS) reading matches the speedometer. This excludes vehicles with electronic transmissions where some variation between VSS and the speedometer is normal. |
| Sensor Inspection | Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure with a scan tool. The actual fuel rail pressure should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the fuel rail pressure (FRP) sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . Test for an intermittent FRP sensor signal by wiggling the harness between the sensor and the engine control module (ECM) with the ignition ON and the engine OFF, while monitoring the parameter with a scan tool. Observe the FRP sensor and the fuel pressure regulator commanded percent at idle. FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor issues exists. Inspect the crankshaft position (CKP) sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Fuel System Inspection | Inspect the fuel supply system vacuum while the problem exists. Refer to Fuel System Diagnosis . If the ECM glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect for a sticking Fuel Pressure Regulator. The symptom for this condition will be an idle surge of at least 100 RPM. This surge will be from 50 RPM above Desired Idle Speed to 50 RPM below Desired Idle Speed. Refer to Fuel Pressure Regulator Diagnosis . |
| Additional Inspection | Inspect the control module grounds for being clean, tight, and in their proper locations. Inspect the generator output voltage. Repair if less than 9 volts or more than 16 volts. Inspect the TCC operation. |
Surges/Chuggles
Lack of Power, Sluggishness, or Sponginess
| Checks | Action |
|---|---|
| DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. | |
| Preliminary Checks | Refer to Symptoms - Engine Controls . Inspect for auxiliary fuel filters. Refer to Fuel Injection Line Routing Diagram for proper fuel filter locations. Aftermarket fuel filters may restrict fuel flow. Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem. Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . Remove the air filter and check for dirt, or for air ducts being plugged or leaking. Repair or replace as necessary. Inspect for a proper transmission operation. Inspect the engine oil level and quality. |
| Sensor Inspection | Observe the fuel rail pressure (FRP) sensor and the fuel pressure regulator commanded percent at idle. FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor issue exists. Inspect the crankshaft position (CKP) sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Fuel System Checks | Inspect the fuel supply to the fuel injection pump. Refer to Fuel System Diagnosis . Observe the actual vs desired fuel rail pressure with a scan tool, with the engine idling. Inspect the engine speed signal circuit for high resistance. If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect for restricted or plugged fuel injectors. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . |
| Exhaust System Checks | Inspect the exhaust system for a possible restriction. Refer to Restricted Exhaust . |
| Air Intake System Checks | Inspect for an air leak or restriction in the air inlet ducts or the intake manifold. Refer to DTC P0234 . Inspect for an air leak or restriction in the charge air cooler with a J 46091 Charge Air Cooler Tester. See Special Tools . Inspect for a worn or damaged turbo charger turbine wheel, shaft or compressor wheel. Inspect for a skewed mass air flow (MAF) sensor. Refer to Diagnostic Aids in DTC P0101 . |
| Engine Mechanical Check | Inspect the engine for the following: Low compression Improper valve timing Improper or worn camshaft Refer to Engine Compression Test . |
| Additional Checks | Inspect the control module grounds for being clean, tight, and in their proper location. Inspect the torque converter clutch (TCC) operation. Inspect the air conditioning system for proper operation. Refer to Air Conditioning (A/C) System Performance Test (Diesel Engine) or Air Conditioning (A/C) System Performance Test (Gas Engine w/ Electric Cooling Fan ) or Air Conditioning (A/C) System Performance Test (Gas Engine w/Engine Driven Fan) . Inspect the generator output voltage. Refer to Charging System Test . |
Lack of Power, Sluggishness, or Sponginess
Hesitation, Sag, Stumble
| Inspection | Action |
|---|---|
| DEFINITION: The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur at any vehicle speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe enough, the condition may cause the engine to stall. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . |
