1 Mbe900 05a

15 TROUBLESHOOTING
Section Page
15.1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .................................................................................................. 15-3
15.2 GENERAL TROUBLESHOOTING ........................................................... 15-11
15.3 FUEL INJ ECTION TROUBLESHOOTING ............................................... 15-24
15.4 MISFIRING CYLINDER ........................................................................... 15-46
15.5 STARTING DIFFICULTY (ENGINE ROTATES) ....................................... 15-56
15.6 NO START (ENGINE WILL NOT ROTATE) ............................................. 15-71
15.7 EXCESSIVE OIL CONSUMPTION .......................................................... 15-76
15.8 EXCESSIVE CRANKCASE PRESSURE ................................................. 15-83
15.9 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY) ............................ 15-90
15.10 EXCESSIVE BLUE SMOKE .................................................................... 15-107
15.11 EXCESSIVE WHITE SMOKE .................................................................. 15-112
15.12 ROUGH RUNNING OR STALLING .......................................................... 15-122
15.13 LACK OF POWER ................................................................................... 15-126
15.14 LOWOIL PRESSURE ............................................................................. 15-140
15.15 HIGH ENGINE COOLANT TEMPERATURE ........................................... 15-151
15.16 LOWCOOLANT TEMPERATURE ........................................................... 15-162
15.17 POOR FUEL ECONOMY ......................................................................... 15-165
(Rev. 2005) All information subject to change without notice.
15-2 FromBulletin 1MBE90005 6SE414 0404 Copyright 2005DETROIT DIESEL CORPORATION
MBE900 SERVICE MANUAL
15.1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM
Prior toperformingtroubleshootingtasksfamiliarizeyourself withSafety Instructions and
PrecautionsfoundintheGeneral InformationSection.
Whentheelectronicenginecontrol systemdetectsafault, it broadcastsamessageonthedatalink.
Thedashdisplaywill showthecode"128," indicatingthereisanenginefault.
Troubleshootingproblemsandsolutionsfor theMBE 900enginearelistedinTable15-1and15-2.
Probl em Recommended Soluti on
The Engine Will Not Crank Listed in Table 15-10
The Engine Turns Slowly Listed in Table 15-11
The Engine Cranks, But Won't Start Listed in Table 15-12
The Engine Starts Only After Cranking for a Long Time Listed in Table 15-13
The Engine Starts, But Dies Listed in Table 15-14
The Engine Fan Doesn't Work Listed in Table 15-15
The Engine Fan is Constantly On Listed in Table 15-16
Fuel Consumption is Too High Listed in Table 15-17
The Engine Performs Poorly, Does Not Develop Full
Power
Listed in Table 15-18
The Engine is in Emergency Running Mode (constant
speed 1300 rpm)
The Coolant Temperature is Above Normal Listed in Table 15-20
The Coolant Temperature is BelowNormal Listed in Table 15-21
The Cooling Systemis Losing Coolant Listed in Table 15-22
There is Coolant in the Engine Oil Listed in Table 15-23
There is Foamin the Engine Oil Listed in Table 15-24
The Engine Oil Pressure is Low Listed in Table 15-25
The Engine Exhaust is White Listed in Table 15-26
The Engine Exhaust is Black Listed in Table 15-27
The Engine Exhaust is Blue Listed in Table 15-28
The Engine Brake Performance is Poor Listed in Table 15-29
Cruise Control is Not Working Listed in Table 15-30
The Fuel Pressure is Too High Downstreamof the Fuel
Filter
Fuel Flows Out of the Fuel Return Line Listed in Table 15-32
Table 15-1 Engine Troubleshooting Problems and Recommended Solutions
(1 of 2)
All information subject to change without notice. (Rev. 2005)
6SE414 0404 Copyright 2005DETROIT DIESEL CORPORATION FromBulletin 1MBE90005 15-3
Probl em Recommended Solution
Fuel FlowQuantity is Too Lowat the OverowValve and
Too High at the Filter
Fuel FlowQuantity is Too Lowat the OverowValve and
Within Range at the Filter
The Fuel Inlet Pressure is Too Low Listed in Table 15-35
The Fuel Inlet Pressure is Too High Listed in Table 15-36
The LowPressure Fuel Systemis Leaking Listed in Table 15-37
Table 15-2 Engine Troubleshooting Problems and Recommended Solutions
(2 of 2)
NOTE:
To read the complete fault code, use a minidiag2 or Diagnostic Data Reader (DDR).
15.1.1 Engine Fault Codes
Theenginefault codesandtheir causesarelistedinTable15-3:
J1939
SPN
J1587
PID
J1587
SID
FMI Descripti on
45 45 3 Grid Heater Open Circuit
45 45 4 Grid Heater Shortened to Ground
45 45 14 Grid Heater Special Instructions
45 45 12 Grid Heater Defect
84 84 1 Vehicle Speed Sensor Anti-tamper Fault 1
84 84 5 Vehicle Speed Sensor Anti-tamper Fault 2
84 84 0
Vehicle Speed Sensor Data Valid but Above Normal
Range
84 84 3 Vehicle Speed Sensor Open Circuit
84 84 4 Vehicle Speed Sensor Short to Ground
84 84 2
Vehicle Speed Sensor Data Erratic (Output shaft speed
fromJ 1939 ETCI not in normal range)
84 84 14 Vehicle Speed Sensor not Plausible
86 86 14 Adaptive Cruise Control Fault
91 91 3 AcceleratorPedal VoltageAboveNormal orShortedHigh
91 91 4 Accelerator Pedal VoltageBelowNormal or ShortedLow
91 91 2 Accelerator Pedal Data Erratic
Table 15-3 DDEC-VCU and DDEC-ECU Fault Codes (1 of 7)
J1939
SPN
J1587
PID
J1587
SID
FMI Descri pti on
94 94 3 Fuel Pressure Sensor Open Circuit
94 94 4 Fuel Pressure Sensor Short to Ground
94 94 0 Fuel Pressure High
94 94 1 Fuel Pressure Low
94 94 2 Engine Fuel Pressure Sensor Data Not Correct
94 94 14
Engine Fuel Pressure Sensor Measured Data Not
Correct
95 95 0 Fuel Restriction High
95 95 3 Fuel Restriction Circuit Failed High
95 95 4 Fuel Restriction Circuit Failed Low
98 98 14 Engine Oil Level Data Valid but Very low
98 98 0 Engine Oil Level High
98 98 1 Engine Oil Level Low
98 98 3 Engine Oil Level Sensor Voltage High
98 98 4 Engine Oil Level Sensor Voltage Low
98 98 5 Engine Oil Level Sensor Open Circuit
98 98 2 Engine Oil Level Too High or Too Low
100 100 1 Engine Oil Pressure Low
100 100 3 Engine Oil Pressure Sensor Open Circuit
100 100 2 Engine Oil Pressure Sensor Data Erratic
100 100 4 Engine Oil Pressure Sensor Short to Ground
100 100 14 Engine Oil Pressure Too Low
102 102 0 Boost Pressure High
102 102 1 Boost Pressure Low
102 102 2 Boost Pressure Sensor Data Erratic
102 102 3 Boost Pressure Sensor Open Circuit
102 102 4 Boost Pressure Sensor Short to Ground
102 102 13 Boost Pressure Out of Range
103 103 7 Turbocharger 1 No Rev
103 103 14 Turbocharger 2 No Rev
105 105 3 Intake Manifold Temperature Sensor Open Circuit
105 105 4 Intake Manifold Temperature Sensor Short to Ground
105 105 0 Intake Manifold Temperature High
107 107 0 Air Filter Restriction High
J1939
SPN
J1587
PID
J1587
SID
FMI Descripti on
107 107 3 Air Filter Sensor Open Circuit
107 107 4 Air Filter Sensor Short to Ground
110 110 14 Engine Coolant Temperature Very High
110 110 0 Engine Coolant Temperature High
110 110 4 Engine Coolant Temperature Sensor Short to Ground
110 110 3 Engine Coolant Temperature Sensor Open Circuit
111 111 1 Coolant Level Low
111 111 3 Coolant Level Sensor Open Circuit
111 111 4 Coolant Level Sensor Short to Ground
111 111 14 Coolant Level Very Low
123 7 Optimized Idle (OI) Loop Fault
158 158 0 Switched Battery Voltage High
158 158 1 Switched Battery Voltage Low
158 158 2
Switched Battery Voltage Does Not match DDEC-ECU
and DDEC-VCU
168 168 3 Battery Voltage High
168 168 4 Battery Voltage Low
174 174 3 Fuel Temperature Sensor Open Circuit
174 174 4 Fuel Temperature Sensor Short to Ground
175 175 3 Engine Oil Temperature Sensor Open Circuit
175 175 4 Engine Oil Temperature Sensor Short to Ground
190 190 0 Engine Speed High
216 216 14 Other DDEC-ECU Fault (Missing Information)
230 230 1 Idle Variation Switch (IVS) Wired Backwards
404 404 0 Turbo Compressor Out Temp High
404 404 1 Turbo Compressor Out Temp Low
527 254 12 Cruise Control DDEC-VCU Internal Error
558 230 5 Idle Validation Switch (IVS) Open Circuit
558 230 12
Both Idle Validation Switches Closed
Idle Validation Switch (IVS) not Idle and Accelerator
Pedal Signal Idle
Idle Validation Switch Idle (IVS) and Accelerator Pedal
Signal not Idle
599 242 12
Cruise Control Switch Contact Set +Coast Both SET
and RES Contacts Closed at the Same Time
J1939
SPN
J1587
PID
J1587
SID
FMI Descripti on
601 243 12
Cruise Control Switch Contact Resume &Accel Both
contacts are closed at the same time.
609 233 2 Anti-Theft Device Wrong Key
609 233 9 Anti-Theft No Transponder Code on Hardwire
609 233 11 Anti-Theft Calibration Error
609 233 0 Anti-Theft No Additional Key Can be Learned
609 233 12 DDEC-ECU Failure
609 233 14 DDEC-ECU Calibration Error
611 151 4 Oil Separator Diagnosis Short to Ground
611 151 12 Oil Separator Defect
620 232 2 Throttle Pedal Supply Data Erratic
620 232 3 Throttle Pedal Supply Above Normal
620 232 4 Throttle Pedal Supply BelowNormal
625 248 14 Proprietary Data Link CAN Failed
625 248 2
Proprietary Data Link No Communication Between
ECU and VCU
629 254 12 DDEC-VCU Internal Error ChecksumFault Flash
630 253 9 Engine Brake Calibration Parameters Invalid
633 21 1 Crankshaft Position Sensor Signal Voltage Too Low
633 21 7 No Match of Camshaft and Crankshaft Signals
633 21 8 Crankshaft Position Sensor Time Out
633 21 14 Crankshaft Position Sensor Pins Swapped
633 21 4 Crankshaft Position Sensor Short to Ground
633 21 3 Crankshaft Position Sensor Open Circuit
639 231 2 J 1939 ETCI Message Missing
651 1 6 Injector Cylinder #1 Shorted Circuit
651 1 7 Injector Cylinder #1 No Plunger
651 1 5
Injector Cylinder #1 Current BelowNormal or Open
Circuit
651 1 4 Injector Cylinder #1 Short to Ground
651 1 3 Injector Cylinder #1 Shorted High
651 1 12 Injector Cylinder #1 Idle Smoothness Governor at Limit
651 1 14 Injector Cylinder #1 Single Cylinder Correction at Limit
J1939
SPN
J1587
PID
J1587
SID
FMI Descri ption
652 2 5 Injector Cylinder #2Current BelowNormal or OpenCircuit
677 39 3 Engine Starter Relay Shorted to High Source
J1939
SPN
J1587
PID
J1587
SID
FMI Descri ption
677 39 5 Engine Starter Relay Open Circuit
677 39 6 Engine Starter Relay Shorted to Ground
677 39 7 Engine Starter Relay Starter Does Not Engage
677 39 14 Engine Starter Relay J ammed
696 57 3 Aux PWM #1 Shorted High
696 57 4 Aux PWM #1 Short to Ground
696 57 5 Aux PWM #1 Open Circuit
696 57 6 Aux PWM #1 High Side Line Shorted to Ground
705 53 4 Aux PWM #5 Short to Ground
705 53 11 Aux PWM #5 Bank 2 Shorted
723 64 3 Camshaft Position Sensor Open Circuit
723 64 4 Camshaft Position Sensor Short to Ground
723 64 8 Camshaft Position Sensor Time Out
723 64 14 Camshaft Position Sensor Pins Swapped
71 5 Grid Heater Valve Open Circuit
71 6 Grid Heater Valve Short to Ground
730 38 0 Grid Heater No Increase Boost Temperature
730 38 1 Grid Heater Relay Closed
730 38 2 Grid Heater Relay Open
730 38 3 Grid Heater Open Circuit
730 38 4 Grid Heater Short to Ground
974 29 2 Remote Throttle Pedal Supply Out of Range
974 29 3 Remote Throttle Pedal Supply Open Load
974 29 4 Remote Throttle Pedal Short to Ground
986 159 0 Fan Speed Time Out
1004 56 3 Accessory Bus Shutdown Open Circuit
1004 56 4 Accessory Bus Shutdown short to Ground
1005 43 3 Gear Output 1 Open Circuit
1005 43 4 Gear Output 1 Short to Ground
1006 44 3 Gear Output 2 Open Circuit
1006 44 4 Gear Output 2 Short to Ground
2791 146 0 EGR Temperature High
2791 146 1 EGR Temperature Low
2791 146 2 EGR SystemData Erratic
2791 146 7 EGR Valve Not Responding
2791 146 12 EGR Bad Component
15.2 GENERAL TROUBLESHOOTING
Thetablesthatfollowaredesignedtoidentifythecausesof commonproblemsandsuggestfurther
checksandappropriateremedies. Whentechnical support isnecessary, itisaddressedinthetable.
NOTE:
Resolve all electronic diagnostic codes prior to performing mechanical checks.
Probl em - The Engi ne Wi ll Not Crank
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged and/or corroded. Replace the battery cables.
The starter is damaged and/or worn. Replace the starter.
The clutch or transmission is damaged. Refer to OEM guidelines.
There is internal damage to the engine. Repair the internal damage.
Table 15-10 Problem The Engine will Not Crank
Probl emThe Engi ne Turns Over Sl owl y
Cause Remedy
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged and/or corroded. Replace the battery cables.
The starter is damaged and/or worn. Replace the starter.
The engine oil does not meet the correct specications. Change the engine oil, using the correct type of oil.
The transmission uid does not meet the correct
specications.
Change the transmission uid, using the correct type
of uid.
Table 15-11 Problem The Engine Turns Over Slowly
Probl emThe Engine Cranks, But Won' t Start
Cause Remedy
The cranking speed is slow. Inspect the starter. Replace if needed.
No intake air preheater is installed, and it is too cold to
start without one.
Install an intake air preheater.
The intake air preheater is malfunctioning.
Check the intake air preheater, and replace it, if
necessary.
The camshaft TDC sensor and/or the crank angle
position sensor are out of adjustment.
Push both sensors into their holes as far as they will go.
If this does not solve the problem, replace the sensor(s).
position sensor are damaged.
Replace the camshaft TDC sensor and/or the crank
angle position sensor.
There is air in the fuel system.
Check the fuel lines for leaks. Bleed the fuel system
and start the engine according to the instructions in the
service manual.
The air lter is clogged. Clean or replace the air lter.
The fuel lter is clogged. Replace the lter element.
The exhaust brake valve is malfunctioning. Repair or replace the exhaust brake valve.
The valves are not adjusted properly. Check the valve lash.
There are other problems in the fuel system. Check the fuel system.
Table 15-12 Problem The Engine Cranks, But Won't Start
Probl emThe Engi ne Starts Onl y After Cranki ng for a Long Ti me
Cause Remedy
The fuel tank is lowor empty. Add fuel and bleed the fuel system, if necessary.
There are leaks in the fuel lines.
Check the fuel lines for leaks and repair them, if
necessary.
The fuel line, the fuel pre-lter, or the screen in the fuel
tank is blocked.
Clean and bleed the system. Check the fuel lines and
lters. Repair or replace as necessary.
If this does not solve the problem, replace the camshaft
TDC sensor and/or crank angle sensor.
Replace the camshaft TDC sensor and/or the crank
angle position sensor.
Table 15-13 Problem The Engine Starts Only After Cranking for a Long Time
Probl emThe Engi ne Starts, But Di es
Cause Remedy
The fuel tank is lowor empty. Add fuel and bleed the fuel system, if necessary.
The fuel line, the fuel pre-lter, or the screen in the fuel
tank is blocked.
Clean and bleed the system. Check the fuel lines and
lters.
If this does not solve the problem, replace the camshaft
TDC sensor and/or crank angle sensor.
Replace the camshaft TDC sensor and/or crank angle
position sensor.
The constant-throttle valve(s) are malfunctioning. Replace the constant throttle valve(s).
Table 15-14 Problem The Engine Starts, But Dies
ProblemThe Engine Fan Doesn' t Work
Cause Remedy
The fan hub is damaged. Replace the fan hub.
The fan wiring is damaged. Repair the fan wiring.
Theparameter settings intheDDEC-ECU or DDEC-VCU
are incorrect.
Contact Detroit Diesel Customer Support Center at
3135925800.
Table 15-15 Problem The Engine Fan Doesn't Work
Probl emThe Engi ne Fan Is Constantl y On
Cause Remedy
The fan override switch is on. Check the operation of the fan override switch.
The fan hub is damaged. Replace the fan hub.
Theparameter settings intheDDEC-ECU or DDEC-VCU
are incorrect.
3135925800.
Table 15-16 Problem The Engine Fan is Constantly On
Probl emFuel Consumpti on Is Too Hi gh
Cause Remedy
The tires are not properly inated. Check all tires for correct pressure.
The air lter and/or intake air systemis clogged.
Check the air restriction indicator. Clean the intake air system
and replace the air lter if necessary.
The exhaust brake valve is malfunctioning. Check the operation of the valve. Replace if necessary.
The engine performs poorly, or does not develop
full power.
The remedies are listed in Table 15-21 "The Engine Performs
Poorly, Does Not Develop Full Powerin this section.
Table 15-17 Problem Fuel Consumption is Too High
ProblemThe Engi ne Performs Poorl y, Does Not Develop Full Power
Cause Remedy
Check the air restriction indicator. Clean the intake air
systemand replace the air lter if necessary.
The exhaust brake valve is malfunctioning. Repair or replace exhaust brake valve.
There are other problems with the fuel system. Check the fuel system.
The coolant temperature sensor is damaged or reading
incorrectly.
Replace the coolant temperature sensor.
The fuel temperature sensor is damaged or reading
incorrectly.
Replace the fuel temperature sensor.
The engine oil temperature sensor is damaged or
reading incorrectly.
Replace the oil temperature sensor.
The charge air temperature sensor is damaged or
reading incorrectly.
Replace the charge air temperature sensor.
There are problems with the DDEC-ECU or DDEC-VCU.
3135925800.
There is internal damage to the engine. Repair the internal damage.
Table 15-18 Problem The Engine Performs Poorly, Does Not Develop Full
Power
Probl emThe Engi ne Is i n Emergency Running Mode (constant speed 1300 rpm)
Cause Remedy
The DDEC-ECU or DDEC-VCU is damaged. Replace the DDEC-ECU or DDEC-VCU.
Table 15-19 Problem The Engine is in Emergency Running Mode (constant
speed 1300 rpm)
Probl emThe Cool ant Temperature Is Above Normal
Cause Remedy
The coolant level is too low. Check for coolant leaks, and repair as needed.
The poly-vee belt is loose. Tighten or replace the poly-vee belt.
The coolant temperature gauge and/or sensor is not
reading correctly.
Replace the coolant temperature gauge and/or sensor.
The radiator is damaged or dirty.
Clean the radiator. Repair or replace the radiator if
necessary.
The coolant pump is damaged. Replace coolant pump.
The thermostat is damaged. Replace the thermostat.
The fan is not operating properly.
Check the fan hub.
Contact Detroit Diesel Customer Support Center
at 3135925800 to have parameter settings
reprogrammed in the DDEC-ECU or DDEC-VCU.
Table 15-20 Problem The Coolant Temperature is Above Normal
ProblemThe Cool ant Temperature Is Bel ow Normal
Cause Remedy
The coolant temperature gauge and/or sensor is not
reading correctly.
Replace the coolant temperature gauge and/or sensor.
The thermostat is damaged. Replace the thermostat.
The fan is not operating properly.
Check the fan hub.
