Driveability - Diesel - Non-Dtc-Based Diagnostics: Diagnosis Jeep Liberty II

Diagnostic Test

1. APP SENSOR IDLE VOLTAGE NOTE: If there are any Accelerator Pedal Position Sensor DTCs active in the ECM, diagnose DTCs before continuing this test. NOTE: The APP Sensor is a device that contains two separate potentiometer type sensors. Each sensor has its own 5-volt supply circuit, sensor ground circuit and signal circuit. The APP Sensor no longer incorporates a low-idle switch. NOTE: The APP Sensor 1 signal should always be double the voltage of the APP Sensor 2 signal. NOTE: Ensure the accelerator pedal is free from any restriction or binding before continuing. Turn the ignition on. With the scan tool, read the APP Sensor 1 and APP Sensor 2 Volts with the accelerator pedal in the at rest position. Does the scan tool display between 0.20 and 0.61 volt for sensor 1 and 0.10 and 0.30 volt for sensor 2? Yes Go to step 2 No Check the APP Sensor circuits for proper resistance. If no problems are found, replace the APP Sensor in accordance with the Service Information. Perform the ECM VERIFICATION TESt. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
2. APP SENSOR 1 While back probing, measure the voltage of the APP Sensor 1 Signal circuit at the ECM. Monitor the voltmeter while slowly pressing the accelerator pedal completely down. NOTE: APP signals are displayed in voltage and percentage on the scan tool. Although APP 1 voltage is double APP 2 voltage, the percentage display of APP 1 and APP 2 should be within 2.5% of each other during all phases of accelerator pedal travel. Did the voltage increase smoothly with pedal travel? Yes Go to step 3 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
3. APP SENSOR 2 While back probing, measure the voltage of the APP Sensor 2 Signal circuit at the ECM. Monitor the voltmeter while slowly pressing the accelerator pedal completely down. NOTE: APP signals are displayed in voltage and percentage on the scan tool. Although APP 1 voltage is double APP 2 voltage, the percentage display of APP 1 and APP 2 should be equal during all phases of accelerator pedal travel. Did the voltage increase smoothly with pedal travel? Yes Go to step 4 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
4. APP SENSOR WIDE OPEN THROTTLE VOLTAGE Fully depress the accelerator pedal. With the scan tool, read the voltage for APP Sensor 1 and APP Sensor 2. Does the scan tool display between 4.30 and 4.80 volts for sensor 1 and 2.15 and 2.40 volts for sensor 2? Yes Test Complete. No Check the APP Sensor circuits for proper resistance. If OK, replace the APP Sensor in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .

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1. ECM GROUND CIRCUIT(S) OPEN Turn the ignition off. Disconnect the ECM harness connectors. Using a 12-volt test light connected to 12-volts, check each of the ECM ground circuits in ECM harness connector C2 cavities 2, 4 and 6. Did the test light illuminate for each cavity? Yes Go to step 2 No Repair the ECM Ground circuit(s) for an open. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
2. (F202) FUSED IGNITION SWITCH START/RUN OUTPUT CIRCUIT OPEN Turn the ignition to the Start position. Using a 12-volt test light connected to ground, check the (F202) Fused Ignition Switch Start/Run Output circuit in ECM harness connector C2 cavity 41. Turn the ignition to the Run position. Using a 12-volt test light connected to ground, check the (F202) Fused Ignition Switch Start/Run Output circuit in ECM harness connector C2 cavity 41. Is the test light on for both ignition switch positions? Yes Go to step 3 No Repair the (F202) Fused Ignition Switch Start/Run Output circuit for an open. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
3. CHECKING THE ASD RELAY SYSTEM Turn the ignition off. Connect a jumper wire between ground and the (K51) ASD Relay Control circuit in ECM C2 harness connector cavity 42. Turn the ignition on. Using a 12-volt test light connected to ground, check the (F344) Fused ASD Relay Output circuits at the ECM C2 harness connector cavities 1, 3 and 5. Does the test light illuminate brightly for each circuit? Yes Test Complete. No Go to step 4
4. FUSED ASD RELAY BATTERY SUPPLY CIRCUIT OPEN Turn the ignition off. Remove the ASD Relay from the TIPM. Using a 12-volt test light connected to ground, check both Fused ASD Relay Battery Supply circuits in ASD Relay connector. Is the test light on? Yes Go to step 5 No Repair the Fused ASD Relay Battery Supply circuit(s) for an open. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
5. (F344) ASD RELAY OUTPUT CIRCUIT OPEN Connect a jumper wire between cavity 30 and cavity 87 in the ASD Relay connector. Using a 12-volt test light connected to ground, check the (F344) ASD Relay Output circuit in ECM harness connector C2 cavities 1, 3 and 5. Did the test light illuminate for each circuit? Yes Go to step 6 No Repair the (F344) ASD Relay Output circuit(s) for an open. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
6. ASD RELAY Turn the ignition off. Install a known good relay in place of the ASD Relay. Connect a jumper wire between ground and the (K51) ASD Relay Control circuit in ECM C2 harness connector cavity 42. Turn the ignition on. Using a 12-volt test light connected to ground, check the (F344) Fused ASD Relay Output circuits at the ECM C2 harness connector cavities 1, 3 and 5. Did the test light illuminate brightly for each circuit? Yes Replace the ASD Relay. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 7
7. (K51) ASD RELAY CONTROL CIRCUIT OPEN Turn the ignition off. Remove the ASD Relay from the TIPM. Measure the resistance of the (K51) ASD Relay Control circuit between the TIPM connector and the ECM harness connector. Is the resistance below 10.0 ohms? Yes Go to step 8 No Repair the (K51) ASD Relay Control circuit for an open. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
8. (K51) ASD RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector in the TIPM. Turn the ignition on. Measure the voltage on the (K51) ASD Relay Control circuit. Is the voltage above 1.0 volt? Yes Repair the (K51) ASD Relay Control circuit for a short to voltage. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Test Complete.