| Fuel System Inspection | Inspect the fuel supply system vacuum. Refer to Fuel System Diagnosis . Inspect for water contamination in the fuel. Refer to Contaminants-in-Fuel Diagnosis . Perform the Fuel Injector Balance Test. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . Inspect for high fuel supply system vacuum after a cold start or during moderate or full throttle acceleration. If the vacuum jumps above specification, there is a restriction in the fuel system. |
| Sensor Inspection | Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure (FRP) with a scan tool. The actual FRP should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . Test for an intermittent FRP sensor signal by wiggling the harness between the sensor and the engine control module (ECM) with the ignition ON and the engine OFF, while monitoring the parameter with a scan tool. Observe the FRP sensor and the fuel pressure regulator commanded percent at idle. FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor exists. Inspect for an intermittent crankshaft position (CKP) sensor signal. Refer to Testing for Intermittent Conditions and Poor Connections . Inspect the CKP sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Additional Inspection | Review the service bulletins for control module software updates. Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . Inspect the generator output voltage. Refer to Charging System Test . |
Hesitation, Sag, Stumble
Cuts Out, Misses
| Inspection | Action |
|---|---|
| DEFINITION: A constant jerking that follows the engine speed, usually more pronounced as the engine load increases which is not normally felt above 1,500 RPM or 48 km/h (30 mph). The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . |
| Sensor Inspection | Observe the fuel rail pressure (FRP) sensor and the fuel pressure regulator commanded percent at idle. The FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor issue exists. Inspect for an intermittent crankshaft position (CKP) sensor signal. Refer to Testing for Intermittent Conditions and Poor Connections . Inspect the CKP sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Engine Mechanical Inspection | Perform the Engine Compression Test. Refer to Engine Compression Test . Inspect the engine for the following conditions: Improper valve timing Bent pushrods Worn rocker arms Worn camshaft lobes Broken or weak valve springs-Refer to Symptoms - Engine Mechanical . Inspect the intake and exhaust manifold passages for casting flash. |
| Fuel System Inspection | Inspect the fuel system for a plugged fuel filter, high vacuum, air in the fuel system, etc. Refer to Fuel System Diagnosis . If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect for water contamination in the fuel. Refer to Contaminants-in-Fuel Diagnosis . Inspect the fuel injectors for proper operation. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . |
Cuts Out, Misses
Poor Fuel Economy
| Inspection | Action |
|---|---|
| DEFINITION: Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Inspect the air filter for dirt or being plugged. Inspect for an air leak in the charge air cooler with a J 46091 Charge Air Cooler Tester. See Special Tools . Inspect the air conditioning system for proper operation. Inspect the tires for correct air pressure. Inspect the driving habits of the owner. Are heavy loads being carried? Suggest to the owner to fill the fuel tank and inspect the fuel economy. Suggest to the driver to read the Important Facts on Fuel Economy in the Owner Manual. |
| Sensor Inspection | Observe the fuel rail pressure (FRP) sensor and the fuel pressure regulator commanded percent at idle. FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor concern exists. Inspect for an intermittent crankshaft position (CKP) sensor signal. Refer to Testing for Intermittent Conditions and Poor Connections . Inspect the CKP sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. |
| Fuel System Inspection | Inspect the fuel type and quality. Inspect the fuel system vacuum. Refer to Fuel System Diagnosis . |
| Cooling System Inspection | Inspect the engine coolant level. Inspect the engine thermostats for always being open or for the wrong heat range. Refer to Thermostat Diagnosis . |
| Additional Inspection | Inspect the transmission for proper operation. Inspect the torque converter clutch (TCC) operation. When the TCC is commanded ON, a scan tool should indicate an RPM drop. Inspect the Service Bulletins for control module software updates. Inspect the brake for proper operation. |
Poor Fuel Economy
Rough, Unstable, or Incorrect Idle and Stalling
| Inspection | Action |
|---|---|
| DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. | |