Contact Detroit Diesel Customer Support Center
at 3135925800 to have parameter settings
reprogrammed in the DDEC-ECU or DDEC-VCU.
Table 15-21 Problem The Coolant Temperature is Below Normal
Probl emThe Cool ing System Is Losi ng Coolant
Cause Remedy
There is an external coolant leak. Repair the leaking component.
The radiator cap is leaking. Replace the radiator cap.
The air compressor head is damaged. Replace the air compressor.
The cylinder head gasket is leaking. Replace the head gasket.
Table 15-22 Problem The Cooling System is Losing Coolant
Probl emThere Is Coolant in the Engine Oil
Cause Remedy
The cylinder head gasket is damaged. Replace the head gasket.
The oil/water heat exchanger is leaking. Replace the heat exchanger.
There is an internal coolant leak. Check the cooling systemfor leak and repair.
Table 15-23 Problem There is Coolant in the Engine Oil
Probl emThere Is Foam in the Engi ne Oi l
Cause Remedy
The oil level is too lowor too high. Correct the oil level.
The oil has not been changed within the recommended
interval.
Change the oil.
The oil is not of the recommended quality. Change the oil.
Table 15-24 Problem There is Foam in the Engine Oil
Probl emThe Engi ne Oil Pressure Is Low
Cause Remedy
The oil pressure gauge and/or sensor is not reading
correctly.
Replace the oil pressure gauge and/or sensor.
There is fuel in the oil. Check fuel systemfor leak.
The oil lter is clogged. Replace the lter element.
The oil lter bypass valve is damaged. Replace the bypass valve.
The oil pump and/or relief valve is damaged. Replace the oil pump and/or relief valve.
Table 15-25 Problem The Engine Oil Pressure is Low
Probl emThe Engine Exhaust Is White
Cause Remedy
Fuel quality is not within DDC specications.
Take a fuel sample and have it tested. Fuel must have
a cetane number greater than 45 and a cetane index
greater than 40. Drain fuel and replace with correct fuel.
The intake air preheater is malfunctioning. Check the intake air preheater, and replace if necessary.
There are air bubbles in the fuel.
Check for leaks at fuel lter, fuel lines or fuel pump.
Repair/replace as necessary.
Charge air cooler is damaged. Replace damaged charge air cooler.
There are air bubbles in the coolant.
Check for leaking cylinder head gasket. Replace if
necessary.
Lowcylinder compression.
Damaged cylinder components. Performcylinder
compression test. Repair/replace damaged parts as
necessary.
Turbocharger boost sensor is damaged or reading
incorrectly.
Replace the turbocharger boost sensor.
Faulty DDEC-ECU. Check DDEC-ECU; replace if necessary.
Defective fuel pump. Replace defective fuel pump.
Faulty turbocharger control unit. Replace turbocharger and control unit.
Faulty fuel injector nozzle holder. Replace fuel injector nozzle holder.
Table 15-26 Problem The Engine Exhaust is White
ProblemThe Engine Exhaust Is Black
Cause Remedy
Check the air restriction indicator. Clean the intake air
systemand replace the air lter if necessary.
The exhaust brake valve is malfunctioning. Replace exhaust brake valve.
The intake air preheater is malfunctioning.
Check that the preheater is not staying on all of the time.
Replace preheater if necessary.
There is damage to the fuel system: the fuel pump, fuel
nozzle(s), or unit pump(s).
Check the fuel system. Replace defective fuel pump, fuel
nozzle(s), or unit pump(s).
The charge air temperature sensor is damaged. Replace the charge air temperature sensor.
There is internal damage to the engine. Repair internal damage in engine.
EGR valve not operating properly. Replace EGR valve.
Turbocharger turbine wheel does not spin freely. Replace the turbocharger.
necessary.
There are air bubbles in the fuel.
Check for leaks at fuel lter, fuel lines or fuel pump.
The air lter is clogged. Clean or replace the air lter.
Charge air cooler is damaged. Replace damaged charge air cooler.
The turbocharger is leaking oil. Replace the turbocharger.
Fuel quality is not within DDC specications.
Take a fuel sample and have it tested. Fuel must have a
cetane number greater than 45 and cetane index greater
than 40. Drain fuel and replace with correct fuel.
Air intake manifold gasket leaking. Replace the intake manifold gasket.
Faulty exhaust manifold gaskets. Replace faulty exhaust manifold gaskets.
Misadjusted exhaust brake valve. Adjust exhaust brake valve.
Faulty exhaust brake valve. Replace exhaust brake valve.
Faulty constant throttle valve. Replace constant throttle valve.
Table 15-27 Problem The Engine Exhaust is Black
Probl emThe Engi ne Exhaust Is Blue
Cause Remedy
The engine oil level is too high (engine oil is reaching
the combustion chamber).
Adjust the oil level, and then recheck oil level.
The turbocharger is leaking oil. Replace the turbocharger.
The valve stemseals are loose or damaged. Replace the valve stemseals.
The piston rings are worn. Replace the piston rings.
necessary.
The oil is not of the recommended quality. Change the oil.
Table 15-28 Problem The Engine Exhaust is Blue
Probl emEngine Brake Performance Is Poor
Cause Remedy
The engine brake control switch is damaged. Replace the brake control switch.
The exhaust brake is not operating properly.
Check the operation of the valve. Replace valve if
necessary.
The constant-throttle valves are malfunctioning. Replace the malfunctioning constant-throttle valve(s).
Components of the DDEC-ECU and/or DDEC-VCU are
damaged.
Replace the damaged DDEC-ECU and/or DDEC-VCU.
Table 15-29 Problem Engine Brake Performance is Poor
Probl emCrui se Control Is Not Working
Cause Remedy
One or more of the cruise control switches are damaged. Replace the damaged switch(es).
Components of the DDEC-ECU and/or DDEC-VCU are
damaged or not working properly.
Replace the damaged DDEC-ECU and/or DDEC-VCU.
Table 15-30 Problem Cruise Control is Not Working
Probl em The Fuel Pressure i s Too Hi gh Downstream of the Fuel Fi lter
Possi ble Cause Remedy
The continuous ventilation port in the cap of the main
fuel lter is blocked.
Inspect the continuous ventilation port for blockage.
Clean the port and replace the cap if necessary.
The fuel drainlines downstreamof themainlter housing
are kinked or blocked.
Repair/Replace as necessary.
The check valve in the fuel feed line is blocked or not
open wide (the ange at the tting connection is bent.)
Repair/Replace as necessary.
The fuel return line and/or strainer at the fuel level
sensor is blocked or kinked.
Remove the fuel level sensor and repair or replace the
line or strainer, as necessary.
The overowvalve is faulty, or the incorrect valve has
been installed. The valve jams when closed as a result
of wear or impurities in the fuel.
Inspect the overowvalve. Replace as necessary.
NOTE: Do not attempt to disassemble the overow
valve. The overowvalve cannot be repaired.
Table 15-31 Problem Fuel Pressure is Too High Downstream of the Fuel Filter
Problem Fuel Flows Out of the Fuel Return Li ne
At one or more of the nozzle holders, the transfer tube is
leaking, cracked, or incorrectly installed.
Replace the damaged transfer tube(s), or install it
correctly.
One or more nozzle holders are leaking, cracked, or
incorrectly installed.
Remove and inspect the nozzle holder(s). Replace if
necessary.
On one or more nozzle holders, the O-ring between the
nozzle holder and the heat isolator is leaking.
Remove the nozzle holder(s) and replace the O-ring(s).
On one or more nozzle holders, the O-ring between the
nozzle holder and the cylinder head is leaking.
Inspect the engine oil at the dipstick for the presence of
fuel. Inspect all the nozzle holders, and especially their
O-rings, for leaks. Remove the nozzle holder(s) and
replace the O-rings, if necessary. Replace the nozzle
holder(s) if cracked or otherwise broken, and install
correctly.
At one or more nozzle holders, the heat isolator is
cracked, faulty, or not sealing properly.
Remove and inspect the heat isolator(s). Replace if
necessary.
The cylinder head is cracked or there is cavitation in the
oil chamber.
fuel. Replace the cylinder head if necessary.
Table 15-32 Problem Fuel Flows Out of the Fuel Return Line
Problem Fuel Flow Quantity is Too Low at the Overow Val ve and Too Hi gh at the Fil ter
Possi bl e Cause Remedy
The main fuel lter is leaking. Repair or replace the leaking main fuel lter.
The O-ring in the main fuel lter is worn, missing, or
incorrectly installed.
Replace the O-ring, or install it correctly.
The main fuel lter cap is loose. Tighten the to cap 25 Nm(18 lbft).
At one or more of the nozzle holders, the transfer tube is
leaking, cracked, or incorrectly installed.
Replace the transfer tube(s), or install it correctly.
One or more nozzle holders are leaking, or cracked. Replace the nozzle holder(s).
Table 15-33 Problem Fuel Flow Quantity is Too Low at the Overow Valve
and Too High at the Filter
Probl em Fuel Fl ow Quantity i s Too Low at the Overow Val ve and Wi thin Range at the Fi lter
The lter element in the fuel pre-lter is blocked. Replace the lter element.
The lter element in the main fuel lter is blocked or
contaminated.
Clean the inside of the main fuel lter housing. Replace
the lter element.
The fuel feed lines are kinked or blocked. Inspect the lines, ttings, and check valve for blockage.
Repair any kinks and replace the lines.
The suction pipe or the strainer at the fuel level is
blocked, or touching the bottomof the fuel tank.
Open the fuel ll cap. Inspect the suction pipe and
strainer. Remove any blockages, and reposition the
suction pipe, if necessary. Remove the fuel level sensor
and replace it if necessary.
The check valve in the fuel feed line is blocked or is not
sufcientlyopen(the openingange is bent at thetting).
The overowvalve is faulty, or the incorrect valve has
been installed. The valve jams when closed as a result
of wear or impurities in the fuel.
Inspect the overowvalve. Replace as necessary.
NOTE: Do not attempt to disassemble the overow
valve. The overowvalve cannot be repaired.
Table 15-34 Problem Fuel Flow Quantity is Too Low at the Overow Valve
and Within Range at the Filter
Probl em The Fuel Inl et Pressure i s Too Low
The pre-lter is leaking (drawing air). Replace the O-ring. Replace the lter element and
tighten the cap on the lter housing 25 Nm(18 lbft).
The fuel feedlines andconnections are leaking(drawing
air).
Replace the seals on the leaking lines. Tighten the
ttings on the fuel lines to 25 Nm(18 lbft) and perform
a fuel leak test.
The fuel pump is worn. Replace the fuel pump.
The pressure limiting valve in the fuel pump is jammed
open or the drive lever is loose or broken.
Replace the fuel pump.
The air-admission valve in the fuel tank is blocked. Remove air-admission valve blockage.
The suction line and/or strainer at the fuel level sensor
is blocked or is touching the bottomof the fuel tank.
Inspect the suction line and/or strainer through the fuel
ll opening in the fuel tank. Remove the fuel level sensor
and repair or replace the line or strainer, as necessary.
Table 15-35 Problem The Fuel Inlet Pressure is Too Low
Probl em The Fuel Inlet Pressure is Too Hi gh
The fuel feed lines are kinked or blocked. Inspect the lines andttings for blockage. Repair/replace
as necessary.
The suction line and/or strainer at the fuel level sensor is
blocked or is touching the bottomof the fuel tank.
Inspect the suction line and/or strainer through the fuel
ll openinginthe fuel tank. Remove the fuel level sensor
and repair or replace the line or strainer, as necessary.
The check valve in the fuel feed line is blocked or not
open wide (the ange at the tting connection is bent).
Table 15-36 Problem The Fuel Inlet Pressure is Too High
Probl em The Low-Pressure Fuel System i s Leaki ng
The engine is leaking at external connections such as
the fuel temperature sensor, the ttings at the base of
the fuel lter housing, and/or the overowvalve.
Replace seals and/or gaskets as necessary. Tighten
all high-pressure lines to 25 Nm(18 lbft) and all banjo
bolts to 40 - 50 Nm(30 - 37 lbft).
The O-ring at one or more unit pumps is leaking, worn,
or missing.
fuel. Inspect the injector line ttings at the fuel pumps
for leaks. Remove the unit pump(s) and replace the
O-rings, if necessary.
The O-ring at one or more nozzle holders is leaking, or
the nozzle holders themselves are cracked or incorrectly
installed.
fuel. Inspect all the nozzle holders, and especially their
O-rings, for leaks. Remove the nozzle holder(s) and
replace the O-rings, if necessary. Replace the nozzle
holder(s) if cracked or otherwise broken, and install
correctly.
The cylinder head is cracked or there is cavitation in the
oil chamber.
fuel. Replace the cylinder head if necessary.
There are balls of sealant in the fuel feed line, or the
return port is leaking at the cylinder block.
Replace the cylinder block seals.
Table 15-37 Problem The Low-Pressure Fuel System is Leaking
15.3 FUEL INJECTION TROUBLESHOOTING
Therearevefuel injectionsystemtestswhichmeasurefuel deliveryperformanceof theMBE
900engine. Performthefollowingtestsandmakecorrectionsor usethetroubleshootingtables:
Test #1: DownstreamPressureTest
Test #2: FlowTest At NozzleHolder
Test #3: FlowTest At Fuel Filter
Test #4: UpstreamPressureTest
Test #5: Leak Test
15.3.1 General Fuel System Information and Troubleshooting
Thefuel systemcontainsvesub-systems. SeeFigure15-1. Thevesub-systemsare:
Fuel feed
Fuel return
Fuel delivery, lowpressureside
Fuel delivery, highpressureside
Fuel drain
1. Fuel Pump 10. Nozzle Holder
2. Check Valve (in fuel pump) 11. OverowValve
3. Pressure Limiting Valve 12. Constant Ventilation (overow)
4. Main Fuel Filter 13. Air Admission Valve
5. Drain Valve 14. Fuel Tank
6. Constant Ventilation (in fuel lter) 15. Assembly Valve (in return line)
7. Fuel Temperature Sensor 16. Assembly Valve (in feed line)
8. Unit Pump (fuel injection) 17. Check Valve (in pre-lter)
9. Bypass (to fuel return port) 18. Fuel Pre-lter
Figure 15-1 Fuel System Schematic
Thefuel pumpfeedsfuel fromthetank throughthefuel pre-lter uptothefuel pump. Thisis
thefuel feedsub-system.
Thefuel pumpdeliversfuel at lowpressuretothemainfuel lter, andfromtheretotheunit
pumps(individual fuel injectionpumps onefor eachcylinder). Ontheway, afuel temperature
sensor monitorstheowdownstreamfromthelter. Thisisthelowpressuresideof thefuel
delivery sub-system.
Eachunit pumpdeliversfuel at highpressuretothefuel injectors. Thisisthehighpressure
sideof thefuel delivery sub-system.
Excessfuel entersthereturnsub-systemthroughaleak line. Theleak linecollectsunusedfuel
andemptiesthroughanoverowvalve. Thereturnlines bringthefuel back tothefuel tank.
This is thefuel returnsub-system.
Fuel caught inthefuel lter drainsbanktothereturnline. Thisisthefuel drainsub-system.
15.3.1.1 Principles of Operation
Thefuel pumpcontrolsthedeliveryof fuel fromthefuel tank totheunit pumps. Fuel pressure
downstreamof thefuel lter rangesfrom400to650kPa(58to94psi). Thefuel pumphasa
pressurelimitingvalvetoprevent fuel pressurefromgettingtoohigh(920kPa[133psi]) anda
check valvetoprevent pressurefromgettingtoolow(20kPa[3psi]). SeeFigure15-2.
1. Fuel Pump 9. Fuel Return Port
2. Main Fuel Filter (secondary) 10. Unit Pump
3. Fuel Delivery Port (to unit pumps) 11. Return Line
4. Fuel Leak Port 12. Fuel Pre-lter
5. Nozzle Holder 13. Fuel Feed Line (frompre-lter to fuel pump)
6. Transfer Tube 14. Assembly Valve (in fuel feed line)
7. Injector Line 15. Assembly Valve (in fuel return line)
8. OverowValve
Figure 15-2 Fuel Circuit Flow Diagram
Fuel istwiceltered, onceinapre-lter upstreamof thefuel pump, andfor thesecondtimeinthe
mainlter downstreamof thefuel pump. Themainlter hasadrainvalvetoreturnfuel caught in
thelter tothefuel tankandconstant ventilationtoreduceandreturnanyfuel vapor tothetank.
Unit pumps, onefor eachcylinder, boost minimumfuel pressureto24,500kPa(3,553psi) for
purposesof injection. Thefuel passesthroughahigh-pressureline, ahigh-pressureconnector
insertedintothewall of thecylinder head, andnallyintothenozzleholder, whereit isinjected
intoaspecially-designedswirl cupintheheadof thepiston.
SoftwaremapsintheDDEC-ECU regulatethetimingandamount of fuel injected. Bothfuel
consumptionandhorsepower canbechangedbydownloadingdifferent softwaremapping.
Unusedfuel isnot wasted. It runsoff intoaleak linewhichiscontrolledbya450kPa(65psi)
overowvalveandreturnedtothefuel tank. Theoverowvalveisalsoequippedwithconstant
ventilationtoreduceandreturnfuel vapor.
15.3.1.2 Troubleshooting Tests
Performthefollowingtroubleshootingtestsontheengine:
1. Runtheenginefor twotothreeminutesat ratedspeed, 2500rpm.
NOTICE:
Correct torque on the high pressure lines is critical. Incorrect
torques could result in leaks or lack of power due to restricted
fuel ow.
2. Performavisual inspectionof all fuel lines, pressurettings, andcomponents, including
all thettingsthat connect thefuel feedanddrainhosestothefuel lter housing. Replace
anycomponentsfoundtobedamagedor leaking. If necessary, tightenall high-pressure
ttingsto25Nm(18lbft) andall banjoboltsto40-50Nm(30-37lbft).
3. Inspect thelter element inthefuel pre-lter. Replaceif necessary.
4. Inspect thelter element inthemainfuel lter. Replaceif necessary.
5. Onengines withspeedgovernors, connect minidiag2tothevehicleandincreasethe
enginespeedto4000rpm. Notethegovernedenginespeedgiven.
6. Continuetoruntheengineuntil it reachestheoperatingtemperatureof approximately
82C (180F). Whentheoperatingtemperaturehasbeenreached, shut theenginedown
andgoto thenext step.
NOTE:
When doing these tests, be sure the temperature of the fuel in the fuel tank is no higher
than 40C (104F). Collect any fuel which ows out during the test. The fuel should ow
through free of bubbles.
7. Performthefuel systemtroubleshootingtestsandcorrect anyproblems. Asindicatedby
thetest results, performanyfollow-uptestsor check troubleshootingtables, asrequired.
Makethenecessary repairs and/or replacements. For troubleshootingtestsandtables
seethefollowingsubjects:
[a] Test #1: DownstreamPressureTest. Refer tosection15.3.2.
[b] Test #2: FlowTest At NozzleHolder. Refer tosection15.3.3.
[c] Test #3: FlowTest At Fuel Filter. Refer tosection15.3.4.
[d] Test #4: UpstreamPressureTest. Refer tosection15.3.5.
[e] Test #5: Leak Test. Refer tosection15.3.6.
[f] Troubleshootingtables.
8. Whenall thetestsarecompleted, thetest equipmentremoved, andall repairs/replacements
havebeenmade, primethefuel system.
[a] If equippedwithahandpumponthefuel/water separator, work thehandpump
until resistanceis felt.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
[b] Crank theenginefor 30secondsat atime, but nolonger. Beforecrankingtheengine
again, wait at least twominutes. Theengineshouldstart withinfour 30-second
attempts. Thefuel systemisbledautomatically.
9. If theproblemhas still not beenresolved, test vehicleperformanceonachassis
dynamometer. If thereisnoimprovement infuel consumptionor performance, connect a
fuel consumptionmeasuringsystem.
15.3.2 Test #1: Downstream Pressure Test
Performthefollowingtest set-upandtest todeterminethedownstreampressure.
15.3.2.1 Test Set-Up
1. Removetheenginetrimpanel. SeeFigure15-3.
1. Engine TrimPanel 3. Fuel Temperature Sensor
2. Engine Wiring Harness
Figure 15-3 Test Setup #1: Downstream Pressure Test
2. Disconnect theenginewiringharnessfromthefuel temperaturesensor. SeeFigure15-4.
1. Fuel Temperature Sensor 2. Engine Wiring Harness
Figure 15-4 Disconnecting the Sensor
3. Removethefuel temperaturesensor.
4. Install thedisconnectedfuel temperaturesensor intotheenginewiringharnessandtieit
upout of theway.