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For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS .

1. ECT SENSOR - COLD NOTE: The thermostat must be operating correctly for this test to be valid. With the scan tool in Sensors, read and note the engine coolant temperature. Using a temperature probe, measure the engine block temperature near the ECT Sensor. NOTE: The engine temperature should be below 50°C (120°F). Are the readings within 7°C (13°F) of each other? Yes Go to step 2 No Check the wiring and connectors associated with the ECT Sensor for corrosion, damage or other problems. Repair as necessary. If no problems are found, replace the Engine Coolant Temperature Sensor. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
2. ECT SENSOR - HOT NOTE: The thermostat must be operating correctly for this test to be valid. Start the engine and bring the engine to operating temperature (thermostat open). Turn the engine off and wait 10 minutes to allow the engine temperature to stabilize. Using a temperature probe, measure the engine block temperature near the ECT Sensor. With the scan tool, select Engine, then Sensors and read the engine coolant temperature. Are the readings within 7°C (13°F) of each other? Yes Test Complete. No Check the wiring and connectors associated with the ECT Sensor for corrosion, damage or other problems. Repair as necessary. If no problems are found, replace the Engine Coolant Temperature Sensor. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .

1. CHECKING ENGINE MECHANICAL WARNING: Do not attempt to remove or separate high pressure fuel line. Attempting to do so could result in possible serious or fatal injury. NOTE: The following items should be checked as a possible cause of a Driveability or No-Start problem: Engine Valve Timing - must be within specification Engine Compression - must be within specifications Camshaft Lobes - check for abnormal wear Camshaft Position Sensor - check the camshaft position sensor tooth for debris and deterioration Crankshaft Position Sensor - check the crankshaft magnetic strip for debris and deterioration Engine Exhaust System - must be free of any restriction Engine Drive Belt and Sprockets - must be properly positioned Vacuum System - must operate properly and be free of any vacuum leaks Fuel - must have adequate supply and must be free of contamination (ie. debris, water and gasoline) Fuel Injectors - must not be plugged or restricted Fuel Lift Pump - must operate properly (where applicable) Fuel Injection Pump - must be producing the correct output volume and pressure Inspect the Fuel Lines, Fuel Filter and Fuel Pressure Relief Valve for signs of restriction and leaks NOTE: Check for any Technical Service Bulletins that may relate to the problem. Are there any problems evident? Yes Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Test Complete.

1. VACUUM SUPPLY TO EGR SOLENOID Turn the ignition off. Disconnect the vacuum supply hose to the EGR Solenoid. Connect a vacuum gauge to the disconnected vacuum supply hose to the EGR Solenoid. Start and idle the engine. Observe the vacuum gauge reading. Does the vacuum gauge display vacuum above 24 inches of mercury? Yes Go to step 2 No Check vacuum pump and vacuum supply system for problems related to low vacuum. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
2. VACUUM SUPPLY TO EGR VALVE NOTE: The engine must be at operating temperature for this test. Turn the ignition off. Reconnect the vacuum supply hose to the EGR Solenoid. Disconnect the vacuum hose at the EGR Valve. Connect a vacuum gauge to the disconnected vacuum hose at the EGR Valve. Start and idle the engine. Observe the vacuum gauge reading for at least 10 minutes beginning at engine start up. Does the vacuum gauge display vacuum above 14 inches of mercury for approximately 10 minutes from engine start up then drop to 0? Yes Go to step 3 No Check the vacuum hose between the EGR Solenoid and the EGR Valve for crack, kinks cuts, or other damage that may prevent proper vacuum operation. If the hose is functioning properly, replace the EGR Solenoid. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
3. EGR VALVE Turn the ignition off. Reconnect the vacuum hose at the EGR Valve. Disconnect both vacuum hoses at the EGR Solenoid. Using a vacuum tee connector, connect both disconnected hose ends at the EGR Solenoid. NOTE: This test will apply continual vacuum to the EGR Valve. If the EGR Valve is functioning properly, a dramatic loss of engine power will occur when attempting to accelerate and/or load the engine. Test drive the vehicle. Does the vehicle exhibit a noticeable loss of power on acceleration? Yes Test Complete. No Replace the EGR Valve in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .

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For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS .

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1. VISUAL INSPECTION NOTE: If there are any DTCs present for the Fuel Pressure Solenoid, Fuel Quantity Solenoid, Fuel Injectors, or Fuel Pump Control Circuit or relay, repair those DTCs before continuing with the Fuel Delivery System test. NOTE: For best results, perform Fuel Delivery System test with vehicle at room temperature. Extreme cold temperatures can cause inaccurate results. NOTE: Make sure that the vehicle has at least 1/8 of a tank of fuel before proceeding with this test. Perform a visual inspection of the fuel system for any signs of a fuel leak. Were any signs of a leak detected? Yes Repair the leak. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 2
2. CHECKING SENSORS VALUES WITH THE SCAN TOOL Turn the ignition on, engine not running. With a scan tool, perform the following checks for a no start or hard start: Check and compare the values of the Ambient Temperature Sensor, Coolant Temperature Sensor and Fuel Temperature Sensor with the key on. The values should read within 5°C (41°F) of each other. Check and compare the values of the Air Inlet Pressure Sensor, Boost Pressure Sensor and Exhaust Differential Pressure Sensor. The sensors should read approximately the same. Check the Crank/Cam synchronization during cranking. Are the Cam and Crank sensors synchronized and the sensors reading normal? Yes Go to step 3 No Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
3. SCAN TOOL TEST Perform the following tests with the scan tool: Compression Test. The RPM drop in each cylinder should be approximately equal. Cylinder Balance Test. The RPM drop in each cylinder should be approximately equal. Injector Kill Test. The RPM drop in each cylinder should be approximately equal. Fuel Quantity Correction Test. Cylinder values should not exceed +4 mm 3 . Were any of the cylinders out of range as compared to the others during the scan tool tests? Yes Evaluate the results of the scan tool tests. If any of the cylinders are found to be performing poorly as compared to the others, check for engine mechanical issues on the suspect cylinder and repair as necessary. If a fuel injector is suspected, Go to step 4 No Go to step 5
4. CHECKING THE FUEL INJECTOR WIRING Disconnect the Fuel Injector harness connector of the suspect injector. Disconnect the Engine Control Module harness connector. Using the wiring diagram as a guide, perform the following measurements: Measure the resistance of the Fuel Injector High Side Control circuit between the Fuel Injector harness connector and the Engine Control Module harness connector. Measure the resistance of the Fuel Injector Low Side Control circuit between the Fuel Injector harness connector and the Engine Control Module harness connector. Is the resistance below 5.0 Ohms on both circuits? Yes Replace the Fuel Injector that has the highest Fuel Quantity Correction first. Replace only one injector at a time and perform the Scan Tool test procedure again. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Repair the open or high resistance in the circuit which was out of range. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
5. CHECKING FUEL PRESSURE NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the scan tool readings. It may be easier to track both values by using the graph feature on the scan tool in data display. With the scan tool, read and compare the Fuel Pressure reading with the Fuel Pressure Setpoint while cranking the engine on a no start, or while test driving the vehicle under various load conditions such as idle, hard acceleration, cruise and deceleration. NOTE: The Fuel Pressure reading should closely follow the Fuel Pressure Setpoint reading. Fuel Pressure should stay within approximately 100 psi of the Fuel Pressure Setpoint at steady state/idle and 300 psi at load transitions. Select the conclusion that best matches the result of the test: The Fuel Pressure reading follows closely to the Fuel Pressure Setpoint reading. Go to step 14 The Fuel Pressure reading is too low. Go to step 16 The Fuel Pressure reading is excessive. Go to step 6 The Fuel Pressure reading is oscillating excessively above and below the Fuel Pressure Setpoint reading. Go to step 21
6. CHECKING FUEL PRESSURE SOLENOID MINIMUM PRESSURE Turn the ignition off. Disconnect the Fuel Pressure Solenoid. Crank the engine for ten seconds. With the scan tool, read the Fuel Pressure. Select the conclusion that best matches the result of the test: Fuel pressure reading is at or below 950 psi (65.5 bar) Go to step 7 Fuel pressure reading is still above 950 psi (65.5 bar) Go to step 8
7. CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS Disconnect the Fuel Pressure Solenoid harness connector. Disconnect the Engine Control Module harness connector. Using the wiring diagram as a guide, measure the resistance between ground and the Fuel Pressure Solenoid Control circuit. Is the resistance below 10k Ohms? Yes Repair the short to ground in the Fuel Pressure Solenoid Control circuit. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Inspect the wiring harness for a possible intermittent short to ground. Check for proper routing of the harness. If the wiring harness is okay, replace the Engine Control Module. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