| Preliminary Inspection | Refer to Important Preliminary Inspections Before Starting . Search for bulletins. Inspect the vehicle for factory or aftermarket accessories that may contact the body and chassis. A grounding out condition may simulate a misfire or rough run concern. Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . Inspect the engine control module (ECM) grounds for being clean, tight, and in the proper locations. Remove and inspect the air filter element for dirt or for being restricted. Refer to Air Cleaner Element Replacement . Replace as necessary. |
| Sensor Inspection | Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure (FRP) with a scan tool. The actual FRP should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . Test for an intermittent FRP sensor signal by wiggling the harness between the sensor and the ECM with the ignition ON and the engine OFF, while monitoring the parameter with a scan tool. Observe the FRP sensor and the fuel pressure regulator commanded percent at idle. The FRP should be near 40 MPa, and commanded percent should be near 40 percent. If the command is high, a fuel pressure or sensor issue exists. Inspect for an intermittent crankshaft position (CKP) sensor signal. Refer to Testing for Intermittent Conditions and Poor Connections . Inspect the CKP sensor reluctor wheel. Remove the CKP sensor and attempt to move the reluctor wheel front to back or side to side with a probe. If there is any movement the reluctor wheel retaining bolts are loose. Inspect for proper crankcase ventilation. |
| Fuel System Inspection | Perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . Inspect for a restricted fuel filter. Refer to Fuel System Diagnosis . Inspect for a contaminated fuel condition. Refer to Contaminants-in-Fuel Diagnosis . If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect for a sticking Fuel Pressure Regulator. The symptom for this condition will be an idle surge of at least 100 RPM. This surge will be from 50 RPM above Desired Idle Speed to 50 RPM below Desired Idle Speed. Refer to Fuel Pressure Regulator Diagnosis . |
| Engine Mechanical Inspection | Inspect engine mechanical for the following: Inspect the cylinder compression. Refer to Engine Compression Test . Sticking or leaking valves Worn camshaft lobes Valve timing Bent push rods Worn rocker arms Broken valve springs Excessive oil in the combustion chamber-Leaking valve seals. Refer to Oil Consumption Diagnosis . Inspect the following components for incorrect basic engine parts: Camshaft-Refer to Camshaft and Bearings Cleaning and Inspection . Cylinder heads-Refer to Cylinder Head Cleaning and Inspection . Pistons, connecting rods, or bearings-Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection . |
| Additional Inspection | Inspect the following components of the exhaust system for possible restrictions: The exhaust system for damaged or collapsed pipes The exhaust manifold for a collapsed inner wall The mufflers for heat distress or possible internal failure Electromagnetic interference (EMI) on the reference circuit can cause an engine miss condition. A scan tool can usually detect EMI by monitoring the engine RPM. A sudden increase in RPM, with little change in actual engine RPM change, indicates that EMI is present. If a problem exists, inspect routing of high voltage components, such as fuel injector wiring, near the sensor circuits. Inspect the park neutral position (PNP) switch circuit. Inspect for faulty motor mounts. Refer to Engine Mount Inspection . Inspect the intake manifold and the exhaust manifold passages for casting flash. |
Rough, Unstable, or Incorrect Idle and Stalling
Excessive Smoke (Black)
| Inspection | Action |
|---|---|
| DEFINITION: Black smoke under load, idle or start up hot or cold. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Ensure the customer has an actual problem. Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . |
| Fuel System Inspection | Observe the actual vs. desired fuel rail pressure with a scan tool, with the engine running. If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect the fuel injectors. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . |
| Sensor Inspection | Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself. Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure (FRP) with a scan tool. The actual FRP should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . |
| Air Intake System Inspection | Inspect for a restriction in the air cleaner or the air intake ducts. Inspect for a restriction in the turbocharger charge air cooler. Inspect for a restriction in the intake manifold. Inspect for an air leak in the charge air cooler with a J 46091 Charge Air Cooler Tester. See Special Tools . Inspect for an air leak in the air ducts between the turbocharger and the intake manifold. |