5. Install theadaptor andseal fromthefuel adaptor partskit(J -46377) inthefuel temperature
sensor locationandtightenadaptor securely. SeeFigure15-5andFigure15-6.
Figure 15-5 Fuel Adaptor Parts Kit J-46377
1. Banjo Fitting 3. Adaptor fromkit J -46377
2. Unit Pump
Figure 15-6 Connecting the Adaptor
6. Attachthebanjottingandbanjobolt unionfromthefuel adaptor kit (J -46377) tothe
adaptor.
7. Connect thehigh-pressurefuel line(J -46372) andgauge(J -46378) totheadaptor.
15.3.2.2 Test #1
1. Openthefuel ll captoreleasepressureinthefuel tank.
PERSONAL INJURY
2. Start theengineandrunit at aslowidle, 600to650rpm.
3. Readoff thefuel pressureonthehigh-pressuregauge. Thegaugeshouldreadat least
430kPa(62psi). If thefuel pressureistoolow, performtest #3: FlowTestAt Fuel
Filter, andcorrect theproblem. Refer tosection15.3.4.
4. Increasetheenginespeedto 2500rpm.
5. Readoff thefuel pressureonthehigh-pressuregauge. Thegaugeshouldreadfrom400to
650kPa(58to 94psi).
[a] If thefuel pressureiswithinlimits, performtest #2: FlowTestAt NozzleHolder,
andcorrect theproblem. Refer tosection15.3.3.
[b] If thefuel pressureistoolow, performtest #3: FlowTestAt Fuel Filter, andcorrect
theproblem. Refer tosection15.3.4.
[c] If thefuel pressureistoohigh, seethecauseslistedinTable15-31, Problem The
Fuel PressureisTooHighDownstreamof theFuel Filter, andcorrect theproblem.
Makeanynecessary repairsand/or replacements.
6. Removeall test equipment. Reconnect thefuel temperaturesensor.
7. Makesurethefuel ll capistightlyclosedandthevehiclehasbeenrestoredtooperating
condition.
15.3.3 Test #2: Flow Test At Nozzle Holder
Performthefollowingtest set-upandtest todeterminetheowat thenozzleholder:
1. Engine TrimPanel 4. Banjo Fitting
2. Fuel Return Line 5. Seal Ring fromkit J -46377
3. Washers 6. Adaptor fromkit J -46377
Figure 15-7 Test Setup #2: Flow Test at Nozzle Holder
2. Usingtheinjector linesocket (J -46371), removetheinjectionlineat cylinder #4onthe
6-cylinder engineandat cylinder #2onthe4-cylinder engine.
NOTE:
When removing the injection line, the transfer tube thrust nut must be held inorder to
keep the line fromtwisting.
3. Removethefuel returnline, banjottingandwashersfromthecylinder headat thesame
cylinder fromwhichtheinjectionlinewasremoved.
4. Usingtheadaptor andseal ringsfromthefuel adaptor partskit (J -46377) toinstall thefuel
returnlineback ontothecylinder head. Tightenadaptor securely.
5. Install theinjectionlineusingtheinjector linesocket (J -46371). Torqueinjectionlineto
25Nm(18lbft).
6. Placeacleanclothbelowtheopeningintheadaptor tocatchanyfuel whichleaksout
of thereturnlineduringthetest.
15.3.3.2 Test #2
PERSONAL INJURY
2. Start theengineandrunit at aslowidle, 600to650rpmuntil theadaptor openingappears
moist. If fuel or coolant owsout of thereturnline, seethecauseslistedinTable15-32,
Problem Fuel FlowsOut of theFuel ReturnLine, andcorrect theproblem. Make
any necessary repairs and/or replacements.
3. Increasetheenginespeedto2500rpm. At most, dropsof fuel shouldappear attheadaptor
opening. If fuel or coolant owsout of thereturnline, seethecauseslistedinTable15-32,
Problem Fuel FlowsOut of theFuel ReturnLine, andcorrect theproblem. Make
any necessary repairs and/or replacements.
4. Removetheadaptor andseal ringpart of kit (J -46377). Restorethefuel returnlinetothe
original installation, asremoved. Tightenbanjobolt to40-50Nm(30-37lbft).
condition.
15.3.4 Test #3: Flow Test At Fuel Filter
Performthefollowingtest set-upandtest todeterminetheowat thefuel lter.
1. Fuel Drain Line (at lter) 6. Banjo Bolt Union fromkit J -46377
2. Drain Line Fitting 7. Banjo Fitting
3. Main Filter Housing (secondary) 8. OverowValve
4. Engine TrimPanel 9. Clean Container
5. Fuel Return Line (at injector) 10. Hose
Figure 15-8 Test Setup #3: Flow Test at Fuel Filter
2. Disconnect thefuel returnlineat theoverowvalve. Whenlooseningthebanjobolt, hold
asecondwrenchontheoverowvalvetoavoidlooseningthevalve.
3. Usingabanjobolt, nut, andwasher fromthefuel adaptor partskit (J -46377), seal off
thefuel returnline.
4. Inplaceof thefuel returnline, attachthehosewithabanjottingfromthefuel adaptor
partskit (J -46377) totheoverowvalve. Whentighteningtheunion, holdasecond
wrenchontheoverowvalvetoavoidover-tighteningthevalve.
5. At themainfuel lter, detachthefuel drainlineanditsttingfromthemainlter housing.
6. Inplaceof thefuel drainline, attachaunionfromthefuel adaptor partskit tothemain
lter housing.
7. At theunion, attachahoseandruntheother endof thehoseintoanother cleancontainer.
15.3.4.2 Test #3
PERSONAL INJURY
2. Start theengineandrunit at aslowidle, 600to650rpm, until thefuel owsintothe
container withlittleor no bubbling.
3. Check thefuel owat thefuel lter.
NOTE:
When beginning the timed portion of this test, take the transparent hose out of the clean
container and insert it into a calibrated container or measuring cup.
[a] Measurethequantityof fuel that owsout of thehoseinoneminute(60seconds). If
morethan300mL (10.1oz.) owout, fuel owat thelter istoohigh(at idle).
[b] Increasetheenginespeedto 2500rpm.
[c] Measurethequantityof fuel that owsout of thehoseinoneminute. If morethan
300mL (10.1oz.) owout, fuel owat thelter istoohigh(at ratedspeed).
NOTE:
If fuel owon either test is too high, correct the problem. Fuel owis OK if the system
passes both tests.
4. Check thefuel owat theoverowvalve.
[a] Reduceenginespeedback toslowidle, 600to650rpm.
NOTE:
When beginning the timed portion of this test, take the transparent hose out of the clean
container and insert it into a large calibrated container.
[b] Measurethequantityof fuel that owsout of thehoseinoneminute(60seconds). If
morethan1.7Liter (1.8qt) owsout, overowvalvefuel owistoohigh. If less
than0.9Liter (0.95qt) owsout, overowvalvefuel owistoolow.
If between0.9Liter (0.95qt) and1.7Liter (1.8qt) owsout, overowvalvefuel
owis withinrange.
[c] Increasetheenginespeedto2500rpm.
[d] Measurethequantity of fuel that owsout of thehoseinoneminute. If morethan
7.5Liter (7.9qt) owsout, overowfuel owistoohigh. If lessthan2.7Liter (2.9
qt) owsout, overowfuel owistoolow.
If between2.7Liter (2.9qt) and7.5Liter (7.9qt) owsout, overowfuel owis
withinrange.
5. If overowvalvefuel owis too lowandlter fuel owis too high, seethe
causeslistedinTable15-33, Problem Fuel FlowQuantityisTooLowat theOverow
ValveandTooHighat theFilter, andcorrect theproblem. Makeanynecessaryrepairs
and/or replacements. If overowvalvefuel owistoolowandfuel owisOK at the
lter, seethecauseslistedinTable15-34, Problem Fuel FlowQuantityisTooLow
at theOverowValveandWithinRangeat theFilter, andcorrect theproblem. Make
any necessary repairsand/or replacements.
If overowvalvefuel owistoolowandfuel owisalsotoolowat thelter, perform
test #4: UpstreamPressureTest. Refer tosection15.3.5.
If overowvalvefuel owis OK andnofuel ows out at thelter, thecontinuous
ventilationport inthefuel lter isblockedbyimpurities. Openthefuel lter andcleanor
replacetheblockedport.
If overowvalvefuel owisOK andfuel owisalsoOK at thelter, theoverowvalve
isfaulty, leaking, jammedopen, worn, or incorrectly installed. Replacetheoverow
valve. Refer to section15.13.5.
NOTE:
Donot attemptto disassembletheoverowvalve. Theoverowvalvecannot berepaired.
6. Removetheunion, transparent hose, banjobolt, andnut. Restorethefuel returnanddrain
lines totheoriginal installation, as removed.
condition.
15.3.5 Test #4: Upstream Pressure Test
Performthefollowingtest set-upandtest todeterminetheupstreampressure.
1. At themainlter housing, disconnect thefuel feedlineandfeedlinetting. Thisttingis
aft of thefuel returnlineandconnectstothefuel pre-lter. SeeFigure15-9.
1. Main Filter Housing 3. Test Hose
2. Check Valve 4. Fuel Feed Line
Figure 15-9 Test Setup #4: Upstream Pressure Test
2. Install thepressuretester (J -46380). Connect oneendof thetransparent test hosetothe
fuel pre-lter, usingaunionfromthefuel adaptor partskit (J -46377). Connect theother
endof thetransparent test hosetothedisconnectedfuel feedline, usingabarbedadaptor
totheproper-sizedfuel linetting.
NOTE:
The opening armof the union at the pre-lter should press open the check valve.
3. Inspect thesealsat thettingonthefuel pre-lter for damageandreplaceif necessary.
4. Primethefuel system.
[a] If equippedwithahandpumponthefuel/water separator, work thehandpump
until resistanceis felt.
PERSONAL INJURY
[b] Cranktheenginefor 30secondsat atime, but nolonger. Beforecrankingtheengine
again, wait at least twominutes. Theengineshouldstart withinfour 30-second
attempts. Thefuel systemisbledautomatically.
5. Standthepressuretester onalevel spot, suchastheframerail.
NOTE:
The pressure tester must be level to indicate correctly.
15.3.5.2 Test #4
PERSONAL INJURY
2. Start theengineandrunit at aslowidle, 600to650rpm.
NOTE:
The pressure tester reads in bar. 1 bar =14.5 psi or 100 kPa.
NOTE:
This test measures suction at the fuel inlet. All pressure values are negative.
3. Readoff thefuel pressureonthepressuretester. Thegaugeshouldreadfrom0.09bar to
0.12bar (1.3to1.7psi [9to12kPa]). If thefuel pressureistoolow(lesssuction),
seethecauseslistedinTable15-35, Problem TheInlet PressureisTooLow, and
correct theproblem. Makeanynecessary repairsand/or replacements.
If thefuel pressureis toohigh(moresuction), seethecauses listedinTable15-36,
Problem TheInlet Pressureis Too High, andcorrect theproblem. Makeany
necessary repairs and/or replacements.
4. Increasetheenginespeedto 2500rpm.
5. Readoff thefuel pressureonthepressuretester. Thegaugeshouldreadbetween0.4and
0.5bar (5.8to7.3psi [40to50kPa]). If thefuel pressureistoolow(lesssuction),
seethecauseslistedinTable15-35, Problem TheInlet PressureisTooLow, and
correct theproblem. Makeanynecessaryrepairsand/or replacements.
If thefuel pressureis toohigh(moresuction), seethecauses listedinTable15-36,
Problem TheInlet Pressureis Too High, andcorrect theproblem. Makeany
necessary repairs and/or replacements.
6. Removeall test equipment. Reconnect thefuel feedline.
condition.
15.3.6 Test #5: Leak Test
Performthefollowingtest set-upandtest todetermineif andwherethefuel systemisleaking.
1. Engine TrimPanel 4. Cap
2. Main Filter Housing 5. Fuel Return Line
3. Fitting 6. Fuel Feed Line
Figure 15-10 Test Setup #5: Leak Test
2. Disconnect thefuel temperaturesensor. SeeFigure15-11.
3. Plugthedisconnectedfuel temperaturesensor intotheenginewiringharnessandtieit
upout of theway.
4. Install theadaptor andseal fromthefuel adaptor partskit (J -46377). SeeFigure15-12.
2. Unit Pump (fuel)
5. Attachabanjottingtotheadaptor, andusethat toconnect thehigh-pressurefuel line
(J -46372) andgauge(J -46378).
6. Disconnect thefuel returnlineat themainlter housing. Seal theopeningwithacap.
7. Disconnect thefuel feedlineandfeedlinettingat themainlter housing. Intheir place,
attachthehosewithabanjottingandtheshut-off lever fromthefuel adaptor parts
kit (J -46377).
15.3.6.2 Test #5
2. Fill thelow-pressurefuel circuit withcompressedair until thefuel pressureonthe
high-pressuregaugereads 1,000kPa(145psi).
3. Turntheshut-off lever totheOFF positionandwait veminutes.
4. At theendof veminutes, readthepressureonthegaugeagain. Thegaugeshouldreadat
least 975kPa(141psi). If thegaugepressureistoolow, seethecauseslistedinTable
15-37, Problem TheLowPressureFuel SystemisLeaking, andcorrect theproblem.
Makeany necessaryrepairs and/or replacements.
5. Check theengineoil for presenceof fuel. If thereisfuel intheengineoil, seethecauses
listedinTable15-37, ProblemTheLowPressureFuel SystemisLeaking, andcorrect
theproblem. Makeanynecessaryrepairsand/or replacements.
6. Opentheshut-off valveandremoveall thetest equipment. Connect thefuel feedand
returnlines, asremoved. Reconnect thefuel temperaturesensor.
condition.
15.4 MISFIRING CYLINDER
Thereareseveral causesfor theenginecylinder tobemisring. Theseprobablecausesare:
Poor VehicleGround
AeratedFuel
Improper ValveClearance, Wornor DamagedCamshaft LobesandRoller Followers
Faulty Fuel Nozzle
Faulty DDEC-ECU
Wornor DamagedValveor Cylinder Kit
15.4.1 Troubleshooting Procedure for Poor Vehicle Ground
Todetermineif poor vehiclegroundiscausingthecylinder tomisre, performthefollowingsteps:
1. Removethealternator belt. Refer tosection8.2.1.
PERSONAL INJURY
2. Start theengine.
3. Runtheenginethroughoperatingrange.
4. Listenfor enginemisring.
[a] If theengineisnot misring, refer tosection15.4.2. Shut downtheengine.
[b] If theengineisstill misring, check for aeratedfuel; refer tosection15.4.3.
15.4.2 Negative Lead Repair
Performthefollowingsteps for negativeleadrepair:
1. Shut downtheengine.
2. Removenegativelead(s) at framegroundstudnear batterybox.
3. Cleangroundstud; refer toOEM guidelines.
4. Cleannegativelead(s) terminal lugswithlowgrit sandpaper.
5. Repair anylooseor damagedlead(s), usingthesplicemethodor rosincoresolder.
6. Install negativelead(s) toframegroundstud; refer toOEM guidelines.
7. Install alternator belt. Refer tosection8.2.1.
NOTE:
Drive belts (Vee and poly-vee) should be replaced every 2,000 hours or 100,000 miles
(160,000 km).
8. Verify negativeleadrepair; refer tosection15.4.2.1.
15.4.2.1 Verication of Repair for Negative Lead
Performthefollowingstepstodetermineif negativeleadrepair resolvedthemisringcylinder
condition:
PERSONAL INJURY
1. Start theengine.
2. Runenginespeeduptotheoccurrenceof themisring.
3. Listenfor misringcylinder.
[a] If theengineis not misring, nofurther troubleshootingis required. Shut down
theengine.
[b] If theengineis misring, check for aeratedfuel. Shut downtheengine;
refer to section15.4.3.
15.4.3 Troubleshooting Procedure for Aerated Fuel
Todetermineif aeratedfuel iscausingthecylinder tomisre, performthefollowingsteps:
1. Disconnect thefuel linereturnhosefromthettinglocatedat thefuel tank.
2. Placetheopenedendof fuel lineintoasuitablecontainer.
PERSONAL INJURY
3. Start theengine.
4. Runtheengineat 1000rpm.
5. Visuallychecktoseeif air bubblesarerisingtothesurfaceof thefuel withinthecontainer.
[a] If air bubblesarepresent, refer tosection15.4.4.
[b] If air bubbles arenot present, shut downtheengine. Check for improper valve
clearance, andwornor damagedcamshaft lobesandroller followers; refer tosection
15.4.5.
15.4.4 Aerated Fuel Repair
Performthefollowingstepstorepair theair inthefuel:
2. Tightenall fuel lineconnections betweenfuel tank andfuel pump; refer to OEM
guidelines.
3. Visuallyinspect all fuel linesbetweenfuel tank andfuel pumpfor leaks.
4. Replaceany damagedcomponents.
5. Verify repair of fuel lines:
[a] If noair inthefuel return, refer tosection15.4.4.1.
[b] If air inthefuel return, locateandrepair. Thenrefer tosection15.4.4.1.
15.4.4.1 Test the Engine with Repair for Aerated Fuel
Performthefollowingstepstodetermineif theaeratedfuel repair resolvedthemisringcylinder
condition:
PERSONAL INJURY
1. Start engine.
theengine.
[b] If theengineismisring, check for improper valveclearance, or wornor damaged
camshaft lobesor rollers. Shut downtheengine; refer tosection15.4.5.
15.4.5 Troubleshooting Procedure for Improper Valve Clearance, Worn
or Damaged Camshaft Lobes and Rollers
Intakeandexhaust valveclearanceareadjustedbymeansof anadjustingset screwandlocknut
locatedat thepushrodendof therocker arm; SeeFigure15-13for intakevalves. Exhaust valve
is similar.
1. Rocker Arm 3. Intake Valves
2. Pushrod 4. Valve Bridge
Figure 15-13 Intake Valves
Todetermineif improper valveclearanceiscausingthecylinder tomisre, check if awornor
damagedcamlobeor followersis causingthemisre.
Bar theengineover andinspect thecamshaft androller followersfor wear or damage.
1. If damageisfoundonthecamshaftlobesor roller followers, replacedamagedcomponents
as necessary.
2. If nodamagewasfoundtocamshaft or roller followers, continuewithtask. Verify the
proper lashsettingfollowingtheprocedureintheValveLashCheckingandAdjustment
section; refer tosection1.17.2.
15.4.5.1 Verication of Repair for Improper Valve Clearance or Injector
Height Setting
Performthefollowingstepstodetermineif valveclearanceadjustment resolvedthemisring
cylinder condition:
PERSONAL INJURY
1. Start theengine.
[a] If engineis not misring, shut downtheengine. Nofurther troubleshootingis
required.
[b] If engineis misring, shut downtheengineandcheck for faulty fuel nozzle;
15.4.6 Troubleshooting Procedure for Faulty Fuel Nozzle/Unit Pump
Todetermineif afaultyfuel nozzleor unit pumpiscausingthecylinder tomisre, check for
thefollowingitems:
1. Usetheminidiag2todetect any fault codes.
2. Makesurethat thetransfer tubeisinstalledat theproper torque. Refer tosection2.3.2. A
leakingtransfer tubemaybeidentiedbycylinder cut-out evaluation.
15.4.7 Faulty Fuel Nozzle/Unit Pump Repair
Refer totheInjector Unit Pump section2.1for unit pumpandnozzlereplacement.
15.4.7.1 Verication of Repair for Faulty Fuel Nozzle/Unit Pump
Performthefollowingsteps todetermineif thereplacedfuel nozzle/unit pumpresolvedthe
misringcylinder conditions:
PERSONAL INJURY
1. Start theengine.
2. Runtheenginespeeduptotheoccurrenceof themisring.
[a] If theengineisnot misring, shut downtheengine. Nofurther troubleshootingis
required.
[b] If theengineismisring, shut downtheengineandcheck for afaultyDDEC-ECU;
15.4.8 Troubleshooting Procedure for a Faulty DDEC-ECU
Todetermineif afaultyDDEC-ECU iscausingthecylinder tomisre, install atest DDEC-ECU.
NOTE:
Carefully disengage the lock tab on the vehicle wiring harness and engine wiring
harness connectors when removing. Followinstructions in the DDEC-ECUsection;
refer to section 2.5.1.
15.4.9 Faulty DDEC-ECU Repair
Thereisnoauthorizedrepair for theDDEC-ECU.