8. CHECKING FUEL RETURN PRESSURE AT THE FUEL PRESSURE SOLENOID Turn the ignition off for two minutes to make sure fuel pressure has purged from return system. Connect a separate hose to the fuel return outlet port of the fuel rail. Install a fuel pressure gauge inline of return line. Crank the engine or run the engine for ten seconds. Is the fuel return pressure below 14.5 psi (1 bar)? Yes Go to step 9 No Go to step 12
9. CHECKING FUEL RETURN VOLUME AT THE FUEL PRESSURE SOLENOID Turn the ignition off for two minutes to make sure fuel pressure has purged from return system. Disconnect the fuel pressure gauge. Connect a separate hose to the fuel return outlet port of the fuel rail and route the open end in a container (one liter capacity). Turn the ignition on for ten seconds. Is the measured volume of fuel above 200 ml? Yes Go to step 10 No Replace the Fuel Pressure Solenoid. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
10. CHECKING FUEL RETURN PRESSURE FROM THE HIGH PRESSURE DELIVERY PUMP Turn the ignition off. Reconnect the Back Flow Return Line at the fuel return outlet port of the fuel rail. Disconnect the Fuel Return Line coming from the High Pressure Delivery Pump at the Fuel Return Line junction/splice. Install a fuel pressure gauge inline between the Fuel Return Line and the splice. Crank the engine or run the engine for ten seconds. Is the fuel return pressure below 14.5 psi (1 bar)? Yes Go to step 11 No Go to step 12
11. CHECKING FUEL RETURN VOLUME AT THE HIGH PRESSURE DELIVERY PUMP Turn the ignition off for two minutes to make sure fuel pressure has purged from return system. Disconnect the fuel pressure gauge. Route the open end of the return line in a container (one liter capacity). Turn the ignition on for ten seconds. Is the measured volume of fuel above 200 ml? Yes Go to step 12 No Replace the High Pressure Delivery Pump. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
12. CHECKING THE BACKFLOW RETURN LINE Isolate for restriction in the Backflow Return Line by installing the fuel pressure gauge at different connecting points in the return line. Were any restrictions found in the Backflow Return Line? Yes Repair or replace the restricted part in the fuel return system. Debris in the system may indicate a failing component. Determine where the debris in the system came from and replace the component or repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 13
13. CHECKING THE FUEL RAIL PRESSURE SENSOR CIRCUITS Disconnect the Fuel Rail Pressure Sensor harness connector. Disconnect the Engine Control Module harness connector. Using the wiring diagram as a guide, measure the resistance between the Fuel Rail Pressure Sensor harness connector and the Engine Control Module harness connector of the: Fuel Rail Pressure Sensor 5-Volt Supply circuit. Fuel Rail Pressure Sensor Signal circuit. Fuel Rail Pressure Sensor Return circuit. Is the resistance below 5 Ohms for each circuit? Yes Replace the Fuel Rail Pressure Sensor. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Repair the circuit which has high resistance. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
14. CHECKING THE HIGH PRESSURE DELIVERY PUMP Turn the ignition off. Disconnect all four Fuel Injector harness connectors. Using the DRBIII® as a lab scope: Connect the positive lead to the signal circuit of the Rail Pressure Sensor by back probing the connector of the Rail Pressure Sensor. Be careful not to damage connector or terminals. Connect the negative lead to a good engine or chassis ground. Select PEP Module Tools on the DRBIII® screen. Select Lab Scope. Select Live Data. Select 5-Volt Sensor. Select Lab Scope with the F2 key. Select Start with the F3 key. Adjust the lab scope parameters as follows: Time - 0.2 s/Div. Voltage range - 2.0 Volts. Crank the engine for 10 seconds and press hold. NOTE: The High Pressure Delivery Pump uses three separate internal pistons to build high pressure in the fuel rail. The peaks on the lab scope correspond to the pressure spikes that occur when the pistons in the High Pressure Delivery Pump compress the fuel. Compare the graph of the vehicle with the two sample graph's provided. Figure one is an example of a properly working High Pressure Delivery Pump. Figure two is an example of a High Pressure Delivery Pump with one faulty piston. Are all three pistons operating properly in the High Pressure Delivery Pump? Yes Go to step 15 No Replace the High Pressure Delivery Pump. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
15. CHECKING FUEL QUALITY/CONTAMINATION Collect a fuel sample from the vehicle in a clean see through container. Collect a fuel sample of fresh clean fuel in a clean see through container for reference. Check the vehicle's fuel sample for the following: Check the color of the fuel. Diesel fuel will generally be a yellow color. Allow the fuel to settle and look for cloudiness indicating contamination. Check the volatility of the fuel. Look for a parting line in the fuel sample indicating another type of liquid mixed with the fuel. Look for any signs of debris in the fuel sample. Are there any signs of contamination or poor quality detected? Yes Refer to the Service Information to replace the fuel in the entire fuel system. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No The fuel system is operating normally. Check for any Service Bulletins that may apply. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