| Engine Mechanical Inspection | Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, etc. Inspect for excessive oil entering the combustion chamber. Refer to Oil Consumption Diagnosis . |
Excessive Smoke (Black)
Excessive Smoke (Gray or Blue)
| Inspection | Action |
|---|---|
| DEFINITION: Gray or blue smoke under load, idle or start up hot or cold. | |
| Preliminary Inspections | Refer to Symptoms - Engine Controls . Ensure the customer has an actual problem. Check the coolant level in the reservoir. White coolant smoke may be mistaken for blue/gray smoke. If the coolant level is low refer to Loss of Coolant . Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . |
| Fuel System Inspection | Observe the actual vs. desired fuel rail pressure with a scan tool, with the engine running. If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect the fuel injectors. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . |
| Sensor Inspection | Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself. Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure (FRP) with a scan tool. The actual FRP should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . |
| Air Intake System Inspection | Inspect the air cleaner and the air intake ducts for restriction. Inspect for contamination of the mass air flow (MAF) sensor. Inspect for a restriction in the turbocharger charged air cooler. Inspect for a restriction in the intake manifold. |
| Engine Mechanical Inspection | Perform a cylinder leakage test. Perform the engine compression test. Refer to Engine Compression Test . Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, piston rings, and valves. Inspect for excessive oil entering the combustion chamber. Refer to Oil Consumption Diagnosis . |
| Turbocharger Inspection | Inspect for leaking seals in the turbocharger. A slight film on the intake side is normal. |
Excessive Smoke (Gray or Blue)
Excessive Smoke (White)
| Inspection | Action |
|---|---|
| DEFINITION: White smoke under load, idle or start up hot or cold. | |
| Preliminary Inspection | Refer to Symptoms - Engine Controls . Ensure the customer has an actual condition. Check the coolant level in the reservoir. White coolant smoke may be mistaken for blue/gray smoke. If the coolant level is low refer to Loss of Coolant . Compare the scan tool data at idle with the scan tool data list. Refer to Scan Tool Data List (Engine Control Module) or Scan Tool Data List (Glow Plug Control Module) . |
| Fuel System Inspection | If excessive smoke is present, inspect for a stuck open fuel injector by performing the following procedure: Remove the ignition 1 relay. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 and Glow Plug Replacement - Bank 2 . IMPORTANT: Do not stand in front of the glow plug holes while cranking the engine. Crank the engine while observing the glow plug holes for fuel spray. Replace the fuel injectors for the cylinders that spray fuel. Inspect for contaminated oil or high oil level. Refer to Fuel in Engine Oil . If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to Fuel Injector Flow Rate Programming . Inspect the fuel injectors. Refer to Fuel Injector Balance Test with Tech 2 (Manual Transmission) or Fuel Injector Balance Test with Tech 2 (Automatic Transmission) . |
| Sensor Inspection | Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself. Turn ON the ignition with the engine OFF. Observe the actual fuel rail pressure (FRP) with a scan tool. The actual FRP should be between 1.1-1.8 MPa. If it is not, inspect for high resistance in the FRP sensor circuits or the FRP sensor. Refer to Circuit Testing and Wiring Repairs . |
| Air Intake System Inspection | Inspect the air cleaner and the air intake ducts for restriction. Inspect for a restriction in the turbocharger charge air cooler. Inspect for a restriction in the intake manifold. Refer to Intake Manifold Cleaning and Inspection . |
| Engine Mechanical Inspection | Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, etc. Inspect for coolant entering the combustion chamber. |
| IMPORTANT |
|---|
| Do not stand in front of the glow plug holes while cranking the engine. |
Excessive Smoke (White)
Circuit/System Verification
The MIL should turn ON and OFF when commanded with a scan tool.
Repair Procedures
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Control Module References for ECM and IPC replacement, setup, and programming.
- If DTCs P0087, P0090, P0191, P0193, P0335, P0336, P0340, P0370, P0374, P0602, P0603, P0604, P0606, P0642, P0643, P064C, P0698, or P0699 are set diagnose those DTCs first.
- The engine starts and runs. If the engine does not start and run perform «Circuit/System Testing»(ref-238231-S09570586752006072400000) .