15.4.9.1 Verication of Replacement for Faulty DDEC-ECU
Performthefollowingstepstodetermineif thetest DDEC-ECU has resolvedthemisring
cylinder condition:
PERSONAL INJURY
1. Start theengine.
2. Increasetheenginespeeduptotheoccurrenceof themisring.
[a] If theengineisnot misring, shut downtheengine. Nofurther troubleshootingis
required. ReplacetheDDEC-ECU withanewunit.
[b] If theengineismisring, shut downtheengine, install original DDEC-ECU, and
check for wornor damagedvalvesandcylinder kits; refer tosection15.4.10.
15.4.10 Troubleshooting Procedure for Worn or Damaged Valve or
Cylinder Kit
Lossof compressioninMBE 900enginesmayresult fromavarietyof sources, includingworn
or brokenreor compressionrings, holes inpistons, leaky valves, scoredor worncylinder
walls, leaky or brokengaskets andcrackedcylinder headsor cylinder liners. Thedetection
andeliminationof thecauseor causesof cylinder pressurelossesisvital toenginelifeand
efcient operation. Toassist themechanicineffectivelymeasuringthelossof cylinder pressure
andlocatingthesourceof abnormal leaksinindividual cylinders, thefollowingtest procedure
has beendeveloped.
1. Movethevehiclerequiringtest tothechassisdynamometer; refer toOEM guidelines.
2. Removeair compressor; refer tosection10.1.1.
3. Performacrankcasepressuretest. Refer tosection15.4.10.1.
4. Removethevehiclefromthechassisdynamometer.
5. Reviewthecrankcasepressuretest results.
[a] If thecrankcasepressurewasgreater than0.62kPa(2.5in. H
2
O); refer tosection
15.4.11.
[b] If thecrankcasepressurewaslessthan0.62kPa(2.5in. H
2
O); performacylinder
compressiontest. Refer tosection1.2.2.2.
6. Comparethecylinder compressiontest resultstospecications; refer tosection1.2.2.2.
[a] If cylinder pressureisbelowspecications, refer tosection15.4.11.
[b] If cylinder pressureiswithinspecications, call Detroit Diesel Customer Support
Center at 3135925800.
15.4.10.1 Crankcase Pressure Test
Performthefollowingstepstocheck theenginecrankcasepressure:
PERSONAL INJURY
1. Start theengine.
2. Runtheengineandbringtheenginecoolant temperaturetonormal operatingrange,
approximately 88-96C (190-205F).
3. Returnenginetoidleandremovetheoil dipstick.
4. Attachamanometer calibratedtoreadpressureinkPaor inches of (H
2
O), totheoil
dipstick opening.
5. Runthevehicletofull loadandratedspeed.
6. Measureandrecordcrankcasepressure.
8. Removethemanometer fromtheoil dipstick openingandinstall thedipstick.
15.4.11 Worn or Damaged Valve or Cylinder Kit Repair
Performthefollowingstepstodetermineawornor damagedvalveor cylinder kit:
1. Removecylinder head; refer tosection1.2.1.
2. Inspect thecylinder headfor wornor damagedvalves; refer tosection1.17.
3. Inspect thecylinder headcomponentsfor wornor damagedlinersexaminethepistons
or pistonrings.
4. Verify repairs madetocylinder valve(s) or cylinder kit components; refer tosection
15.4.11.1.
15.4.11.1 Verication of Repair for Worn or Damaged Valve or Cylinder Kit
Performthefollowingsteps to determineif therepairedvalveor cylinder kit resolvedthe
misringcylinder condition:
PERSONAL INJURY
1. Start theengine.
2. Runtheenginespeeduptotheoccurrenceof themisring.
theengine.
[b] If theengineis misring, shut downtheengine. Call Detroit Diesel Customer
Support Center at 3135925800.
15.5 STARTING DIFFICULTY (ENGINE ROTATES)
Thereareseveral causesfor theenginetohavestartingdifculty. Theseprobablecausesare:
DDEC-ECU WiringHarness Damage
Empty Fuel Tank
LowBattery Voltage
Corrodedor DamagedBattery Terminals
DefectiveMagnetic Switch
DefectiveStarter
LowCrankingSpeed
Faulty Fuel Supply Valve
PluggedFuel Filter(s)
Faulty Fuel Pump
AeratedFuel
RestrictiveAir Filter
LowCompression
15.5.1 Troubleshooting Procedure for DDEC-ECU Wiring Harness
Todetermineif theDDEC-ECU wireharnessiscausingstartingdifculty, performthefollowing
steps:
1. TurntheignitionswitchtotheON position.
2. Install theDiagnosticDataLink (DDL) adaptor tothedatacableandplugtheadaptor into
theDDL connector inthevehicle.
3. Determineif DDEC-ECU dataisbeingreceivedbytheDDR. If nodataisbeingreceived
bytheDDR, checkfor intermittent codeor afault andnocodesbydoingthefollowing:
[a] Check for poor matingof theconnector halvesor terminalsnot fullyseatedinthe
connector body (backed-out terminals).
[b] Look for improperlyformedor damagedterminals. All connector terminalsinthe
problemcircuit shouldbecarefullyinspectedtodetermineproper contact tension.
Useamatingterminal totest thecontact tension.
[c] Electrical systeminterferencemaybecausedbyadefectiverelay, or aswitchcausing
anelectrical surge. Look for problemswiththechargingsystem(alternator, etc.).
Incertaincases, theproblemcanbemadetooccur whenthefaulty component is
operatedas inthecaseof arelay.
[d] Verify alternator grounds arecleanandmakinggoodcontact. Disconnect the
alternator belt to test.
[e] Wigglewiresandharnessestotrytomaketheproblemactiveor tooccur again.
4. If datais beingreceivedby theDDR, check thevehiclecircuit breakers or fuses;
15.5.2 Vehicle Circuit Breakers or Fuses Check
To determineif thevehiclecircuit breakers arecausingstartingdifculty, visually check
DDEC-ECU circuit breakers or fusestodetermineif circuit breaker(s) or fuse(s) aretripped
or blown.
1. If circuit breakersaretripped, determinecauseandrepair or replaceasnecessary; refer to
OEM guidelines. Performvalidation; refer tosection15.5.4.1.
2. If circuit breakersarenot tripped, measurethevoltageat theDDEC-ECU power harness.
AnElectronicControl TroubleshootingGuideiscurrently under development for this
procedure. Contact DDC Customer Support Center at 313-592-5800intheinterim.
15.5.3 DDEC-ECU Power Harness Voltage Test
AnElectronic Control TroubleshootingGuideiscurrently under development. Contact DDC
Customer Support Center at 313-592-5800intheinterim.
15.5.4 Power Harness Repair
Performthefollowingstepstorepair thepower harness:
1. Repair thedamagetothepower harness.
2. Verifyrepair of thepower harness; refer tosection15.5.4.1.
15.5.4.1 Test Engine with Repaired Power Harness
Todetermineif therepair resolvedthestarter difculty, performthefollowingsteps:
PERSONAL INJURY
1. Attempttostartandruntheengine, if theenginestartsandruns, nofurther troubleshooting
is required. Shut downtheengine.
2. If theenginefailstostart andrun, checkfor anemptyfuel tank; refer tosection15.5.5.
15.5.5 Troubleshooting Procedure for an Empty Fuel Tank
Todetermineif anempty fuel tank iscausingstartingdifculty, check theamount of fuel in
fuel tank; refer to OEM guidelines.
1. If fuel isat recommendedlevel, check for aweak battery; refer tosection15.5.7.
2. If fuel isbelowrecommendedlevel, refer tosection15.5.6.
15.5.6 Low Fuel Level Resolution
Performthefollowingstepsinorder toresolvelowfuel level:
1. Fill fuel tank tofull; refer toOEM guidelines.
2. Verify fuel tank rell; refer tosection15.5.6.1.
15.5.6.1 Test Engine with Filled Tank
Todetermineif alledfuel tank resolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, check thebattery; refer tosection15.5.7.
15.5.7 Troubleshooting Procedure for Low Battery Voltage
Todetermineif aweak battery iscausingstartingdifculty, measurethebatteryvoltage; refer
to OEM guidelines.
1. If voltageis between10.5- 14volts (21- 26volts for a24-volt system), check the
terminalsfor corrosionor damage; refer tosection15.5.9.
2. If voltageislessthan10.5volts(21voltsfor a24-volt system), battery replacement is
necessary; refer tosection15.5.8.
15.5.8 Battery Replacement
Performthefollowingsteps for battery repair:
1. Removeandreplacethebattery; refer toOEM guidelines.
2. Verifybattery replacement; refer tosection15.5.8.1.
15.5.8.1 Test Engine with Replaced Battery
Todetermineif thebatteryreplacement resolvedstartingdifculty, attempt tostart andrunthe
engine.
PERSONAL INJURY
1. If theenginestartsandruns, nofurther troubleshootingisrequired. Shut downtheengine.
2. If theenginefailstostart andrun, checktheterminals; refer tosection15.5.9
15.5.9 Troubleshooting Procedure for Corroded or Damaged Battery
Terminals
Todetermineif corrodedor damagedterminalsarecausingstartingdifculty, visually inspect
terminals for corrosionor damage.
1. If corrosionor damagearenot found, checkthemagneticswitch; refer tosection15.5.11.
2. If corrosionor damagearefound, repair isnecessary; refer tosection15.5.10.
15.5.10 Corroded or Damaged Battery Terminal Repair
Performthefollowingstepstorepair corrodedor damagedbatteryterminals:
1. Repair or replaceanycorrodedor damagedterminals; refer toOEM guidelines.
2. Verifyrepair of corrodedor damagedterminals; refer tosection15.5.10.1.
15.5.10.1 Test with Repaired Battery Terminals
Todetermineif therepair resolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, checkthemagneticswitch; refer tosection15.5.11.
15.5.11 Troubleshooting Procedure for Defective Magnetic Switch
Todetermineif adefectivemagneticswitchiscausingstartingdifculty:
PERSONAL INJURY
1. Start theengine.
2. Clampaheavy gaugebattery jumper cablebetweenthetwolargestudsof themagnetic
switch. SeeFigure15-14.
Figure 15-14 Basic Cranking Circuit
[a] If theenginecrankedwiththejumper cableinplace, themagnetic switchmust be
replaced; refer to section15.5.12.
[b] If theenginedidnot crank withthejumper cableinplace, check thestarter;
15.5.12 Magnetic Switch Replacement
Performthefollowingstepsfor magneticswitchreplacement:
1. Replacethemagnetic switch; refer toOEM guidelines.
2. Verifymagneticswitchreplacement; refer tosection15.5.12.1.
15.5.12.1 Test Engine with Replaced Magnetic Switch
Todetermineif themagnetic switchreplacement resolvedthestartingdifculty, performthe
followingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, check thestarter; refer tosection15.5.13.
15.5.13 Troubleshooting Procedure for a Defective Starter
Todetermineif adefectivestarter iscausingstartingdifculty, performthefollowingsteps:
1. Placetheredleadof avoltmeter tothesolenoidBAT terminal; seeFigure15-15.
1. Black Voltmeter Lead 4. Harness Tube
2. Starter Ground Terminal Lug 5. Volt OhmMeter
3. Red Voltmeter Lead
Figure 15-15 Starting Motor Available Voltage Test
2. Placetheblack voltmeter leadtothestarter groundterminal; seeFigure15-15.
3. Engagethestarter switch.
4. Viewthevoltagereadingonthemeter.
[a] If thevoltageislessthanspecicationwhilecrankingtheengine, replacement is
necessary; refer tosection15.5.14.
[b] If thevoltageistospecicationwhilecrankingtheengine, checkthecrankingspeed;
15.5.14 Starter Replacement
Performthefollowingsteps for starter replacement:
1. Replacethestarter. Refer tosection8.1.
2. Verifyreplacement of starter; refer tosection15.5.14.1.
15.5.14.1 Test Engine with Replaced Starter
Todetermineif thereplacedstarter resolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, check thecrankingspeed; refer tosection15.5.15.
15.5.15 Troubleshooting Procedure for Low Cranking Speed
Todetermineif lowcrankingspeediscausingstartingdifculty, install atachometer totheengine
andrecordenginerevolutionwhilecrankingtheengine. Refer toOEM guidelines.
If thecrankingspeedis greater than100rpm, check theOEM fuel supply valve;
If thecrankingspeedislessthan100rpm; refer tosection15.5.16.
15.5.16 Low Cranking Speed Repair
Performthefollowingstepsfor lowcrankingspeedrepair:
1. Draintheengineoil. Refer tosection13.1.4.
2. Removetheoil lter(s).
3. Install newoil lter(s). Refer tosection13.1.4.
4. Rell thelubricationsystemwithnewoil.
5. Verifylowcrankingspeedrepair; refer tosection15.5.16.1.
15.5.16.1 Test Engine with Replaced Oil
Todetermineif thereplacedoil resolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
Attempt tostart andruntheengine, if theenginestartsandruns, nofurther troubleshooting
If theenginefailstostart andrun, checkthefuel supplyvalve; refer tosection15.5.17.
15.5.17 Troubleshooting Procedure for the Fuel Supply Valve
Todetermineif thefuel supplyvalveiscausingstartingdifculty, checkthat thefuel supplyvalve
isopen; refer to OEM guidelines.
1. If thefuel supplyvalveisopen, check thefuel lters; refer tosection15.5.19.
2. If thefuel supplyvalveisclosed, repair isnecessary; refer tosection15.5.18.
15.5.18 Fuel Supply Valve Repair
Performthefollowingstepsfor fuel supply valverepair:
1. Correct valveoperationor replacevalve.
2. Primethefuel system; refer tosection11.1.5.
3. Verifyfuel supplyvalverepair; refer tosection15.5.18.1.
15.5.18.1 Test Engine with Fuel Supply Valve Open
Todetermineif openingthefuel supplyvalveresolvedstartingdifculty, performthefollowing
steps :
PERSONAL INJURY
2. If theenginefailstostart andrun, checkthefuel lters; refer tosection15.5.19.
15.5.19 Troubleshooting Procedure for Plugged Fuel Filter(s)
Todetermineif apluggedfuel lter(s) iscausingstartingdifculty, performthefollowingsteps:
1. Disconnect thefuel linereturnhosefromthettinglocatedat thefuel tank.
2. Placetheopenedendof thefuel lineintoavegalloncontainer.
PERSONAL INJURY
3. Start theengine.
5. Clock fuel ratefor oneminute.
6. Measuretheamount of fuel deliveredintothecontainer.
[a] If thefuel owisgreater than1.7L/min. (0.5gal/min.) andaerated(small bubbles),
check for air infuel; refer tosection15.5.23.
[b] If thefuel owis less than1.7L/min. (0.5gal/min.), replacethefuel lters;
15.5.20 Plugged Fuel Filter(s) Replacement
Performthefollowingstepstoreplacethefuel lter(s):
1. Replacethefuel lter; refer tosection13.1.3.
2. Test theenginetodetermineif startinghasbeenimproved; refer tosection15.5.20.1.
15.5.20.1 Test Engine with Replaced Fuel Filters
Todetermineif thereplacedfuel ltersresolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, checkthefuel pump; refer tosection15.5.21.
15.5.21 Troubleshooting Procedure for Fuel Pump
Todetermineif thefuel pumpiscausingstartingdifculty, performthefollowing:
PERSONAL INJURY
1. Start andruntheengine. If pressureat idlespeed(600650rpm) is-0.09to-0.12bar (-1.3
to-1.7), check for aeratedfuel. Refer tosection15.5.23.
2. If pressureat idlespeed(600650rpm) isless than-0.09to-0.12bar (-1.3to-1.7),
refer to Table15-35.
3. If pressureat idlespeed(600650rpm) isgreater than-0.09to-0.12bar (-1.3to-1.7),
refer to Table15-36.
4. If anopressurereadingisobserved, replacethefuel pump, refer tosection2.15.1.
Check fuel intakepressureupstreamof fuel pump.
15.5.22 Fuel Pump Replacement
Performthefollowingstepsfor fuel pumpreplacement:
1. Replacethefuel pump: refer tosection2.15.1.
PERSONAL INJURY
2. Test theenginetodetermineif startinghasbeenimproved; refer tosection15.5.22.1.
15.5.22.1 Engine Test with Replaced Fuel Pump
Todetermineif thereplacedfuel pumpresolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, check for aeratedfuel; refer tosection15.5.23.

Todetermineif aeratedfuel iscausingstartingdifculty, performthefollowingsteps:
1. Disconnect thefuel linereturnhosefromthettinglocatedat thefuel tank; refer toOEM
guidelines.
2. Placetheopenedendof thefuel lineintoasuitablecontainer.
PERSONAL INJURY
3. Start theengine.
[a] If air bubblesarepresent, repair isnecessary; refer tosection15.5.24.
[b] If air bubblesarenot present, check for arestrictiveair lter. Shut downtheengine;
15.5.24 Aerated Fuel Resolution
Performthefollowingsteps for aeratedfuel resolution:
guidelines.
4. Replacedamagedcomponentsasrequired; refer toOEM guidelines.
5. Verify aeratedfuel resolution; refer tosection15.5.24.1.
15.5.24.1 Test Engine with Aerated Fuel Resolution
Todetermineif aeratedfuel resolutionresolvedstartingdifculty, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart andrun, checkfor arestrictiveair lter; refer tosection15.5.25.
15.5.25 Troubleshooting Procedure for Restrictive Air Filter
Todetermineif arestrictiveair lter iscausingstartingdifculty, performthefollowingsteps:
1. Removetheair lter element; refer toOEM guidelines.
PERSONAL INJURY
2. Attempt tostart andruntheengine.
[a] If theenginestarts andruns, nofurther enginetroubleshootingis required. Shut
downtheengine.
[b] If theenginefailstostart andrun, refer tosection15.5.26.
15.5.26 Air Filter Replacement
Performthefollowingsteps for air lter replacement:
1. Visually inspect theair lter for cloggingandreplaceas necessary; refer to OEM
guidelines.
2. Visually inspect gaskets for deteriorationandreplaceas necessary; refer to OEM
guidelines.
3. Visuallyinspect air inletsfor restrictionsandcleanasnecessary; refer toOEM guidelines.
4. Verifyair lter replacement; refer tosection15.5.26.1.
15.5.26.1 Test Engine with Replaced Air Filter
Todetermineif thereplacedair lter resolvedstartingdifcult, performthefollowingsteps:
PERSONAL INJURY
1. Attempt tostart theengine, if theenginestartsandruns, nofurther troubleshootingis
required. Shut downtheengine.
2. If theenginefailstostart andrun, check compression; refer tosection15.5.27.
15.5.27 Troubleshooting Procedure for Low Compression
Todetermineif lowcompressioniscausingstartingdifculty, performthefollowingsteps:
1. Performacylinder compressiontest. Refer tosection1.2.2.2.
2. Comparecylinder compressiontest resultstospecicationsaslistedinTable15-38.
Descripti on Pressure i n kPa (psi )
Compression Pressure at Starter Speed 2800 (406)
Permissible Difference between Individual Cylinders 400 (58)
Table 15-38 Compression Testing Speci cations
Center at 313-592-5800.
15.5.28 Low Compression Repair
Performthefollowingstepsfor lowcompressionrepair:
3. Replacedamagedvalves; refer tosection1.17.
4. Inspect thecylinder kit componentsfor wornor damagedliners; pistonsor pistonrings.
5. Verifyrepairsmadetocylinder headvalve(s) or cylinder kit components; refer tosection
15.5.28.1.
15.5.28.1 Test Engine with Repaired Cylinder Head Valve(s), and Cylinder
Kit
Todetermineif thecylinder headvalveandcylinder kitrepair resolvedstartingdifculty, perform
thefollowingsteps:
PERSONAL INJURY
2. If theenginefails tostart andrun, call theDetroit Diesel Customer Support Center at
313-592-5800.
15.6 NO START (ENGINE WILL NOT ROTATE)
Thereareseveral causesfor theenginetonot start. Theseprobablecausesare:
DischargedBattery
DefectiveMagnetic Switch
DefectiveStarter
Internal EngineDamage
15.6.1 Troubleshooting Procedure for Discharged Battery
Todetermineif adischargedbattery iscausingtheenginenot tostart, measureandrecordthe
voltageat thebattery terminals; refer toOEM guidelines.
1. If, after charging, thevoltagerecordedisbelowOEM specications, voltageisbetween
10.5- 14volts (21- 26volts for a24-volt system), andtheenginefailedto start,
replacement is necessary; refer tosection15.6.2.