16. CHECKING THE FUEL LIFT PUMP OPERATION Turn the ignition on. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for the Fuel Lift Pump operation at the fuel tank. CAUTION: Stop all actuation tests before continuing. Does the Fuel Lift Pump operate? Yes Go to step 17 No Go to step 28
17. CHECKING THE LOW SIDE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Disconnect the Fuel Filter Outlet fuel line at the Fuel Filter. Install the Fuel Pressure Tester 8798 between the Fuel Filter Outlet port and the fuel line. Turn the ignition on. Using the scan tool, actuate the Fuel Pump Relay Control to ON (100%). Observe the fuel pressure gauge. NOTE: The fuel pressure should read between 50 psi (3.5 bar) and 65 psi (4.5 bar). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification. Go to step 19 Fuel pressure is below the stated specification. Go to step 18 Fuel pressure is above the stated specification. Check for a restriction in the fuel line between the Fuel Filter and the High Pressure Pump. If no restriction is found, the cascade valve is not working properly. Replace the High Pressure Delivery Pump. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
18. CHECKING THE FUEL PRESSURE BEFORE THE FUEL FILTER Turn the ignition off. Remove the Fuel Pressure Tester 8798 and reconnect the Fuel Filter Outlet line to the filter. Disconnect the Fuel Filter Inlet line at the Fuel Filter. Install the Fuel Pressure Tester 8798 between the Fuel Filter Inlet and the fuel line. Turn the ignition on. Using the scan tool, actuate the fuel pump relay control to ON (100%). Observe the fuel pressure gauge. NOTE: The fuel pressure should read between 50 psi (3.5 bar) and 65 psi (4.5 bar). CAUTION: Stop all actuation tests before continuing. Is the fuel pressure reading within the stated specification? Yes Replace the Fuel Filter. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 19
19. CHECKING THE FUEL PUMP MAXIMUM OUTPUT AND PRESSURE RELIEF VALVE Ignition on. Using the scan tool, actuate the fuel pump relay control to ON (100%). Observe the fuel pressure gauge. Close the valve after the gauge to allow maximum fuel pressure to build in the system. NOTE: The fuel pressure should read between 90 psi (6.5 bar) and 116 psi (8.5 bar). CAUTION: Stop all actuation tests before continuing. Is the fuel pressure within the stated specification? Yes If coming to this test step from step 17: Go to step 20 If coming to this test step from step 18: Replace the High Pressure Fuel Pump. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Check the fuel supply line for leaks. If the fuel supply line is okay, replace the Fuel Lift Pump Module. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
20. FUEL SUPPLY VOLUME TEST AT FUEL FILTER OUTLET Turn the ignition off. Reopen the valve after the gauge. Turn the ignition on. Open the valve leading into the measuring container. Using the scan tool, actuate the Fuel Pump Relay Control to ON (100%) for 10 seconds. Measure the amount of fuel collected in the container. CAUTION: Stop all actuation tests before proceeding. Is the measured volume of fuel above 450 ml? Yes Go to step 21 No Go to step 26
21. CHECKING THE FUEL SUPPLY SYSTEM FOR AIR Turn the ignition off. Remove the Fuel Pressure Tester 8798 from the line. Install a clear hose inline as close to the High Pressure Pump inlet as possible. Crank or star the engine and check for air bubbles in the clear tubing. Were any air bubbles evident in the clear tubing? Yes Work backward in the system to determine where air is entering the system and repair the leak. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No If you came to this test step from step 20: Go to step 22 If you came to this test step from step 5: Go to step 24
22. CHECKING THE FUEL PRESSURE SOLENOID FOR LEAKAGE Turn the ignition off. Disconnect the Back Flow Return Line at the Fuel Pressure Solenoid. Connect one end of a separate hose to the Fuel Rail Return Outlet Port and put the other end into a container. NOTE: Keep in mind that the High Pressure Delivery Pump Fuel Return and the Fuel Pressure Solenoid Fuel return are both connected to the fuel return line. The fuel return line should either be capped or put into a container during the next step to catch any fuel spillage. Crank the engine for 10 seconds and observe for any fuel coming from the Fuel Pressure Solenoid return. With the Fuel Pressure reading less than the Fuel Pressure Setpoint reading, the Fuel Pressure Solenoid should be closed and little or no fuel should be present. Is there any fuel present from the Fuel Pressure Solenoid during cranking? Yes Go to step 23 No Go to step 24
23. CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS Disconnect the Fuel Pressure Solenoid harness connector. Disconnect the Engine Control Module harness connector. Using the wiring diagram as a guide, measure resistance between the Fuel Pressure Solenoid harness connector and the ECM harness connectors the: Fuel Pressure Solenoid Control circuit. Fuel Pressure Solenoid 12-Volt Supply circuit. Is the resistance below 5.0 Ohms? Yes Replace the Fuel Pressure Solenoid in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Repair the circuit which is open or has high resistance. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
24. CHECKING THE HIGH PRESSURE DELIVERY PUMP Turn the ignition off. Reconnect the Back Flow Return Line at the Fuel Pressure Solenoid if disconnected. Disconnect all four Fuel Injector harness connectors. Using the DRBIII® as a lab scope: Connect the positive lead to the signal circuit of the Rail Pressure Sensor by back probing the connector of the Rail Pressure Sensor. Be careful not to damage connector or terminals. Connect the negative lead to a good engine or chassis ground. Select PEP Module Tools on the DRBIII® screen. Select Lab Scope. Select Live Data. Select 5-Volt Sensor. Select Lab Scope with the F2 key. Select Start with the F3 key. Adjust the lab scope parameters as follows: Time - 0.2 s/Div. Voltage range - 2.0 Volts. Crank the engine for 10 seconds and press hold. NOTE: The High Pressure Delivery Pump uses three separate internal pistons to build high pressure in the fuel rail. The peaks on the lab scope correspond to the pressure spikes that occur when the pistons in the High Pressure Delivery Pump compress the fuel. Compare the graph of the vehicle with the two sample graph's provided. Figure one is an example of a properly working High Pressure Delivery Pump. Figure two is an example of a High Pressure Delivery Pump with one faulty piston. Are all three pistons operating properly in the High Pressure Delivery Pump? Yes Go to step 25 No Replace the High Pressure Delivery Pump. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
25. FUEL QUANTITY SOLENOID Turn the ignition off. Disconnect the lab scope from the Rail Pressure Sensor. Turn the ignition on. Use a stethoscope the listen to the Fuel Quantity Solenoid. Using the scan tool, actuate the Fuel Quantity Solenoid. Use the table as a guide to check the operation of the Fuel Quantity Solenoid. Compare the audible sound with the PWM actuation percentage from the chart. FUEL QUANTITY SOLENOID ACTUATED SOUND FROM FUEL QUANTITY SOLENOID 0% NO SOUND AUDIBLE 20% SOUND STEADY BUT HARDLY NOTICEABLE 40% SOUND STEADY AND NOTICEABLE 60% SOUND STEADY AND LOUD 80% SOUND STEADY BUT HARDLY NOTICEABLE 100% NO SOUND AUDIBLE
26. FUEL SUPPLY VOLUME TEST AT FUEL FILTER INLET Turn the ignition off. Remove the Fuel Pressure Tester 8978A from between the Fuel Filter Outlet and the fuel line. Install the Fuel Pressure Tester 8978A between the Fuel Filter Inlet and the fuel line. Empty the fuel in the container. Turn the ignition on. Using the scan tool, actuate the Fuel Pump Relay Control to ON (100%) for 10 seconds. Measure the amount of fuel collected in the container. CAUTION: Stop all actuation tests before proceeding. Is the measured volume of fuel above 450 ml? Yes Replace the Fuel Filter. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 27
27. CHECKING FOR A RESTRICTED EVAPORATIVE EMISSIONS SYSTEM Turn the ignition off. Remove the Fuel Cap. Empty the fuel in the container. Turn the ignition on. Using the scan tool, actuate the Fuel Pump Relay Control to ON (100%) for 10 seconds. Measure the amount of fuel collected in the container. CAUTION: Stop all actuation tests before proceeding. Is the measured volume of fuel above 450 ml? Yes Repair the restriction in the Evaporative Emissions System causing the excessive vacuum. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Check the fuel supply line for leaks and restrictions. If the fuel supply line is okay, replace the Fuel Lift Pump Module. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
28. CHECKING THE FUEL PUMP CIRCUITS Turn the ignition on. Disconnect the Fuel Pump Module harness connector. Connect a 12-volt test light between the Fuel Pump Control Output circuit and the Ground circuit at the Fuel Pump Module harness connector (body side). With a scan tool, actuate the fuel pump control to ON (100%). NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. CAUTION: Stop all actuation tests before continuing. Is the test light illuminated and bright? Yes Replace the Fuel Lift Pump Module. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 29
29. FUEL PUMP OUTPUT CIRCUIT CHECK Using a 12-volt test light connected to ground, check the Fuel Pump Output circuit at the Fuel Pump Module harness connector. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Go to step 30 No Repair the Fuel Pump Output circuit for an open or short to ground. If the Fuel Pump Output circuit is okay, replace the Totally Integrated Power Module. Perform the BODY VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure»(ref-350093-S36937059432009121400000) .
30. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Using a 12-volt test light connected to 12 Volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Fuel Lift Pump Module in accordance with the Service information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Repair the Fuel Pump Ground circuit for an open circuit or high resistance. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .

1. ECM CODES PRESENT NOTE: The ECM must have proper power and ground connections for the following tests to be valid. Refer to «CHECKING THE ECM POWER AND GROUND CIRCUITS»(ref-350101-S14111147252009121400000) in the symptom list. Turn the ignition on. With the scan tool, read the ECM DTCs. Does the scan tool display any ECM DTCs? Yes Refer to symptom list for problems related to ECM DTC. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 2
2. WCM CODES PRESENT With the scan tool, read the WCM DTCs. Does the scan tool display any WCM/SKREEM DTCs? Yes Refer to «DTC-Based Diagnostics/MODULE, Wireless Control (WCM) - Diagnosis and Testing»(ref-350088-S20787830402009121400000) and perform the appropriate Diagnostic Procedure. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 3
3. CHECK FOR INTAKE SYSTEM RESTRICTIONS Turn the ignition off. Ensure vehicle has adequate fuel supply in fuel tank. Inspect all air intake and turbocharger related hoses/tubes and connections. Inspect the air filter for excessive dirt, soiling or other problems that may cause restricted air flow. Were any problems found? Yes Repair or replace as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) No Go To 4
4. ECT SENSOR Using a temperature probe, check the vehicle temperature near the ECT Sensor. Turn the ignition on. With the scan tool in Sensors, read the ECT Sensor temperature. Compare the temperature probe reading with the scan tool reading. Are the two readings within 10°C of each other? Yes Go to step 5 No Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
5. GLOW PLUGS NOTE: Prior to performing this test, be sure to check the Glow Plug operation. Refer to CHECKING GLOW PLUG OPERATION for the related symptom(s). Refer to the Service Information and check the Glow Plugs for proper operation. Are the Glow Plugs operating properly? Yes Go to step 6 No Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
6. FUEL SYSTEM RESTRICTION Inspect the fuel system lines for restrictions, leaks or other problems. NOTE: Refer to the Service Information to ensure that the fuel system is properly primed. A non-primed system or excessive air in the supply system will cause a no-start condition. Is there any evidence of problems? Yes Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 7
7. FUEL CONTAMINATION Inspect the fuel supply for contamination. Is the fuel contaminated? Yes Refer to the Service Information to remove and replace fuel throughout the fuel system. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 8
8. SUPPLY SIDE FUEL SYSTEM PRESSURE Refer to and perform the Checking the Low Pressure Fuel Delivery System Test in this section. Is the fuel pressure within specification? Yes Go to step 9 No Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
9. FUEL PRESSURE SENSOR Turn the ignition on, engine off. With the scan tool, read the Fuel Pressure Sensor volts. Is the Fuel Pressure Sensor voltage 0.45 and 0.60 volt? Yes Go to step 10 No Refer to the Wiring Information to check Fuel Pressure Sensor circuits. If no problems are found, replace the Fuel Pressure Sensor.
10. CHECK FUEL PRESSURE AT ENGINE CRANKING With the scan tool, read the Fuel Pressure Sensor signal while cranking the engine. Does the Fuel Pressure Sensor signal increase to above 4300 psi (300 bar) within a few seconds after engine cranking begins? Yes Go to step 11 No Go to step 13
11. FUEL INJECTOR LOW-SIDE CONTROL CIRCUIT(S) SHORTED TO VOLTAGE Turn the ignition off. Disconnect the each Fuel Injector harness connector. Disconnect the ECM harness connectors. Remove the ASD Relay from the TIPM. Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay Connector. Turn the ignition on. Measure the voltage of each Fuel Injector Low-Side Control circuit in the Fuel Injector harness connectors. Is there any voltage present? Yes Repair the Fuel Injector Low-Side Control circuit(s) for a short to voltage. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go To 12
12. ENGINE DRIVE BELT Refer to the Service Information to ensure the Engine Drive Belt is installed correctly and the camshaft and crankshaft gears are timed correctly. Were any problems found? Yes Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Replace and program the Engine Control Module in accordance with the Service Information.
13. FUEL PRESSURE SOLENOID Turn the ignition off. Refer to the Service Information and replace the Fuel Pressure Solenoid. Turn the ignition on. With the scan tool, erase the ECM DTCs. Attempt to start the vehicle. Does the vehicle start and run? Yes Repair is complete. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Refer to the Service Information and replace the Fuel Injection Pump assembly. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .

1. CHECKING FOR ECM DTCS WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury. Turn the ignition on. With the scan tool, read the ECM DTCs. Are there any DTCs present? Yes Refer to symptom list for problems related to this DTC. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) No Go to step 2
2. FUEL SYSTEM LEAK Turn the ignition off. WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury. Inspect the entire fuel system for leakage. Is there any evidence of leakage? Yes Repair as necessary in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 3
3. FUEL SYSTEM CONTAMINATION NOTE: Mixing any other fuels such as gasoline or kerosine can cause this symptom to occur. Turn the ignition off. WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury. Inspect the fuel system for contamination. Is the fuel contaminated? Yes Repair as necessary in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 4
4. CHECKING BOOST PRESSURE Turn the ignition on. NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the scan tool readings. With the scan tool in Sensors, read and compare the Boost Pressure (PSI) with the Boost Pressure Desired/Setpoint (PSI) while test driving the vehicle under various load conditions such as idle, hard acceleration, and cruise. NOTE: The Boost Pressure reading should directionally follow (trail) the Boost Pressure Desired/Setpoint reading. Does the Boost Pressure reading follow the Boost Pressure Desired/Setpoint reading? Yes Go to step 5 No Go to step 13
5. CHECKING FUEL PRESSURE Turn the ignition on. NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the scan tool readings. With the scan tool in Sensors, read and compare the Fuel Pressure (PSI) with the Fuel Pressure Desired/Setpoint (PSI) while test driving the vehicle under various load conditions such as idle, hard acceleration, cruise and deceleration. NOTE: The Fuel Pressure reading should directionally follow (trail) the Fuel Pressure Desired/Setpoint reading. Does the Fuel Pressure reading directionally follow the Fuel Pressure Desired/Setpoint reading? Yes Go to step 6 No Go to step 10
6. INJECTOR QUANTITY ADJUSTMENT NOTE: Each Fuel Injector is labeled with a code. This code determines the injector quantity adjustment. Each Injector code must be programmed into the ECM using the scan tool. Turn the ignition off. Refer to the Service Information to locate each fuel injector label and check for the correct code for each fuel injector in the ECM. Are all of the injector codes correct? Yes Go to step 7 No Using the scan tool, program the correct Fuel Injector code into the ECM. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) .