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Injector Replacement (Left) or Fuel Injector Replacement (Right)
Repair Verification
The engine starts and runs.
High Pressure System
The much larger section of the pump assembly is the high-pressure fuel injection pump. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the middle of the right fuel rail.
Return System
Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The Fuel Return System is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the Fuel Rail Pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank.
Reference Information
Special Tools Required
- EN-47620 Fuel Pressure Gage Adapter. See «Special Tools»(ref-238192-S04527813552006072400000) .
- J 34730-1A Fuel Pressure Gauge
- J 23738-A MityVac
- EN-47969 Fuel Supply Diagnostic Hose. See «Special Tools»(ref-238192-S04527813552006072400000) .
- J 44638 Vacuum Gage. See «Special Tools»(ref-238192-S04527813552006072400000) .
- J 44581 Fuel Line Disconnect Tool. See «Special Tools»(ref-238192-S04527813552006072400000) .
Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine RPM's increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should closely match each other.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Injection Pump Replacement
Fuel Sender Assembly Replacement
Inspect the fuel return hoses and lines on the engine and chassis for any external fuel leaks.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Return Pipe Replacement
Fuel Sender Assembly Replacement
Fuel Leaks
- Remove the air cleaner assemble. Refer to «Air Cleaner Assembly Replacement»(ref-238192-S34818141442006072400000) .
- Clean all of the fuel lines between the fuel injection pump and the fuel injectors using brake cleaning solvent, and let dry.
- Add 8 ounces of oil dye to the fuel tank. On dual tanks, add the dye to the front, or primary tank. Refer to «Fuel System Description»(ref-238192-S40364831082006072400000) .
- Start and idle the engine for 3-5 minutes.
- Command the fuel pressure control to 160 MPa (23,206 psi) with a scan tool.
- Inspect for fuel leaks around the fuel injection pump, fuel rails, and fuel injector supply lines with a J 28428-E High Intensity Black Light Kit. Tighten or replace any leaking lines or components. Refer to the following: «Fastener Tightening Specifications»(ref-238192-S02832481882006072400000) «Fuel Injection Line Routing Diagram»(ref-238192-S09070237682006072400000) «Fuel Injector Return Pipe Replacement -Left»(ref-238192-S16909334382006072400000) «Fuel Injector Return Pipe Replacement - Right»(ref-238192-S09151704722006072400000) «Fuel Return Pipe Replacement»(ref-238192-S07701809822006072400000) «Fuel Rail Assembly Replacement - Bank 1»(ref-238192-S35208429452006072400000) «Fuel Rail Assembly Replacement - Bank 2»(ref-238192-S33520819312006072400000) «Fuel Return Junction Block Replacement»(ref-238192-S33117743412006072400000) «Fuel Injection Pump Replacement»(ref-238192-S12947664392006072400000) «Fuel Injector Replacement (Left)»(ref-238192-S20160282322006072400000) «Fuel Injector Replacement (Right)»(ref-238192-S09868187502006072400000)
- A fuel leak may be caused by restricted return fuel lines. Refer to «Fuel Return System Diagnosis»(ref-238231-S42812026142006072400000) .
The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure medal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank.
The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors.
Special Tools Required
- J 45873 Fuel Return Volume Test Kit. See «Special Tools»(ref-238192-S04527813552006072400000) .
- J 45873-30 Fuel Injector Test Adapter Kit
- EN 47589 Fuel Pressure Adapter Caps. See «Special Tools»(ref-238192-S04527813552006072400000) .