2. If thevoltagerecordedisat recommendedOEM specicationsandtheenginefailedto
start, check themagneticswitch; refer tosection15.6.3.
15.6.2 Discharged Battery Resolution
Performthefollowingstepsfor battery replacement:
1. Replacethebattery; refer toOEM guidelines.
2. Verifyreplacement of thebattery; refer tosection15.6.2.1.
15.6.2.1 Test Engine with New Battery
Todetermineif thenewbatteryresolvedthenostart condition, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefailstostart or run, checkthemagneticswitch; refer tosection15.6.3.
15.6.3 Troubleshooting Procedure for a Defective Magnetic Switch
Todetermineif adefectivemagneticswitchiscausingnostart:
PERSONAL INJURY
1. Start engine.
2. Clampaheavy gagebattery cablebetweenthetwolargestudsof themagnetic switch.
SeeFigure15-16.
Figure 15-16 Basic Cranking Circuit
[a] If theenginecrankedwiththejumper cableinplace, themagnetic switchmust be
replaced; refer to section15.6.4.
[b] If theenginedidnot crank withthejumper cableinplace, check thestarter;
15.6.4 Magnetic Switch Replacement
Performthefollowingstepsfor magneticswitchreplacement:
1. Replacethemagneticswitch; refer toOEM guidelines.
2. Performvericationof magneticswitchreplacement; refer tosection15.6.4.1.
15.6.4.1 Test Engine with New Magnetic Switch
Todetermineif themagneticswitchreplacement resolvedthenostart condition, performthe
followingsteps:
PERSONAL INJURY
2. If theenginefailstostart or run, check thestarter; refer tosection15.6.5.
15.6.5 Troubleshooting for a Defective Starter
Todetermineif adefectivestarter iscausingnostart, performthefollowingsteps:
1. Placetheredleadof avoltmeter tothesolenoidBAT terminal. SeeFigure15-17.
1. Black Lead 4. Red Lead
2. Starter Ground 5. Voltmeter
3. Solenoid Terminal
Figure 15-17 Cranking Motor Available Voltage Test
2. Placetheblack voltmeter leadtothestarter groundterminal. SeeFigure15-17.
3. Engagethestarter switch.
4. Viewthevoltagereadingonthemeter.
[a] If thevoltageislessthanspecication(refer toOEM guidelines) whilecrankingthe
engine, replacestarter; refer tosection15.6.6.
[b] If thevoltageistospecication(refer toOEM guidelines) whileattemptingtocrank
theengine, check for internal enginedamage; refer tosection15.6.7.
15.6.6 Starter Replacement
Performthefollowingsteps for starter replacement:
1. Replacethestarter; refer tosection8.1.
2. Verifyreplacement of starter; refer tosection15.6.6.1.
15.6.6.1 Test Engine with New Starter
Todetermineif thenewstarter resolvedno-start conditions, performthefollowingsteps:
PERSONAL INJURY
Attempt tostart andruntheengine, if theenginestartsandruns, nofurther troubleshooting
If theenginefailstostart or run, checkfor internal enginedamage. Refer tosection15.6.7.
15.6.7 Troubleshooting Procedure for Internal Engine Damage
Todetermineif internal enginedamageiscausingno-start condition, performthefollowingsteps:
1. Install a3/4in. breaker bar or ratchet andattempt tobar theengineover byhand.
2. Determinetheseverityof internal enginedamage.
[a] If theenginerotatesfreely, check theDDEC-ECU wiringharness; refer tosection
15.5.1.
[b] If theenginebinds andwill not rotatefreely, replacecrankshaft bearings;
refer to section1.6andcylinder liners.
15.6.8 Internal Engine Damage Replacement
Performthefollowingstepsfor crankshaft bearings, andcylinder liner replacement:
1. Replacethecrankshaft bearings; refer tosection1.6.
2. Replacethecylinder liners.
3. Verifyreplacement of components; refer tosection15.6.8.1.
15.6.8.1 Test Engine with Replaced Components
Todetermineif thenewcomponentsresolvednostart condition, performthefollowingsteps:
PERSONAL INJURY
2. If theenginefails to start or run, call Detroit Diesel Customer Support Center at
313-592-5800.
15.7 EXCESSIVE OIL CONSUMPTION
DDC recommends avehicleaccumulateat least 20,000miles (or 2ndoil change) for oil
consumptiontostabilize. Oil consumptionratesabove700miles/quart areconsiderednormal. A
highmileageenginewill tendtobeless. Thereareseveral causesfor excessiveoil consumption.
Theseprobablecauses are:
MiscalibratedDipstick
External Oil Leaks
LeakingOil Heat Exchanger Core
DefectiveAir Compressor
DefectiveTurbocharger
15.7.1 Troubleshooting Procedure for Miscalibrated Dipstick
To determineif anoverlledcrankcaseis causingexcessiveoil consumption, performthe
following:
1. Ensurethevehicleisparkedonlevel ground.
2. Draintheoil pan. Rell oil pantotheproper capacity. Refer tosection13.1.4.
[a] If acalibrationcheck indicatesthat theoil level isoff bymorethan2.0mm(0.079
in.), contact Detroit Diesel Customer Support Center at 313-592-5800.
[b] Check for oil leaks; refer tosection15.7.2.
15.7.2 Troubleshooting Procedure for External Oil Leaks
Todetermineif oil leaksarecausingexcessiveoil consumption, performthefollowing:
1. Steamcleantheengine.
PERSONAL INJURY
2. Start andruntheenginetooperatingtemperature: 88C (190F).
3. Check for leaksat oil lines, connections, matingjoints, seals, andgaskets.
[a] If nooil leaksarefound, shutdowntheengineandcheckfor aleakingoil cooler core;
[b] If oil leaksarefound, shut downtheengine; refer tosection15.7.3.
15.7.3 Engine Oil Leak Repair
Performthefollowingsteps, asnecessary, toresolveengineoil leaks:
1. Repair or replacecomponentsleakingoil; refer tochapter 3.
2. Verifyrepairsmadetocorrect oil leaks; refer tosection15.7.3.1.
15.7.3.1 Test Engine with Repairs Made to Correct Oil Leaks
Performthefollowingstepstodetermineif therepairsresolvedtheoil leaks:
PERSONAL INJURY
3. Check theenginefor oil leaks.
[a] If no oil leaks areobserved, check for aleakingoil heat exchanger core;
[b] If external oil leaksarepresent, refer tosection15.7.3andrepeat.
15.7.4 Troubleshooting Procedure for a Leaking Oil Heat Exchanger
Core
Todetermineif aleakingoil heat exchanger coreiscausingexcessiveoil consumption, perform
thefollowing:
1. Check for oil intheenginecoolant or radiator.
[a] If oil ispresent ineither theenginecoolant or radiator; gotostep2.
[b] If no oil is present ineither theenginecoolant or radiator, check for adefective
air compressor; refer tosection15.7.5.
2. Removetheoil heat exchanger coreandhousing.
3. Cleanboththeoil sideandwater sideof theoil heat exchanger core.
4. Visually inspect thecorefor cracks.
[a] If cracksarepresent, replaceoil heat exchanger core. Refer tosection3.6.1. Verify
thereplacement of theoil heat exchanger core, refer tosection15.7.4.1
[b] If nocracksarepresent, completealubeoil consumptionreport; call theDetroit
Diesel Customer Support Center at 313-592-5800for aform.
15.7.4.1 Test Engine with New Oil Heat Exchanger Core
Performthefollowingsteps todetermineif thereplacedoil heat exchanger corereducedthe
oil consumption:
PERSONAL INJURY
3. Check theenginecoolant for thepresenceof oil.
[a] If no oil is present inthecoolant, performalubeoil consumptiontest report;
refer to section15.7.4.2.
[b] If oil ispresent inthecoolant, check for adefectiveturbocharger. Refer tosection
15.7.6.
15.7.4.2 Test Engine for Reduced Oil Consumption
Performalubeoil consumptionreport; call theDetroit Diesel Customer Support Center at
313-592-5800for aform.
Reviewtheoil consumptionreport.
1. If theoil consumptionreport datais withinspecications, check for defectiveair
compressor; refer to section15.7.5.
2. If theoil consumptionreportdataisnot withinspecications, call Detroit Diesel Customer
Support Center at 313-592-5800.
15.7.5 Troubleshooting Procedure for a Defective Air Compressor
Todetermineif adefectiveair compressor iscausingexcessiveoil consumption, performthe
following:
1. Performacrankcasepressuretest andrecordthetest results. Refer tosection15.4.10.1.
2. Disconnect theair dischargelinefromtheair compressor. SeeFigure15-18;
1. Discharge Port 4. Unloader Port
2. Unloader Air Line 5. Discharge Air Line
3. Intake Air Line 6. Air Compressor
Figure 15-18 Air Line Attachments
3. Repeat step1andrecordtheresults.
4. Comparetheresults of test onewithtest two.
[a] If theenginecrankcasepressureremainedthesame, check theturbocharger;
[b] If theenginecrankcasepressuredecreased, replacetheaircompressor; refertosection
10.1.1. Verifythereplaced(or new) air compressor, refer tosection15.7.5.1.
15.7.5.1 Test Engine with Repaired Air Compressor
Performthefollowingstepstodetermineif thereplaced(or new) air compressor resolvedthe
excessivecrankcasepressure:
PERSONAL INJURY
1. Start andruntheengine.
[a] If theenginecrankcasepressureexceeds0.62kPa(2.5in. H
2
O), shut downthe
engine. Check for defectiveturbocharger. refer tosection15.7.6.
[b] If theenginecrankcasepressureiswithin0.62kPa(2.5in. H
2
O), shut downthe
engine; nofurther troubleshootingisrequired.
15.7.6 Troubleshooting Procedure for a Defective Turbocharger
Todetermineif adefectiveturbocharger is causingexcessiveoil consumption, performthe
following:
1. Removetheturbocharger drainlineconnectedtothecrankcaseandplacethedrainline
into asuitablecontainer.
[a] If theenginecrankcasepressureislessthan0.62kPa(2.5in. H
2
O), shut downthe
engine. Replacetheturbocharger; refer tosection6.4.2. Verify thereplacement of
theturbocharger, refer tosection15.7.6.1.
[b] If theenginecrankcasepressureindicatesnochange, shut downtheengine. Check
for wornor damagedvalveor cylinder kit. Refer tosection15.7.7.
15.7.6.1 Test Engine with New Turbocharger
Performthefollowingstepstodetermineif anewturbocharger resolvedtheexcessivecrankcase
pressure:
into asuitablecontainer.
[a] If theenginecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), check for
wornor damagedvalveor cylinder kit; shutdowntheengine. Refer tosection15.7.7.
[b] If theenginecrankcasepressureis 0.62kPa(2.5in. H
2
O) or less, no further
troubleshootingisrequired. Shut downtheengine.
Cylinder Kit
A lossof cylinder pressurecancauseincreasedoil consumption. Thedetectionandeliminationof
cylinder pressurelossesisvital toenginelifeandefcient operation. Toassist themechanicin
effectivelymeasuringthelossof cylinder pressure, andlocatingthesourceof abnormal leaksin
individual cylinders, thefollowingtest procedurehasbeendeveloped:
2. Disconnect theair compressor andremove; refer tosection10.1.1.
PERSONAL INJURY
3. Start theengine.
9. Reviewthecrankcasepressuretest results.
[a] If thecrankcasepressureexceeds0.62kPa(2.5in. H
2
O), repair wornor damaged
valve(s) or cylinder kit; refer tosection15.7.8.
[b] If thecrankcasepressurewaslessthanor equal to0.62kPa(2.5in. H
2
O), perform
acylinder compressiontest. Refer tosection1.2.2.2.
10. Comparethecylinder compressiontest resultstospecicationsaslistedinTable1-10.
[a] If thecylinder compressionisbelowspecications, repair wornor damagedvalve(s)
or cylinder kit; refer to section15.7.8.
[b] If thecylinder compressioniswithinspecications, call Detroit Diesel Customer
15.7.8 Worn or Damaged Valve(s) or Cylinder Kit(s) Repair
Performthefollowingstepstorepair wornor damagedvalve(s) andcylinder kit(s):
1. Removethecylinder head; refer tosection1.2.1.
3. Inspect thecylinder kit componentsfor wornor damagedliners; pistonsor pistonrings;
refer tosection1.15.3.1.
4. Replacedamagedcylinder kit components.
5. Verifyrepairsmadetocylinder headvalve(s) or cylinder kit components; refer tosection
15.7.8.1.
Kit
Todetermineif thecylinder headvalveandcylinder kitrepair resolvedstartingdifculty, perform
thefollowingsteps:
PERSONAL INJURY
inrequired.
2. If theenginefails tostart andrun, call theDetroit Diesel Customer Support Center at
313-592-5800.
15.8 EXCESSIVE CRANKCASE PRESSURE
Thereareseveral causesfor excessivecrankcasepressure. Theseprobablecausesare:
Obstructionor DamagetoCylinder HeadCover Breather
DefectiveAir Compressor
15.8.1 Troubleshooting Procedure for Obstruction or Damage to
Cylinder Head Cover Breather
Todetermineif anobstructedor damagedbreather iscausingexcessivecrankcasepressure,
performacrankcasepressuretest. Refer tosection15.4.10.1.
1. If theenginecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), replacewiremesh
element; refer to section15.8.2.
2. If thecrankcasepressureremained thesame, check theair compressor;
15.8.2 Cylinder Head Cover Breather Resolution
Performthefollowingstepstoreplacewiremeshelement:
1. Removethecylinder headcover; refer tosection1.1.1.
2. Removethewiremeshelement fromthecylinder headcover.
3. Install anewwiremeshelement tothecylinder headcover.
4. Install thecylinder headcover totheengine; refer tosection1.1.2.
5. Verifyreplacement of thewiremeshelement; refer tosection15.8.2.1.
15.8.2.1 Test Engine with New Wire Mesh Element
Performthefollowingstepstodetermineif thenewwiremeshelement resolvedtheexcessive
crankcasepressure:
PERSONAL INJURY
2. Performacrankcasepressuretest; refer tosection15.4.10.1.
[a] If theenginecrankcasepressureis less than0.62kPa(2.5in. H
2
O), no further
[b] If theenginecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), check theair
compressor; refer tosection15.8.3. Shut downtheengine.
15.8.3 Troubleshooting Procedure for Defective Air Compressor
Todetermineif adefectiveair compressor iscausingexcessivecrankcasepressure, perform
thefollowing:
1. Performacrankcasepressuretest andrecordthetest results. Refer tosection15.4.10.1.
2. Disconnect theair dischargelinefromtheair compressor; seeFigure15-19.
Refer tosection10.1.1.
1. Discharge Port 4. Unloader Port
2. Unloader Air Line 5. Discharge Air Line
3. Intake Air Line 6. Air Compressor
Figure 15-19 Air Line Attachments
3. Repeat step1andrecordthetest results.
4. Comparetheresults of test onewithtest two.
[a] If theenginecrankcasepressureremainedthesame, check theturbocharger;
[b] If theenginecrankcasepressuredecreased, repair or replacetheair compressor;
refer to section10.1.
15.8.3.1 Test Engine with Repaired Air Compressor
Performthefollowingstepstodetermineif arepairedair compressor resolvedtheexcessive
crankcasepressure:
PERSONAL INJURY
[a] If theenginecrankcasepressureis within0.62kPa(2.5in. H
2
O), no further
[b] If theenginecrankcasepressureisnot within0.62kPa(2.5in. H
2
O), shut downthe
engine. Check theturbocharger; refer tosection15.8.4.
Todetermineif adefectiveturbocharger iscausingexcessivecrankcasepressure, performthe
following:
NOTICE:
Ensure that the engine is not allowed to operate longer than
necessary to performthe crankcase pressure test. A complete
loss of crankcase oil will severely damage the engine.
intoasuitablecontainer; refer tosection6.4.2.
2
O), replacethe
turbocharger; refer tosection6.4.2. Shut downtheengine.
[b] If theenginecrankcasepressureindicatesnochange, check for awornor damaged
valveor cylinder kit; refer tosection15.8.6. Shut downtheengine.
15.8.5 Turbocharger Replacement
Performthefollowingstepstoreplaceadefectiveturbocharger:
1. Removethedefectiveturbocharger fromtheengine; refer tosection6.4.2.
2. Tagtheremovedturbocharger for remanufacture.
3. Install areplacement turbocharger totheengine; refer tosection6.4.3.
4. Verifyreplacement of newturbocharger; refer tosection15.8.5.1.
15.8.5.1 Test Engine with New Turbocharger
To determineif anewturbocharger resolvedtheexcessivecrankcasepressure, performa
crankcasepressuretest. Refer tosection15.4.10.1.
1. If theenginecrankcasepressureis 0.62kPa(2.5in. H
2
O) or less, no further
2. If theenginecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), shut downthe
engine. Check for awornor damagedvalveor cylinder kit; refer tosection15.8.6.
Cylinder Kit
Todetermineif awornor damagedcylinder kit iscausingexcessivecrankcasepressure, perform
thefollowing:
2. Removeair compressor; refer tosection10.1.1.
PERSONAL INJURY
3. Start theengine.
6. Attachamanometer calibratedtoreadpressurekPaor inchesof H
2
O, totheoil dipstick
opening.
10. Reviewthecrankcasepressuretest.
[a] If thecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), gotostep11.
[b] If thecrankcasepressureis less than0.62kPa(2.5in. H
2
O), no further
troubleshootingis required.
11. Performthecylinder compressiontest. Refer tosection1.2.2.2.
[a] If cylinder pressureisbelowspecications, refer toTableandrefer tosection15.8.7.
Center at 313-592-5800.
15.8.7 Worn or Damaged Valve or Cylinder Kit Repair
Performthefollowingstepsfor awornor damagedvalveor cylinder kit:
3. Inspect thecylinder kit componentsfor wornor damagedliners, pistonor pistonrings;
4. Verifyrepair tocylinder valve(s) or cylinder kit components; refer tosection15.8.7.1.
15.8.7.1 Test Engine with Repairs Made to Correct Worn or Damaged
Valve or Cylinder Kit
Performthefollowingtodetermineif therepairedvalveor cylinder kit resolvedtheexcessive
crankcasepressure:
2. Disconnect air compressor; refer tosection10.1.1.
PERSONAL INJURY
3. Start theengine.
6. Attachamanometer calibratedtoreadpressureinkPaor inchesof H
2
opening.
10. Comparethecylinder pressuretest resultstospecicationslistedinTable1-10.
[a] If cylinder pressureiswithinspecications, nofurther troubleshootingisrequired.
[b] If cylinder pressureisnot withinspecications, call Detroit Diesel Customer Support
Center at 313-592-5800.
15.9 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
Therearemanycausesfor excessiveblackor grayexhaust smoke. Theseprobablecausesare:
RestrictedAir Cleaner Element
Restrictedor CrackedChargeAir Cooler
Faulty Air IntakeManifoldGasket
Faulty Exhaust ManifoldGasket
AeratedFuel
Faulty Fuel Nozzle
Improper Gradeof Fuel
Faulty EGR valve
Incorrectly AdjustedExhaust Brake
Faulty Exhaust BrakeValve
Faulty Exhaust BrakeCylinder
Faulty Constant ThrottleValve
Incorrect ValveClearance
LowCompression
15.9.1 Troubleshooting Procedure for Restricted Air Cleaner Element
Todetermineif arestrictiveair cleaner element is causingexcessiveblack or gray smoke,
performthefollowing:
1. Removetheair lter element fromtheair cleaner container; refer toOEM guidelines.
2. Visuallyinspect theair cleaner element for damageor clogging.
[a] If nodamageor cloggingisfound, checkthechargeair cooler; refer tosection15.9.3.
[b] If damageor cloggingisfound, refer tosection15.9.2.
15.9.2 Air Filter Element Replacement
Performthefollowingtoreplacetheair lter element:
1. Removeandreplacethedamagedor cloggedair lter element; refer toOEM guidelines.
2. Verify that replacingtheair lter element eliminatedtheexcessiveexhaust smoke;
15.9.2.1 Test the Engine with Replaced Air Filter Element
Performthefollowingtodetermineif thenewlter element resolvedexcessiveexhaust smoke:
PERSONAL INJURY
2. Runtheengineat idlewithano-loadconditionfor approximatelyveminutes, allowing
theenginecoolant toreachnormal operatingrange, approximately88-96C (190-205F).
3. Visually inspect exhaust for excessivesmoke.
[a] If theengineexhaustemissionappearsnormal, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theengineexhaust emissionisexcessively black or gray, shut downtheengine.