7. ENGINE COMPRESSION Start and idle the engine. With the scan tool, perform the Cylinder Compression Test. Does the Cylinder Compression Test indicate low compression in any of the cylinders? Yes Using the Service Information, repair the engine as necessary to regain proper cylinder compression. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 8
8. FUEL INJECTOR NOTE: An injector that sticks open can cause this symptom. A sticking injector will cause the engine to misfire and emit excessive black smoke from the exhaust system. Start and idle the engine. With the scan tool, perform the Cylinder Fuel Quantity Correction Test. NOTE: A problem injector will be indicated by a significant change in correction quantity as compared to the rest of the injectors. Are any of the injectors displaying a significant amount of injection quantity correction? Yes Using the Service Information, remove and inspect the Fuel Injectors for signs of damage or debris that may cause the injector to stick. Sticking injectors may cause the combustion chamber to become black and oil soaked. Replace Injector(s) as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 9
9. ENGINE DRIVE BELT/CHAIN Refer to the Service Information to ensure the Engine Drive Belt/Chain is installed correctly and the camshaft and crankshaft gears are timed correctly. Were any problems found? Yes Repair as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Test Complete.
10. CHECKING THE SUPPLY SIDE FUEL DELIVERY SYSTEM Refer to the Checking the Low Pressure Fuel Delivery System Test and test for proper Fuel pressure and volume from the fuel tank to the high pressure Fuel Injection Pump. NOTE: The following is a list of problems that can cause fuel pressure to deviate from specification: restricted fuel filter or fuel lines, air in fuel system, failed fuel sending unit, contaminated fuel. Were there any problems with the Fuel Delivery System? Yes Repair as necessary in accordance with the Service Information. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 11
11. CHECKING FOR AIR IN FUEL SYSTEM Start the engine. With the scan tool in Sensors, compare the Fuel Pressure Setpoint with the Actual Fuel Pressure readings. NOTE: If there is air in the fuel system, the Actual Fuel Pressure will oscillate more than 100 psi (7.0 bar) above and/or below the Fuel Pressure Setpoint. Does Actual Fuel Pressure oscillate more than 100 psi (7.0 bar) above and/or below the Fuel Pressure Setpoint? Yes Refer to the Service Information to purge air from the fuel system. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 12
12. FUEL PRESSURE SOLENOID Turn the ignition off. Replace the Fuel Pressure Solenoid in accordance with the Service Information. Test drive the vehicle. Does the vehicle still exhibit a lack of power? Yes Refer to the Service Information and replace the Fuel Injection Pump assembly. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Test Complete.
13. CHECK FOR INTAKE AND EXHAUST SYSTEM RESTRICTIONS Turn the ignition off. Inspect the exhaust system for damaged components that could cause exhaust flow blockage. Inspect all air intake, crankcase vent and turbocharger related hoses/tubes and connections for damage, air leaks or blockage. Inspect the Charge Air Cooler hoses/tubes and connections. Inspect the air filter for excessive dirt, soiling or other problems that may cause restricted air flow. Were any problems found? Yes Repair or replace as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 14
14. CHECKING FOR AIR LEAKS NOTE: Inspect all air intake and turbocharger related tubes for damage, restriction or poor connection. Any of these conditions can cause a poor performance/lack of power symptom. Turn the ignition off. Remove the Crankcase Vent Heater. Remove the Mass Air Flow Sensor from the turbocharger inlet tube. Seal off and/or plug the turbocharger inlet tube where the MAF sensor was removed. Connect smoke machine 84-04 to the Crankcase Vent Heater port in the intake duct and begin injecting smoke into the intake system. Observe all intake system components for evidence of smoke leakage. Is there evidence of smoke leakage? Yes Repair or replace as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Go to step 15
15. EGR SYSTEM See «Non-DTC Diagnostics/Driveability - Diesel - Diagnosis and Testing»(ref-350101-S38901574232009121400000) and perform the CHECKING THE EGR SYSTEM test. Were any problems found during the EGR System test? Yes Repair or replace as necessary. Perform the ECM VERIFICATION TEST. Refer to «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) . No Check for proper linkage connection between the Boost Pressure Servo Motor and the Turbocharge assembly. Repair or replace as necessary. If OK, refer to the Service Information and replace the Turbocharger assembly.