With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
- «Fuel Injection Pump Replacement»(ref-238192-S12947664392006072400000)
- «Fuel Pressure Relief Valve Replacement»(ref-238192-S21031218502006072400000)
- «Fuel Injector Replacement (Left)»(ref-238192-S20160282322006072400000) or «Fuel Injector Replacement (Right)»(ref-238192-S09868187502006072400000)
Observe the Balancing Rate parameters with a scan tool. Normal reading should be between +4 mm 3 and -4 mm 3 at idle. With the engine running at idle, the Actual Fuel Rail Pressure should be close to the Desired Fuel Rail Pressure.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Pressure Regulator Replacement
Fuel Injector Replacement (Left) or Fuel Injector Replacement (Right)
Observe the Balancing Rate parameters with a scan tool. Normal reading should be between +4 mm 3 and -4 mm 3 in Neutral or Park and between +6 mm 3 and - 6 mm 3 in drive. With the engine running at idle the Actual Fuel Rail Pressure should be close to the Desired Fuel Rail Pressure.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
- «Fuel Pressure Regulator Replacement»(ref-238192-S31949039162006072400000)
- «Fuel Injector Replacement (Left)»(ref-238192-S20160282322006072400000) or «Fuel Injector Replacement (Right)»(ref-238192-S09868187502006072400000)
Leak Check Procedure
| CAUTION | Place a dry chemical (Class B) fire extinguisher near the area before performing a Fuel Tank Leak Check. Before removing the fuel tank for a suspected leak, make sure that the fuel pipes or the tubes are not leaking onto the tank. Once removed, make sure that the fuel is not leaking around the fuel sender O-ring. Failure to follow these precautions may result in personal injury. |
This check requires the fuel sender and the O-ring to be installed.
- Disconnect the battery cables.
- Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-238192-S29495647252006072400000) .
- Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-238192-S15561545472006072400000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-238192-S24497046942006072400000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-238192-S41211865872006072400000) .
- Cap the fuel feed tube and the fuel return tube on the fuel sender.
- Connect a piece of hose to the filler tube nipple and plug the opposite end.
- Submerge the tank in water or apply a soap solution to the outside of the tank.
- Apply 35 kPa (5 psi) of air pressure to the vent hose of the fuel tank. A leak will show up as bubbles.
Conditions for Updating the I/M System Status
Each system monitor requires at least one, and sometimes several, diagnostic tests. The results of these tests are reported by a DTC. A system monitor completes when either all DTCs comprising the monitor have run and passed, or any DTC comprising the monitor has illuminated the malfunction indicator lamp (MIL). Once the monitor completes, the I/M system status display will indicate YES in the Completed column. For example, when the Misfire Monitoring System Status display indicates YES, all of the misfire components have been diagnosed. The I/M system status will indicate NO in the Completed column when any of the required DTCs for that system have not run. The following is a list of conditions that would set the I/M System Status indicators to NO
- The vehicle is new from the factory and has not yet been driven through the necessary drive conditions to complete the system monitor.
- The battery has been disconnected or discharged below operating voltage.
- The control module power or ground has been interrupted.
- The control module has been reprogrammed.
- The control module DTCs have been cleared as part of a service procedure.
Monitored Emission Control Systems
The OBD II system monitors all emission control systems that are on-board. Not all vehicles have a full complement of emission control systems. For example, a vehicle may not be equipped with exhaust gas recirculation (EGR). The OBD II regulations require monitoring of the following
- Comprehensive component monitoring-Emission related inputs and outputs
- The EGR system
- Misfire monitoring
For the specific DTCs required for each system, refer to Inspection/Maintenance (I/M) System DTC Table .
Review the I/M system status indicators. All I/M system status indictors should report YES.
Always perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Conditions for Meeting a Cold Engine
- The battery voltage is between 11-18 volts.
- The engine coolant temperature (ECT) is between 57-104°C (133-219°F).
- The intake air temperature (IAT) is more than 5.25°C (41.5°F).
- The barometric pressure (BARO) is more than 74 kPa.
Review the I/M system status indicators. All I/M system status indictors should report YES.
Always perform the Diagnostic Repair Verification after completing the diagnostic procedure.
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Filter/Heater Element Housing Replacement
| IMPORTANT | Always perform the Diagnostic Repair Verification after completing the diagnostic procedure. |
Fuel Filter/Heater Element Housing Replacement