Check thechargeair cooler; refer tosection15.9.3.
15.9.3 Troubleshooting Procedure for a Restricted or Cracked Charge
Air Cooler
Todetermineif achargeair cooler iscausingexcessiveexhaust smoke, performthefollowing:
NOTICE:
To avoid engine damage, follow the installation instructions
provided with the air-to-air charge air cooler test kit.
1. Visuallyinspect thecore, tanks, andweldsfor cracksandholes. If chargeair cooler fails
visual inspectionreplacethechargeair cooler. Refer tosection15.9.4.
2. Pressuretest thechargeair cooler; refer tosection15.9.3.1.
3. Evaluatetheresultsfrompressuretestingthechargeair cooler.
[a] If thepressuredropis34kPa(5psi) or lessin15secondsthecooler isgood. Check
for faulty air intakemanifold. Refer tosection15.9.5.
[b] If thepressuredropisgreater than34kPa(5psi) in15seconds, replacethechargeair
cooler. Refer to section15.9.4.
15.9.3.1 Pressure Testing the Charge Air Cooler
Performthefollowingtopressuretest thechargeair cooler:
1. Usethechargeair cooler tester (J -41473) totest cooler for leaks. SeeFigure15-20for
component parts.
1. Gauge Coupler 6. Gauge
2. Bleed-off Coupler 7. Pressure Relief Valve
3. Bleed Valve 8. Air Regulator Valve
4. Safety Straps 9. Air Shutoff Valve
5. Quick Disconnect 10. Quick Disconnect Fitting
Figure 15-20 Charge Air Cooler Tester J-41473
2. Disconnect theair inlet andoutlet pipingconnectingthechargeair cooler totheengine.
3. Install thechargeair cooler test gaugecoupler intotheinlet hose(hot side) of thecharge
air cooler comingfromtheturbocharger compressor. Securehoseandcoupler withclamp
removedandtorquetheclampto5.6-6.78Nm(50-60lbin.). SeeFigure15-21.
1. Gauge/Regulator Assembly 6. Bleed-off Coupler
2. Quick Disconnect Fitting 7. Charge Air Cooler Hose (Cold Side)
3. Gauge Coupler 8. Clamp
4. Charge Air Cooler Hose (Hot Side) 9. Charge Air Cooler
5. Safety Strap
Figure 15-21 Charge Air Cooler and Tester J-41473
4. Attachthegauge/regulator assemblytothequick disconnect ttingonthegaugecoupler.
5. Usetheclampremovedtoattachthebleed-off coupler totheoutlet hose(coldside) of the
chargeair cooler. Torquetheclampto5.6-6.78Nm(50-60lbin.).
6. Connect thesafety straps onthecouplers to any convenient screwontheradiator
mountingbracket.
PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles
when conducting a pressure test.
7. Attachanair pressureline, withlteredair, to theair shutoff valveandgradually
pressurizethechargeair cooler toapressureof 205kPa(30psi). If necessary, performthe
followingstepstoadjust theair regulator until thegaugereads205kPa(30psi):
[a] Pull regulator knoboutwardtounlock.
[b] Turnknobtoadjust pressureto205kPa(30psi).
[c] Pushtheregulator knobback intolockedposition.
8. Closetheair shutoff valveandmonitor thegaugewithastopwatchfor 15seconds. Note
any decreaseinair pressure.
9. Repeat test at least threetimes toverify results.
[a] Inpressuredropis34kPa(5psi) or lessin15secondsthecooler isgood.
cooler. Refer tosection15.9.4.
10. Slowly releasepressurewiththechargeair cooler byopeningthevalveinthebleed-off
coupler.
11. Removeall chargeair cooler tester piecesandreconnect chargeair cooler pipingtothe
engine.
12. Reconnect air inlet andoutlet pipingtoengine. Torquehoseclampsto5.6- 6.78Nm
(50- 60lbin.).
15.9.4 Charge Air Cooler Replacement
Performthefollowingstepstoreplacethechargeair cooler:
1. Replacethechargeair cooler; refer toOEM guidelines.
2. Verify that thereplacement of thechargeair cooler eliminatedtheexcessiveexhaust
smoke; refer to section15.9.5.1.
15.9.5 Troubleshooting Procedure for a Faulty Air Intake Manifold
Gasket
Performthefollowingstepstotroubleshoot theair intakemanifold:
1. Removetheair intakemanifold; refer tosection6.2.1.
2. Inspect theair intakemanifoldandgaskets.
3. Install theair intakemanifoldwithnewgaskets; refer tosection6.2.2.
4. Verifyrepair of theair intakemanifold; refer tosection15.9.5.1.
15.9.5.1 Test the Engine with a Replaced Charge Air Cooler or Air Intake
Manifold Gasket Replacement
Todetermineif thereplacedchargeair cooler or air intakemanifoldgasket resolvedtheexcessive
exhaust smokecondition, performthefollowing:
PERSONAL INJURY
3. Visually inspect exhaust for excessiveblack or graysmoke.
Shut downtheengine.
Check for afaulty exhaust system; refer tosection15.9.6.
15.9.6 Troubleshooting Procedure for a Faulty Exhaust System
To determineif afaulty exhaust systemis causingexcessiveblack or gray exhaust smoke,
1. Drill an11/32in. holeintheexhaust pipe, 125- 305mm(5- 12in.) fromtheturbocharger
exhaust outlet.
NOTE:
The tapped hole must be in a comparatively straight section of the turbocharger exhaust
outlet.
2. Taptheholetoaccommodatea1/8in. pipeplug.
3. Connect amanometer calibratedtoreadpressureinkPaor inchesof Hgtothetappedhole.
PERSONAL INJURY
6. Runtheenginespeedtofull load.
[a] If theexhaust back pressureat full loadislessthan12kPa(3.5in. Hg), check the
fuel injectorsandnozzles; refer tosection15.9.10. Shut downtheengine.
[b] If theexhaust back pressureat full loadis 12kPa(3.5in. Hg) or greater,
refer tosection15.9.7. Shut downtheengine.
15.9.7 Engine Exhaust System Resolution
Performthefollowingstepstoresolvetheengineexhaust systemconcern:
1. Visuallyinspect theengineexhaust system: refer toOEM guidelines.
2. Repair andreplacedefectiveexhaust systemcomponents; refer toOEM guidelines
3. Verifyexhaust systemresolutionrefer tosection15.9.7.1.
15.9.7.1 Test the Engine with Replaced Exhaust System
Performthefollowingstepstodetermineif replacedengineexhaust manifoldhasresolvedthe
excessiveblack or gray exhaust smokecondition:
PERSONAL INJURY
Shut downtheengine.
Check thefuel nozzles; refer tosection15.9.8.
Todetermineif aeratedfuel iscausingexcessiveexhaust smoke, performthefollowingsteps:
guidelines.
2. Placetheopenedendof thefuel lineintoasuitablecontainer.
PERSONAL INJURY
3. Start theengine.
[a] If air bubblesarepresent, repair isnecessary; refer tosection15.9.9.
[b] If air bubblesarenot present, check for alowcompression. Shut downtheengine;
Performthefollowingsteps for aeratedfuel resolution:
guidelines.
4. Replacedamagedcomponentsasrequired.
5. Verify aeratedfuel resolutioncorrectedtheexcessiveexhaust smokecondition;
refer to section15.9.9.1.
15.9.9.1 Test Engine with Aerated Fuel Resolution
Todetermineif aeratedfuel resolutionresolvedtheexcessiveexhaust smokeconcern, perform
thefollowingsteps:
PERSONAL INJURY
1. Attempt tostart andruntheengine, if theenginestartsandrunswithnoexhaust smoke,
nofurther troubleshootingisrequired. Shut downtheengine.
2. If theenginestill has excessiveexhaust smoke, check for faulty fuel nozzle;
refer tosection15.9.10.
15.9.10 Troubleshooting Procedure for a Faulty Fuel Nozzle
Totroubleshoot thefuel nozzle, refer tosection15.3onFuel InjectionTroubleshooting. After
completingfuel injectiontroubleshooting, verify that repairs madecorrectedtheexcessive
exhaust smoke. Refer tosection15.9.10.1.
15.9.10.1 Test the Engine with Replaced Fuel Nozzle
Performthefollowingstepstodetermineif replacedfuel nozzlehasresolvedtheexcessiveblack
or gray exhaust smokecondition:
PERSONAL INJURY
[a] If theengineexhaust emissionappearsnormal, nofurther troubleshootingisrequired.
Shut downtheengine.
Check theturbocharger; refer tosection15.9.11.
To determineif adefectiveturbochargeis causingexcessiveexhaust smoke, performthe
following:
1. Removetheturbocharger oil drainoutlet lineconnectedtothecrankcaseandplacethe
drainlineintoasuitablecontainer; refer tosection6.4.2.
2. Rotateturbinewheel tocheck for freemovement. If wheel doesnot movefreely, replace
turbocharger; refer tosection6.4.2.
3. Verify that replacingtheturbocharger correctedtheexcessivesmokeproblem;
2
O), shut down
theengineandreplacetheturbocharger; refer to section6.4.2. Verify replaced
turbocharger correctedtheexcessivesmokeproblem; refer tosection15.9.11.1.
[b] If theenginecrankcasepressureisgreater than0.62kPa(2.5in. H
2
O), shut down
theengine. Connect theoil drainoutlet linetotheturbocharger andcall theDetroit
Diesel Customer Support Center at 313-592-5800.
15.9.11.1 Test Engine with a Replaced Turbocharger
Performthefollowingstepstodetermineif areplacedturbocharger hasresolvedtheexcessive
exhaust smokecondition:
PERSONAL INJURY
1. Start theengine.
3. Visuallyinspect theexhaust for excessiveblack or graysmoke.
Shut downtheengine.
[b] If theengineexhaustemissionisexcessive, shutdowntheengine, checkfor improper
gradeof fuel. Refer tosection15.9.12.
15.9.12 Troubleshooting Procedure for Improper Grade of Fuel
Todetermineif animproper gradeof fuel iscausingexcessiveblack or gray smoke, perform
thefollowing:
1. Acquireafuel samplefromthevehiclefuel tank(s).
2. Submit fuel samplefor anASTM test analysis.
[a] If thefuel meetsspecications, checkfor afaultyEGRvalve; refer tosection15.9.14.
[b] If thefuel didnot meetspecications, resolveimproper gradeof fuel; refer tosection
15.9.13andDDC publicationLubricating Oil, Fuel, and Filters (7SE270).
15.9.13 Improper Grade of Fuel Resolution
Performthefollowingstepstoresolvetheimproper gradeof fuel:
1. Drainthefuel tanks, refer toOEM guidelines, anddisposeof fuel properly.
2. Rell thefuel tankswithnewfuel havingacetanenumber greater than45andcetane
index greater than40.
3. Verifyfuel resolutioneliminatedtheexcessiveexhaust smokecondition; refer tosection
15.9.13.1.
15.9.13.1 Test the Engine with New Fuel
Performthefollowingstepstodetermineif thefuel rell resolvedtheexcessiveexhaust smoke
condition:
PERSONAL INJURY
2. Runtheengineat idleunder no-loadconditionsfor approximatelyveminutes, allowing
[a] If theenginesmokeemissionappearsnormal, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theengineexhaust smokeisexcessively black or gray, shut downtheengine.
Check theEGR valve; refer tosection15.9.14.
15.9.14 Troubleshooting Procedure for a Faulty EGR Valve
To determineif afaulty EGR valveis causingexcessiveblack or gray smoke, performthe
following:
1. RemovetheEGR valve; refer tosection10.6.1.
2. Inspect theEGR valveapfor freedomof movement.
[a] If freedomof movement isrestrictedremovesoot andcleandepositsasrequired.
[b] If movement of valveisstill not free, replacetheEGR valve. Refer tosection10.6.2.
Verify thereplacement of theEGR valvecorrectedtheexcessiveexhaust smoke
concern; refer to section15.9.14.1
3. PerformaPV2activationtest to verify apvalvefunctionality. Call Detroit Diesel
Customer Support Center at 313-592-5800for instructions.
15.9.14.1 Test the Engine with Replaced EGR Valve
Performthefollowingstepstodetermineif thereplacedEGR valveresolvedtheexcessive
PERSONAL INJURY
Shut downtheengine.
Check theexhaust brakevalve; refer tosection15.9.16.
15.9.15 Troubleshooting Procedure for a Incorrectly Adjusted Exhaust
Brake Valve
Todetermineif amisadjustedexhaust brakevalveiscausingexcessiveblack or gray smoke,
1. Readjust theexhaust brakevalve; refer to section7.2.3for a6-cylinder engineor
refer tosection7.2.5for a4-cylinder engine.
2. Verifytheadjustment ontheexhaust brakevalve; refer tosection15.9.15.1
15.9.15.1 Test Engine After Adjusting the Exhaust Brake Valve
Performthefollowingstepstodetermineif theexhaust brakeadjustment resolvedtheexcessive
PERSONAL INJURY
Shut downtheengine.
Check theexhaust brakevalve; refer tosection15.9.16.
15.9.16 Troubleshooting Procedure for a Faulty Exhaust Brake Valve
Todetermineif afaulty exhaust brakevalveiscausingexcessiveblack or graysmoke, check
exhaust brakevalvefor freedomof movement.
1. If movement is not free, replaceexhaust brakevalve; refer to section7.2. Verify
replacement of theexhaust brakevalve; refer tosection15.9.16.1.
2. If movement isfree, check theexhaust brakecylinder; refer tosection15.9.17.
15.9.16.1 Test Engine for Replaced Exhaust Brake Valve
Performthefollowingsteps to determineif thereplacedexhaust brakevalveresolvedthe
excessiveexhaust smokecondition:
PERSONAL INJURY
Shut downtheengine.
Check theexhaust brakecylinder; refer tosection15.9.17.
15.9.17 Troubleshooting Procedure for a Faulty Exhaust Brake Cylinder
Todetermineif afaultyexhaust brakecylinder iscausingexcessiveblack or graysmoke, check
exhaust brakecylinder for full movement of travel byapplyingregulatedair tocylinder.
1. If movement of travel isnot full, replacetheexhaust brakecylinder; refer tosection7.2.1.
Verify replacement of exhaust brakecylinder correctedtheexcessiveexhaust smoke
concern; refer tosection15.9.17.1.
2. If full movement of travel isobtained, refer tosection15.9.18.
15.9.17.1 Test Engine for Replaced Engine Brake Cylinder
Performthefollowingsteps to determineif thereplacedenginebrakecylinder resolvedthe
PERSONAL INJURY
Shut downtheengine.
Check theconstant throttlevalve; refer tosection15.9.18.
15.9.18 Troubleshooting Procedure for a Faulty Constant Throttle Valve
Todetermineif afaultyconstant throttlevalveiscausingexcessiveblackor graysmoke, measure
theresistancebetweenwire52inthe55-pinconnector andvehicleground.
1. If theresistanceisgreater than30k, replacetheconstant throttlevalve; refer tosection
3.8.9. Verifythereplacement of theconstant throttlevalve; refer tosection15.9.18.1.
2. If theresistanceislessthan30k, refer tosection15.9.19.
15.9.18.1 Test Engine for Replaced Constant Throttle Valve
Performthefollowingstepstodetermineif thereplacedconstant throttlevalveresolvedthe
PERSONAL INJURY
Shut downtheengine.
Todetermineif animproper valveclearance, wornor damagedcamshaft lobesor rollersare
causingexcessiveexhaust smoke, performthefollowing:
1. Check for improper valveclearance, andwornor damagedcamshaft lobesandrollers.
Repair asrequired. Refer tosection1.17.2andsection1.20.
2. Verifyvalveclearance, wornor damagedcamshaft lobesandrollersrepair correctedthe
excessiveexhaust smokeconcern; refer tosection15.9.19.1.
15.9.19.1 Test Engine with Corrected Valve Clearance, Worn or Damaged
Camshaft Lobes and Rollers
Performthefollowingstepstodetermineif thevalveclearance, wornor damagedcamshaft lobes
androllersrepair hasresolvedexcessiveexhaust smokecondition:
PERSONAL INJURY
theenginecoolant toreachnormal operatingrange.
3. Visually inspect exhaust for excessiveexhaust smoke.
[a] If theengineexhaust smokeemissionappearsnormal, nofurther troubleshootingis
[b] If theengineexhaust smokeemissionisexcessive, shut downtheengine. Check for
lowcompression; refer tosection15.9.20.
15.9.20 Troubleshooting Procedure for Low Compression
Todetermineif lowcompressioniscausingexcessiveexhaustsmoke, performthefollowingsteps:
1. Performacylinder compressiontest; refer tosection1.2.2.2.
Center at 313-592-5800.
15.9.21 Low Compression Repair
Performthefollowingstepsfor lowcompressionrepair.
3. Replacedamagedvalves; refer tosection1.17.5.
4. Inspect thecylinder kit componentsfor wornor damagedliners, pistons; or pistonrings.
5. Verifyrepairsmadetocylinder headvalve(s) or cylinder kit componentshavecorrected
theexcessiveexhaust smokeconcern; refer tosection15.9.21.1.
Kit
Todetermineif thecylinder headvalveandcylinder kit repair resolvedexcessiveexhaust smoke,
performthefollowingsteps:
PERSONAL INJURY
1. Attempt tostart andruntheengine, if theenginestartsandrunswithout excessiveexhaust
smoke, nofurther troubleshootingisrequired. Shut downtheengine.
2. If theenginecontinuestohaveexcessiveexhaust smoke, call theDetroit Diesel Customer
15.10 EXCESSIVE BLUE SMOKE
Thereareseveral causesfor excessiveblueexhaust smoke. Theseprobablecausesare:
MiscalibratedDipstick
Improper Gradeof LubricatingOil
Wornor DamagedIntake/Exhaust Valveor Cylinder Kit
15.10.1 Troubleshooting Procedure for Miscalibrated Dipstick
To determineif anoverlledcrankcaseis causingtheexcessivebluesmoke, performthe
following:
1. Ensurethevehicleisparkedonlevel ground.
2. Draintheoil pan. Rell oil pantotheproper capacity. Refer tosection13.1.4.
[a] If acalibrationcheckindicatesthat theoil level isoff bymorethan2mm(0.079in.),
contact Detroit Diesel Customer Support Center at 313-592-5800.
[b] Verify that thecorrect oil level haseliminatedtheexcessivebluesmokeconcern;
15.10.2 Test the Engine with the Correct Oil Level
Performthefollowingtodetermineif thecorrect oil level resolvedtheexcessivebluesmoke
condition:
PERSONAL INJURY
3. Visually inspect exhaust for excessivebluesmoke.
Shut downtheengine.
[b] If theengineexhaust smokeis excessively blue, shut down theengine.
Refer to section15.10.3
15.10.3 Troubleshooting Procedure for Improper Grade of Lubricating Oil
Todetermineif animproper gradeof lubricatingoil iscausingexcessivebluesmoke, perform
thefollowing:
1. Verifythat theproper gradeof lubricatingoil isbeingusedintheengine.
2. SeeDDC publicationLubricating Oil, Fuel, and Filters (7SE270) for oil specications.
3. If theoil meetsspecications, check for defectiveturbocharger; refer tosection15.10.5.
4. If theoil didnotmeetspecications, resolveimproper gradeof oil; refer tosection15.10.4.
SeeDDC publicationLubricating Oil, Fuel, and Filters (7SE270) for oil specications.
15.10.4 Improper Grade of Lubricating Oil Resolution
Performthefollowingstepstoresolvetheimproper gradeof lubricatingoil:
1. Draintheoil panandlters. Disposeof oil properly.
2. Rell theengineoil panwithrecommendedoil. SeeDDC publicationLubricating Oil,
Fuel, and Filters (7SE270) for oil specications.
3. Verifytheoil resolutioncorrectedtheexcessivebluesmokecondition; refer tosection
15.10.4.1.
15.10.4.1 Test Engine with New Lubricating Oil
Performthefollowingto determineif thenewoil level resolvedtheexcessivebluesmoke
condition:
PERSONAL INJURY
Shut downtheengine.
[b] If theengineexhaust smokeis excessively blue, shut downtheengine.
Todetermineif adefectiveturbocharger iscausingexcessiveblueexhaust smoke, performthe
following:
1. Removethechargeair cooler inlet duct connectedbetweentheturbocharger andcharge
air cooler.
2. Visuallyinspect thecompressor inlet sideof theturbocharger.
[a] If excessiveenginelubeoil ispresent, replacetheturbocharger refer tosection6.4.2.
[b] Verify replacing theturbocharger corrected theexcessivebluesmoke
concern; refer tosection15.10.5.1.
15.10.5.1 Test Engine with Replaced Turbocharger
Performthefollowingstepstodetermineif areplacedturbocharger hasresolvedtheexcessive
blueexhaust smokecondition:
PERSONAL INJURY
2. Runtheengineat idlespeedwithano-loadconditionfor approximately veminutes,
allowingtheenginecoolant toreachnormal operatingrange, approximately 88-96C
(190-205F).
3. Visually inspect theexhaust for excessivebluesmoke.
[b] If theengineexhaust smokeisexcessivelyblue, shut downtheengine. Check for
wornor damagedvalvesor cylinder kit; refer tosection15.10.6.
15.10.6 Troubleshooting Procedure for a Worn or Damaged
Intake/Exhaust Valve or Cylinder Kit
Todetermineif awornor damagedcylinder kit iscausingexcessiveblueexhaust smoke, perform
thefollowing:
1. Movethevehiclerequiringtestingtothechassisdynamometer; refer toOEM guidelines.
2. Disconnect andremovetheair compressor; refer tosection10.1.1.
PERSONAL INJURY
3. Start theengine.
6. Attachamanometer calibratedtoreadpressureinkPaor inchesof H
2
opening.
10. Reviewthecrankcasepressuretest.
[a] If thecrankcasepressurewasgreater than0.62kPa(2.5in. H
2
O), refer tosection
15.10.7.
[b] If thecrankcasepressurewaslessthan0.62kPa(2.5in. H
2
O), performacylinder
compressiontest; refer tosection1.2.2.2.
11. Comparethecylinder compressiontest resultstospecications. Refer tosection1.2.2.2
andspecicationslistedinTable1-10.
Center at 313-592-5800.
15.10.7 Worn or Damaged Intake/Exhaust Valve or Cylinder Kit Repair
Performthefollowingstepsfor wornor damagedintake/exhaust valvesor acylinder kit:
2. Inspect thecylinder headfor wornor damagedvalvesandwornor damagedvalvestem
seals; refer to section1.17.
3. Inspect thecylinder kit componentsfor wornor damagedliners, pistonsor pistonrings;
4. Verifyrepair tocylinder valve(s) or cylinder kit components; refer tosection15.10.7.1.
15.10.7.1 Test Engine with Repairs Made to Correct Worn or Damaged
Intake/Exhaust Valve or Cylinder Kit
Performthefollowingto determineif therepairedintake/exhaust valveor cylinder kit has
resolvedtheexcessivecrankcasepressure:
PERSONAL INJURY
1. Start theengine.
[a] If theengineexhaust smokeemissionappearsnormal for arebuilt engine, nofurther
[b] If theengineexhaust smokeemissionisexcessivelyblue, shut downtheengine. Call
theDetroit Diesel Customer Support Center at 313-592-5800.
15.11 EXCESSIVE WHITE SMOKE
Thereareseveral causesfor excessivewhiteexhaust smoke. Theseprobablecausesare:
Faulty DDEC-ECU
Faulty Turbocharger Boost Sensor
MalfunctioningAir Intake(Grid) Preheater
DefectiveFuel Pump
AeratedFuel
Improper Gradeof Fuel
Faulty Turbocharger Control Unit
Restrictedor CrackedChargeAir Cooler
Faulty Fuel NozzleHolder
Improper ValveClearance, Wornor DamagedCamshaft LobesandRollers
LowCylinder Compression
15.11.1 Troubleshooting Procedure for Faulty DDEC-ECU
Todetermineif afaultyDDEC-ECU iscausingexcessivewhitesmoke, performthefollowing:
1. Check for faulty DDEC-ECU. Refer toDDC publicationMBE Troubleshooting Guide
(6SE422) andSID 233.
2. Replacethefaulty DDEC-ECU; refer tosection2.5.
3. VerifyDDEC-ECU replacement; refer tosection15.11.2.
15.11.2 Test the Engine with Replaced DDEC-ECU
Performthefollowingtodetermineif thereplacedDDEC-ECU hasresolvedtheexcessivewhite
smoke:
PERSONAL INJURY
3. Visuallyinspect theexhaust for excessivewhitesmoke.
Shut downtheengine.
[b] If theengineexhaust emissionis excessively white, shut downtheengine.
Refer to section15.11.3.
15.11.3 Faulty Turbocharger Boost Sensor
Todetermineif afaulty turbocharger boost sensor iscausingexcessivewhitesmoke, perform
thefollowing:
1. Check for faulty turbocharger boost sensor. Refer to DDC publication MBE
Troubleshooting Guide (6SE422) andPID102.
2. Resolvethefaultyturbocharger boost sensor; refer tosection15.11.4.
15.11.4 Turbocharger Boost Sensor Resolution
Performthefollowingstepstoresolveafaultyturbocharger boost sensor:
1. Disconnect harnessconnectionfromturbocharger boost sensor andremovetwobolts
securingtheboost sensor totheair intakemanifold. Discardsensor.
2. Securetheturbocharger boost sensor totheair intakemanifoldwithtwobolts. Torque
bolts to 11Nm(96lbin.).
3. Connect theharnessconnector totheboost sensor.
4. Verifytheturbocharger boost sensor resolution; refer tosection15.11.4.1.
15.11.4.1 Test Engine with Replace Turbocharger Boost Sensor
Performthefollowingto determineif replacingtheturbocharger boost sensor correctedthe
excessivewhitesmokecondition:
PERSONAL INJURY
1. Start theengine.
3. Visually inspect theexhaust for excessivewhitesmoke.
Shut downtheengine.
[b] If theengineexhaust emissionis excessive, shut downtheengine, check for a
malfunctioningair intake(grid) preheater. Refer tosection15.11.5.
15.11.5 Troubleshooting Procedure for a Malfunctioning Air Intake (Grid)
Preheater
Todetermineif amalfunctioningair intake(grid) preheater iscausingtheexcessivewhitesmoke,
1. Check theoperationof theair intake(grid) preheater. Refer toDDC publicationMBE
Troubleshooting Guide (6SE422) andPID45.
[a] If heater operatescorrectly; checkfor adefectivefuel pump. Refer tosection15.11.6.
[b] If heater doesnotoperatecorrectly, replaceair intake(grid) preheater; refer tosection
6.1.1.
2. Verify replacingtheair intake(grid) preheater resolvedtheexcessivewhitesmoke
condition; refer tosection15.11.5.1.
15.11.5.1 Test the Engine with Replaced Air Intake (Grid) Preheater
Performthefollowingtodetermineif replacingtheair intake(grid) preheater correctedthe
PERSONAL INJURY
1. Start theengine.
Shut downtheengine.
defectivefuel pump. Refer tosection15.11.6.
15.11.6 Troubleshooting Procedure for a Defective Fuel Pump
Todetermineif thefuel pumpiscausingexcessivewhitesmoke, performthefollowingtocheck
fuel intakepressureupstreamof fuel pump. Refer tosection15.3.5.
1. If thepressureat idlespeed(600-650rpm) isinthenormal rangeof -0.09to-0.12bar
(-1.3to-1.7psi [-9to-12kPa]), check for aeratedfuel. Refer tosection15.11.8.
2. If thepressureat idlespeed(600-650rpm) isgreater than-0.09to-0.12bar (-1.3to-1.7
psi [-9to-12kPa]); refer toTable15-36.
3. If thepressureat idlespeed(600-650rpm) islessthan-0.09to-0.12bar (-1.3to-1.7
psi [-9to-12kPa]); refer toTable15-35
4. If anopressurereadingisobserved, replacethefuel pump; refer tosection2.15.1.
15.11.7 Replace Faulty Fuel Pump
Performthefollowingstepsfor thereplacement of thefuel pump:
1. Replacethefuel pump; refer tosection2.15.1.
2. Test theenginetodetermineif thewhitesmokeproblemwasresolved; refer tosection
15.11.7.1.
15.11.7.1 Engine Test with Replaced Fuel Pump
Todetermineif thereplacedfuel pumpresolvedexcessivewhitesmokedifculty, performthe
followingsteps:
PERSONAL INJURY
1. Start andruntheengine, if no whitesmokeis visible, nofurther troubleshootingis
2. If whitesmokeisvisible, check for aeratedfuel; refer tosection15.11.8
Todetermineif aeratedfuel iscausingexcessivewhitesmoke, performthefollowingsteps:
guidelines.
2. Placetheopenendof thefuel lineintoasuitablecontainer.
PERSONAL INJURY
4. Operatetheengineat 1000rpm.
[a] If air bubblesarepresent, shut downtheengine; refer tosection15.11.9.
[b] If air bubblesarenot present, shut downtheengine, check for improper gradeof
fuel; refer to section15.11.10.
Performthefollowingstepstoresolveaeratedfuel:
guidelines.
3. Repair damagedcomponentsasrequired; refer toOEM guidelines.
4. Verifyaeratedfuel resolution; refer tosection15.11.9.1.
15.11.9.1 Test the Engine with Aerated Fuel Resolution
Performthefollowingtodetermineif aeratedfuel resolutionresolvedexcessivewhitesmoke
condition:
PERSONAL INJURY
3. Visually inspect exhaust for excessivewhitesmoke.
Shut downtheengine.
[b] If theengineexhaust emissionisexcessivelywhite, shut downtheengine. Check
for improper gradeof fuel; refer tosection15.11.10.
15.11.10 Troubleshooting Procedure for Improper Grade of Fuel
Todetermineif animproper gradeof fuel iscausingtheexcessivewhitesmoke, performthe
following:
1. Acquireafuel samplefromthevehiclefuel tank(s).
2. Submit fuel samplefor anASTM test analysis.
[a] If thefuel meets specications, check for afaulty turbocharger control unit;
[b] If thefuel didnotmeetspecications, resolveimproper gradeof fuel; refer tosection
15.11.11andDDC publicationLubricating Oil, Fuel, and Filters (7SE270).
15.11.11 Improper Grade of Fuel Resolution
Performthefollowingstepstoresolvetheimproper gradeof fuel:
1. Drainthefuel tanks, refer toOEM guidelines, anddisposeof properly.
2. Rell thefuel tankswithnewfuel havingacetanenumber greater than45andcetane
index greater than40.
3. Verifyfuel resolutioneliminatedtheexcessiveexhaust smokecondition; refer tosection
15.11.11.1.
15.11.11.1 Test the Engine with New Fuel
Performthefollowingstepstodetermineif thefuel rell resolvedtheexcessivewhitesmoke
condition:
PERSONAL INJURY
Shut downtheengine.
[b] If theengineexhaust smokeisexcessivelywhite, shut downtheengine. Check the
turbocharger control unit; refer tosection15.11.12.
15.11.12 Troubleshooting Procedure for Faulty Turbocharger Control Unit
Todetermineif animproper turbocharger control unit iscausingexcessivewhitesmoke, inspect
theturbocharger control unit for aleakingdiaphragm. Refer tosection6.4.1.
1. If thecontrol unit diaphragmisleakingreplacetheturbocharger; refer tosection6.4.2.
2. Verifythereplacement of theturbocharger andunit control correctedtheexcessivewhite
smokecondition; refer tosection15.11.12.1.
15.11.12.1 Test Engine with Replace Turbocharger and Control Unit
Performthefollowingtodetermineif replacingtheturbocharger andcontrol unit correctedthe
PERSONAL INJURY
1. Start theengine.
Shut downtheengine.
restrictedor crackedchargeair cooler. Refer tosection15.11.13.
15.11.13 Troubleshooting Procedure for a Restricted or Cracked Charge
Air Cooler
Todetermineif achargeair cooler iscausingexcessiveexhaust smoke, performthefollowing:
NOTICE:
1. Visually inspect thecore, tanks, andweldsfor cracksandholes. If cooler fails visual
inspection, replacethechargeair cooler; refer tosection15.11.14.
2. Pressuretest thechargeair cooler. Refer tosection15.9.3.1.
[a] If thepressuredropis34kPa(5psi) or lessin15secondsthecooler isgood. Check
for faulty fuel injectionnozzle; refer tosection15.11.15.
cooler; refer tosection15.11.14.
1. Replacethechargeair cooler; refer toOEM guidelines.
2. Verifythat thereplacement of thechargeair cooler eliminatedtheexcessivewhiteexhaust
smoke; refer to section15.11.14.1.
15.11.14.1 Test the Engine with a Replaced Charge Air Cooler
To determineif thereplacedchargeair cooler resolvedtheexcessivewhiteexhaust smoke
condition, performthefollowing:
PERSONAL INJURY
Shut downtheengine.
[b] If theengineexhaust emissionisexcessivelywhite, shut downtheengine. Check for
afaulty fuel injectionnozzleholder; refer tosection15.11.15.
15.11.15 Troubleshooting for a Faulty Fuel Injection Nozzle Holder
Todetermineif afaultyfuel injectionnozzleholder iscausingexcessivewhitesmoke, perform
thefollowing:
1. Check for faulty fuel injectionnozzleholder; performFlowTest at NozzleHolder.
2. Repair or replacethefaultyfuel injectionnozzleholder; refer tosection2.3.1.
3. Verifyfuel injectionnozzleholder repair or replacement; refer tosection15.11.15.1.
15.11.15.1 Test the Engine with Repaired Fuel Injection Nozzle Holder
Todetermineif afaulty fuel injector nozzleholder iscausingexcessivewhitesmoke, perform
thefollowing:
PERSONAL INJURY
Shut downtheengine.
[b] If theengineexhaust emissionisexcessivelywhite, shut downtheengine. Check for
improper valveclearanceor damagedcamshaft lobesandrollers; refer tosection
15.11.16.
Todetermineif animproper valveclearance, wornor damagedcamshaft lobesor rollersare
causingexcessivewhiteexhaust smoke, performthefollowing:
1. Check for improper valveclearance, andwornor damagedcamshaft lobesandrollers.
Repair asrequired. Refer tosection1.17.2andsection1.20.1.1.
2. Verifyvalveclearance, wornor damagedcamshaft lobesandrollersrepair correctedthe
excessivewhiteexhaust smokeconcern; refer tosection15.11.16.1.
15.11.16.1 Test Engine with Corrected Valve Clearance, Worn or Damaged
Camshaft Lobes and Rollers
Performthefollowingstepstodetermineif thevalveclearance, wornor damagedcamshaft lobes
androllersrepair hasresolvedexcessivewhiteexhaust smokecondition:
PERSONAL INJURY
3. Visuallyinspect exhaust for excessivewhiteexhaust smoke.
[b] If theengineexhaust smokeemissionisexcessive, shut downtheengine. Check for
lowcylinder compression; refer tosection15.11.17.
15.11.17 Troubleshooting for Low Cylinder Compression
To determineif lowcompressionis causingexcessivewhitesmokecondition, performthe
followingsteps:
1. Performacylinder compressiontest;refer tosection1.2.2.2.
Center at 313-592-5800.
15.12 ROUGH RUNNING OR STALLING
Thereareseveral causesfor roughrunningor stalling. Theseprobablecausesare:
LowBattery Voltage
AeratedFuel
Insufcient Fuel Flow
15.12.1 Troubleshooting Procedure for Low Battery Voltage
Todetermineif aweak batteryiscausingroughrunningor stalling, performthefollowingsteps:
PERSONAL INJURY
2. Measurethebattery voltage; refer toOEM guidelines.
[a] If thebattery voltageisgreater thanor equal to10.5volts, check for aeratedfuel;
[b] If thebattery voltageisless than10.5volts, replacethebattery; refer tosection
15.12.2.
15.12.2 Battery Replacement
Performthefollowingsteps for battery replacement:
1. Removeandreplacethebattery; refer toOEM guidelines.
2. Verifybattery replacement; refer tosection15.12.2.1.
15.12.2.1 Test Engine with Replaced Battery
Performthefollowingstepstodetermineif thebatteryreplacement resolvedtheconcern:
PERSONAL INJURY
theenginecoolant toreachnormal operatingrange, 88-96C (190-205F).
[a] If theengineisnot runningroughor stalling, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theengineisrunningroughor stalling, shut downtheengine. Check for aerated
fuel; refer to section15.12.3.
Todetermineif aeratedfuel iscausingroughrunningor stalling, performthefollowingsteps:
1. Disconnect thefuel linereturnhosefromthettingat thefuel tank; refer toOEM
guidelines.
PERSONAL INJURY
[a] If air bubblesarepresent, shut downtheengine; refer tosection15.12.4.
[b] If air bubblesarenot present, shut downtheengine. Checkfor highfuel temperature
return, whichwouldbeanindicationof insufcient fuel ow.
Performthefollowingstepstoresolveaeratedfuel:
guidelines.
2. Visuallyinspect all fuel linesfor leaksbetweenfuel tank andfuel pump.
4. Verifyaeratedfuel resolution; refer tosection15.12.4.1.
Performthefollowingtodetermineif aeratedfuel resolutionhas resolvedroughrunningor
stallingcondition:
PERSONAL INJURY
3. Test for roughrunningcondition.
[a] If theengineappears normal, nofurther troubleshootingisrequired. Shut down
theengine.
[b] If theengineisstill runningrough, shut downtheengine. Checkfor insufcient fuel
ow. Refer tosection15.12.5.
15.12.5 Troubleshooting Procedure for Insufcient Fuel Flow
Todetermineif insufcient fuel owiscausingroughrunningor stalling, dothefollowingsteps:
1. PerformFuel FlowTest #3andmeasurethefuel returnowrate. Refer tosection15.3.4
andseeFigure15-2.
2. Analyzethefuel owtest results.
[a] If thefuel rateis0.9L/min. (0.2gal/min.) or more, nofurther troubleshootingis
required. Contact Detroit Diesel Customer Support Center at 313-592-5800.
[b] If thefuel rateislessthan0.9L/min. (0.2gal/min.), resolvetheinsufcient fuel
ow; refer to section15.12.6.
15.12.6 Insufcient Fuel Flow Resolution
Performthefollowingstepstoresolvetheinsufcient fuel ow:
1. Replacethefuel lter(s); refer tosection2.14.1.
NOTE:
Always ll the lter(s) with clean fuel oil before installing. Turn the lter(s) until they
contact the gasket fully. Then turn theman additional two-thirds by hand.
2. Inspect thefuel linesfor restrictionsduetopinching, kinking, or other damage. If damage
isfound, repair asnecessary; refer toOEM guidelines.
3. Inspect thefuel returncheck valvefor restrictivemovement.
4. Inspect thefuel pumpdriveassembly. If damageis found, repair as necessary;
5. Verifyrepairsdonetocorrect insufcient fuel ow; refer tosection15.12.6.1.
15.12.6.1 Test the Engine with Resolved Fuel Flow
Performthefollowingsteps to determineif thefuel owresolutionresolvedroughrunning
or stalling:
PERSONAL INJURY
2. Runtheengineat idlewithano-loadcapacityfor approximatelyveminutes, allowing
theenginecoolant toreachnormal operatingrange, 88-96C (190-205F).
[a] If theengineisnot runningroughor stalling, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theengineisrunningroughor stalling, shut downtheengine. Contact Detroit
15.13 LACK OF POWER
15.13 LACK OF POWER
Thereareseveral causesfor lack of power. Theseprobablecausesare:
AeratedFuel
HighFuel Pressure
HighFuel TemperatureReturn
Faulty OverowValve
RestrictedAir Cleaner Element
Restrictedor CrackedChargeAir Cooler or LeakingIntakeManifold
Faulty Exhaust System
HighInlet Air Temperature
Incorrect Camshaft Timing
Todetermineif aeratedfuel iscausinglack of power, performthefollowingsteps:
1. Test for aeratedfuel.
guidelines.
PERSONAL INJURY
6. Visuallychecktoseeif air bubblesarerisingtothesurfaceof thefuel that collectswithin
thecontainer.
[a] If air bubblesarenot present, shut downtheengine, check for highfuel pressure;
[b] If air bubblesarepresent, shut downtheengine; refer tosection15.13.2.
Performthefollowingstepstoresolveaeratedfuel condition:
guidelines.
4. Verify aeratedfuel resolution; refer tosection15.13.2.1.
Performthefollowingstepstodetermineif aeratedfuel resolutionhasresolvedlack of power
condition:
PERSONAL INJURY
3. Test drivethevehicletoensurelack of power hasbeenresolved.
[a] If nolack of power occurredduringthetest drive, nofurther troubleshootingis
[b] If lack of power occurredduringthetest drive, shut downtheengine. Check for high
fuel pressure; refer to section15.13.3.
15.13.3 Troubleshooting Procedure for High Fuel Pressure
Todetermineif highfuel pressureiscausingalackof power, performthefollowingsteps:
15.13 LACK OF POWER
1. Removethefuel temperaturesensor. SeeFigure15-22.
2. Install theadaptor andbanjotting, partof kit(J -46377), andhighpressureline(J -46372).
SeeFigure15-23.
2. Solenoid Unit Pump
15.13 LACK OF POWER
3. Attachacalibratedgauge(J -46378) capableof reading0-100psi, tothehigh-pressurefuel
line(J -46372), leadingtothetee-tting. SeeFigure15-24.
1. Engine TrimPanel 3. Fuel Temperature Sensor
2. Engine Wiring Harness
Figure 15-24 Attaching the Calibrated Gauge
PERSONAL INJURY
4. Start andruntheenginetothespeedslistedinTable15-41andrecordthefuel pressure.
Engine Speed, rpm Fuel Pressure, kPa (psi )
600-650 430 (62)
2500 400-650 (58-94)
Table 15-41 Fuel Pressure at Various Speeds
6. Removetheadaptor, banjotting, highpressureline, andhighpressuregauge.
7. Reinstall thefuel temperaturesensor.
8. Analyzethemeasurefuel pressurereadings.
[a] If thefuel pressureiswithinspecicationslistedinTable15-41, checkfor highfuel
temperaturereturn; refer tosection15.13.6.
[b] If thefuel pressureisgreater thanspecicationslistedinTable15-41, refer tosection
15.13.5.
15.13.4 Troubleshooting Procedure for Faulty Overow Valve
Todetermineif afaultyoverowvalveiscausingalackof power, performthefollowingsteps:
1. RunFuel systemTest #1: DownstreamPressureTest. Refer tosection15.3.2.
2. If Test #1indicatesfaulty overowvalve, proceedtostep3.
3. Runfuel systemTest #3: FlowTest At Fuel Filter. Refer tosection15.3.4.
4. If theoverowvalveisfoundtobefaulty, replacetheoverowvalve. Refer tosection
15.13.5.
15.13.5 Overow Valve Replacement
Performthefollowingstepstoreplacetheoverowvalve.
1. Removetheoverowvalvefromthefuel returnline.
15.13 LACK OF POWER
2. Install anewoverowvalve. Tightenthevalveto48-52Nm(35-38lbft). SeeFigure
15-25.
1. Unit Pump 4. OverowValve
2. Bypass to Fuel Return Port 5. Constant Ventilation (overow)
3. Nozzle Holder
Figure 15-25 Overow Valve Location
3. Verifyoverowvalvereplacement; refer tosection15.13.5.1.
15.13.5.1 Test the Engine with Replaced Overow Valve
Performthefollowingsteps todetermineif thereplacedoverowvalvehas resolvedlack of
power condition:
PERSONAL INJURY
fuel temperaturereturn; refer tosection15.13.6.
15.13.6 Troubleshooting Procedure for High Fuel Temperature Return
Todetermineif highfuel temperaturereturniscausinglackof power, performthefollowingsteps:
1. Test for highfuel temperaturereturn.
2. Analyzethehighfuel temperaturetest results.
[a] If thereturnfuel temperatureis lessthanor equal to60C (140F), check for air
cleaner restriction; refer tosection15.13.8.
[b] If thereturnfuel temperatureis greater than60C (140F), resolvethehighfuel
temperaturereturncondition; refer tosection15.13.7.
15.13.7 High Fuel Temperature Resolution
Performthefollowingstepstoresolvehighfuel temperaturereturn:
1. Removeandreplacefuel lter(s); refer tosection2.14.1.
2. Verifyhighfuel temperaturerepair; refer tosection15.13.7.1.
15.13.7.1 Test the Engine with Resolved High Fuel Temperature
Performthefollowingstepstodetermineif highfuel temperaturerepairs haveresolvedlack
of power condition:
PERSONAL INJURY
[a] If lack of power didnot occur duringthetest drive, nofurther troubleshootingis
[b] If lack of occurredduringthetest drive, shut downtheengine. Checkfor arestricted
air cleaner element; refer tosection15.13.8.
15.13 LACK OF POWER
15.13.8 Troubleshooting Procedure for Restricted Air Cleaner Element
Todetermineif arestrictedair cleaner element iscausinglack of power, performthefollowing
steps:
1. Removetheair lter element fromtheair cleaner container; refer toOEM guidelines.
2. Visuallyinspect theair cleaner element for damageor clogging.
[a] If nodamageor cloggingisfound, check thechargeair cooler; refer tosection
15.13.10.
[b] If damageor cloggingisfound, refer tosection15.13.9.
15.13.9 Air Filter Element Replacement
Performthefollowingstepstoreplacetheair lter element:
1. Removeandreplacethedamagedor cloggedair lter element; refer toOEM guidelines.
2. Verifyair lter element replacement; refer tosection15.13.9.1.
15.13.9.1 Test the Engine with Replaced Air Filter Element
Performthefollowingstepstodetermineif thenewair lter element hasresolvedlackof power:
PERSONAL INJURY
[a] If lack of power didnot occur duringthetest drive, nofurther troubleshootingis
[b] If lack of power occurredduringthetest drive, shut downtheengine. Check the
chargeair cooler; refer tosection15.13.10.
15.13.10 Troubleshooting Procedure for Restricted or Cracked Charge
Air Cooler
Todetermineif arestrictedor crackedchargeair cooler iscausinglack of power, performthe
followingsteps:
NOTICE:
1. Visually inspect thecore, tanks, andweldsfor cracksandholes. If cooler fails visual
inspectionreplacethechargeair cooler; refer tosection15.13.11.
2. Pressuretest thechargeair cooler; refer tosection15.9.3.1.
[a] If thepressuredropis34kPa(5psi) or lessin15seconds, thecooler isgood. Check
for faulty air intakemanifold; refer tosection15.13.12.
cooler; refer tosection15.13.11.
1. Removeandreplacethechargeair cooler; refer toOEM guidelines.
2. Verifyreplacement of thechargeair cooler; refer tosection15.13.12.1.
15.13.12 Troubleshooting Procedure for a Faulty Air Intake Manifold
Gasket
Performthefollowingstepstotroubleshoot afaultyair intakemanifoldgasket:
1. Removetheair intakemanifold; refer tosection6.2.1.
2. Inspect theair intakemanifoldandgaskets.
3. Install theair intakemanifoldwithnewgaskets; refer tosection6.6.2.
4. Verifyrepair of theintakemanifold; refer tosection15.13.12.1.
15.13.12.1 Test the Engine with Replaced Charge Air Cooler or Air Intake
Manifold Gasket
Todetermineif therepairsresolvedthelack of power condition, performthefollowingsteps:
15.13 LACK OF POWER
PERSONAL INJURY
[a] If no lack of power occurredduringthetest drive, nofurther troubleshootingis
[b] If lack of power occurredduringthetest drive, shut downtheengine. Check the
exhaust system; refer tosection15.13.13.
15.13.13 Troubleshooting Procedure for a Faulty Exhaust System
Todetermineif afaultyexhaust systemiscausinglack of power, performthefollowingsteps:
1. Drill an11/32in. holeintheexhaust pipe, 125-305mm(5-12in.) fromtheturbocharger
exhaust outlet.
NOTE:
The tapped hole must be in a comparatively straight area of the turbocharger exhaust
outlet.
2. Taptheholetoaccommodatea1/8in. pipeplug.
3. Connect amanometer calibratedtoreadpressureinkPaor inchesof Hg.
PERSONAL INJURY
[a] If theexhaust back pressureat full loadislessthan12kPa(3.5in. Hg), check for
highinlet air temperature; refer tosection15.13.15.
[b] If theexhaust back pressureat full loadis 12kPa(3.5in. Hg) or greater,
15.13.14 Engine Exhaust System Resolution
Performthefollowingstepstoresolvetheengineexhaust systemconcern:
1. Visuallyinspect theengineexhaust system; refer toOEM guidelines.
2. Repair or replacedefectiveexhaust systemcomponents; refer toOEM guidelines.
3. Verifyexhaust systemresolution; refer tosection15.13.14.1.
15.13.14.1 Test the Engine with Replaced Exhaust System
Performthefollowingstepstodetermineif replacedengineexhaust systemcomponentshave
resolvedthelack of power condition:
PERSONAL INJURY
inlet air temperature; refer tosection15.13.15.
15.13.15 Troubleshooting Procedure for High Inlet Air Temperature
Todetermineif highinlet air temperatureiscausinglack of power, test/check theradiator fan, fan
drive, or fanshroudfor proper operationor conguration. Refer toOEM guidelines.
1. If theradiator fan, fandrive, or fanshroudpasstheOEM test, check camshaft timing;
2. If theradiator fan, driveor shrouddidnot operatecorrectly, refer tosection15.13.16.
15.13.16 Radiator Fan, Drive and Shroud Replacement
Performthefollowingstepstoreplacetheradiator fan, drive, andor shroud:
1. Removeandreplacetheradiator fan, drive, and/or shroud; refer toOEM guidelines.
15.13 LACK OF POWER
2. Verify replacement; refer tosection15.13.16.1.
15.13.16.1 Test the Engine with Radiator Fan, Fan Drive, or Fan Shroud
Replacement
Performthefollowingstepstodetermineif replacedradiator fan, fandrive, or fanshroudresolved
lack of power condition:
PERSONAL INJURY
[a] If no lack of power occurredduringthetest drive, nofurther troubleshootingis
[b] If lackof power occurredduringthetestdrive, shutdowntheengine. Checkcamshaft
timing; refer to section15.13.17.
15.13.17 Troubleshooting Procedure for Incorrect Camshaft Timing
Todetermineif incorrect camshaft timingiscausinglack of power, check thecamshaft timing;
refer to section.
1. If thedial indicator readingontheunit pumplobeis 13.8mm(0.54in.) or above, no
further troubleshootinginrequired.
2. If thedial indicator readingis not above13.8mm(0.54in.), check enginetiming;
15.13.18 Engine Timing Resolution
Performthefollowingstepstoresolveincorrect enginetiming:
1. Performanenginegear traintimingcheck; refer tosection1.7.2.
2. Verifyenginetimingresolution; refer tosection15.13.18.1.
15.13.18.1 Test Engine with Correct Timing
Performthefollowingstepstodetermineif correctedenginetiminghasresolvedlack of power
condition:
PERSONAL INJURY
[b] If lack of power occurredduringthetest drive, shut downtheengine. Call Detroit
15.14 LOW OIL PRESSURE
Thereareseveral causesfor lowoil pressure. Theseprobablecausesare:
Improper EngineOil Level
Improper LubricatingOil Viscosity
LubricatingOil DilutedwithFuel or EngineCoolant
Faulty Oil PressureGaugeSensor
ObstructedOil PressureGaugeLine
RestrictedOil Cooler
DefectiveBypass Valve
DefectivePressureRelief Valve
DefectivePickupScreenTubeandScreenAssembly
DefectiveCrankshaft MainBearingShells
DefectiveOil PumpAssembly
15.14.1 Troubleshooting Procedure for Improper Engine Oil Level
Todetermineif improper engineoil level iscausinglowoil pressure, check theengineoil level
listedinTable15-42.
1. If theengineoil level iscorrect, check lubricatingoil viscosity; refer tosection15.14.3.
2. If theengineoil level isincorrect, refer tosection15.14.2.
Descri pti on 4Cyli nder Engines 6Cyli nder Engi nes
Oil Fill Capacity* 15.8 L (16.7 qt.) 29.0 L (30.6 qt.)
* In standard pan, including oil lter.
Table 15-42 Lubricating Oil Capacity
15.14.2 Low Engine Oil Level Resolution
Performthefollowingsteps for lowengineoil level:
1. Fill engineoil pantocorrect level listedinTable15-42.
2. Verifylowengineoil resolution; refer tosection15.14.2.1.
15.14.2.1 Test for Proper Engine Oil Level
Performthefollowingstepstodetermineif properlylledoil panhasresolvedlowoil pressure:
PERSONAL INJURY
1. Start andvaryenginespeedbetween1800-2100rpm.
2. Measureengineoil pressure.
[a] If theoil pressureis241kPa(35psi) or more, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theoil pressureat ratedspeedislessthan241kPa(35psi), shut downtheengine.
Check lubricatingoil viscosity; refer tosection15.14.3.
15.14.3 Troubleshooting Procedure for Improper Lubricating Oil Viscosity
To determineif improper lubricatingoil viscosity is causinglowoil pressure, performthe
followingsteps:
1. Acquirealubricatingoil samplefromtheengineoil pan.
2. Submit oil samplefor anASTM test analysis.
[a] If engineoil samplemeetsASTM specications, check todetermineif lubricatingoil
isdilutedwithfuel or coolant; refer tosection15.14.5.
[b] If engineoil sampledidnot meet ASTM specications, refer tosection15.14.4and
DDC publicationLubricating Oil, Fuel, and Filters (7SE270).
15.14.4 Lubricating Oil Replacement
Performthefollowingstepstoreplaceengineoil:
1. Drainandrell enginewithnewlubricatingoil. Engineoil capacitiesarelistedinTable
15-42.
2. Verifylubricatingoil replacement; refer tosection15.14.4.1.
15.14.4.1 Test Engine with Replaced Lubricating Oil
Performthefollowingstepstodetermineif replacedlubricatingoil resolvedlowoil pressure:
PERSONAL INJURY
1. Start andrunengineat ratedspeed.
2. Measureengineoil pressure.
[a] If theoil pressureis241kPa(35psi) or more, nofurther troubleshootingisrequired.
Shut downtheengine.
Checkthelubricatingoil for fuel andenginecoolant dilution; refer tosection15.14.5.
15.14.5 Troubleshooting Procedure for Lubricating Oil Diluted with Fuel
or Engine Coolant
Todetermineif lubricatingoil dilutedwithfuel or enginecoolant iscausinglowoil pressure,
1. Acquirealubricatingoil samplefromtheengineoil pan.
2. Visuallyexaminelubricatingoil samplefor presenceof enginecoolant or fuel.
[a] If coolantor fuel arenotpresent, checkfor afaultyoil pressuregauge; refer tosection
15.14.7.
[b] If coolant or fuel arepresent, refer tosection15.14.6.
15.14.6 Contaminated Lubricating Oil Resolution
Performthefollowingstepstoresolvecontaminatedlubricatingoil:
1. If coolant ispresent, consider headgasket replacement andrepair asrequired.
2. If fuel ispresent, consider fuel nozzlereplacement andrepair asrequired.
3. Drainengineoil pan.
4. Rell enginecrankcasewithnewoil.
5. Verifylubricatingoil replacement; refer tosection15.14.6.1.
15.14.6.1 Test Replaced Lubricating Oil
Todetermineif replacedlubricatingoil resolvedlowoil pressure, performthefollowing:
PERSONAL INJURY
1. Start andruntheengineat ratedspeed, if theoil pressureis241kPa(35psi) or more, no
further troubleshootingis required.
2. If theoil pressureatratedspeedislessthan241kPa(35psi), shut downtheengine. Check
for faultyoil pressuregaugesensor; refer tosection15.14.7.
15.14.7 Troubleshooting Procedure for Faulty Oil Pressure Gauge Sensor
To determineif afaulty oil pressuregaugesensor is causinglowoil pressure, performthe
followingsteps:
1. Install theDiagnostic DataReader (DDR).
PERSONAL INJURY
2. Start andvary theenginespeedbetween1800- 2100rpm.
3. Visually examinetheDDR for oil pressurereading.
[a] If theoil pressureisgreater thanor equal to241kPa(35psi) at ratedspeed, shut
downtheengine. Nofurther troubleshootingisrequired.
[b] If theoil pressureislessthan241kPa(35psi) at ratedspeed, shut downtheengine;
15.14.8 Oil Pressure Gauge Sensor Replacement
Performthefollowingstepstoreplacetheoil pressuregaugesensor:
1. Removeandreplacetheoil pressuregaugesensor; refer toOEM guidelines.
2. Verifyoil pressuregaugesensor replacement; refer tosection15.14.8.1
15.14.8.1 Test Replaced Oil Pressure Gauge Sensor
Todetermineif replacedoil pressuregaugesensor resolvedthelowoil pressureconcern, perform
thefollowing:
PERSONAL INJURY
1. Start andruntheengineat ratedspeed, if theoil pressureis241kPa(35psi) or more, no
further troubleshootingis required.
2. If theoil pressureat ratedspeedislessthanis241kPa(35psi), shut downtheengine.
Check for anobstructedoil pressuregaugeline; refer tosection15.14.9.
15.14.9 Troubleshooting Procedure for Oil Pressure Gauge Line
Obstructed
Todetermineif anoil pressuregaugelineobstructioniscausinglowoil pressure, performthe
followingsteps:
1. Disconnect oil gaugelinefromoil pressuregauge; refer toOEM guidelines.
2. Visually inspect oil gaugelinefor obstructions.
[a] If noobstructionsarefound, checktodetermineif rocker armshaft plugsaremissing
(newor rebuilt engines only).
[b] If obstructions arefound, refer tosection15.14.10.
15.14.10 Obstructed Oil Pressure Gauge Line Repair
Performthefollowingstepstoresolveoil pressuregaugelineobstructions:
1. Removeoil pressuregaugeline; refer toOEM guidelines.
2. Cleanoil gaugelinebysoakingincleaningsolutionfor veminutes.
3. Blowout residuecontaminationinoil gaugelinewithcompressedair.
4. Install cleanedoil gaugeline; refer toOEM guidelines.
5. Verifyoil gaugelinerepair; refer tosection15.14.10.1.
15.14.10.1 Test the Engine with Repaired Oil Gauge Line
Todetermineif repairedoil pressuregaugelineresolvedlowoil pressure, performthefollowing
steps:
PERSONAL INJURY
1. Start andruntheengineat ratedspeed. If theoil pressureat ratedspeedis241kPa(35
psi) or more, nofurther troubleshootinginrequired. Shut downtheengine.
2. If theoil pressureat ratedspeedisless than241kPa(35psi), shut downtheengine.
Check for restrictedheat exchanger; refer tosection15.14.11.
15.14.11 Troubleshooting Procedure for Restricted Heat Exchanger
Todetermineif arestrictedheat exchanger iscausinglowoil pressure, performthefollowing
steps:
PERSONAL INJURY
1. Start andruntheengineat ratedspeed.
2. Runtheengineat ratedspeedwithano-loadconditionfor approximatelyveminutes,
allowingtheenginecoolant toreachnormal operatingrange88-96C (190-205F).
[a] If theoil temperaturesensor isindicatingalubricatingoil temperaturelessthanor
equal to110C (230F), shut downtheengineandcheck for adefectiveoil lter
bypass valve; refer tosection15.14.13.
[b] If theoil temperaturesensor isindicatingalubricatingoil temperaturegreater than
110C (230F), shut downtheengineandrepair heat exchanger; refer tosection
15.14.12.
15.14.12 Heat Exchanger Repair
Performthefollowingstepstorepair theheat exchanger:
1. Removetheheat exchanger; refer tosection3.6.1.
2. Cleantheheat exchanger beforesludgehardens. Flushoil passageswithclean, hot water.
3. Inspect theheat exchanger for damage.
4. Install repairedheat exchanger; refer tosection3.6.2.
5. Verifyrepair of heat exchanger; refer tosection15.14.12.1.
15.14.12.1 Test Engine with Repaired Heat Exchanger
Performthefollowingstepstodetermineif heat exchanger repair resolvedlowoil pressure:
PERSONAL INJURY
1. Start andruntheengineat ratedspeed.
2. Runtheenginethroughitsoperatingrangewithno-loadconditionfor approximately
veminutes, allowingtheenginecoolant toreachnormal operatingrange, 88-96C
(190-205F).
[a] If theDDR indicates241kPa(35psi) or moreat ratedspeed, shut downtheengine
anddisconnect theDDR. Nofurther troubleshootingisrequired.
[b] If theDDR indicateslessthan241kPa(35psi) at ratedspeed, shut downtheengine
anddisconnect theDDR. Check for defectiveoil lter bypassvalve; refer tosection
15.14.13.
15.14.13 Troubleshooting Procedure for Defective Oil Filter Bypass Valve
To determineif adefectiveoil lter bypass valveis causinglowoil pressure, performthe
followingsteps:
1. Removetheoil lter cover andelement; refer tosection3.5.1.
2. Inspect theoil lter bypass valvecomponents.
[a] If nodamageisfoundwiththeoil lter housingbypassvalvecomponents, check for
defectivepressurerelief valve; refer tosection15.14.14.
[b] If damageisfoundwiththeoil lter housingbypassvalvebore, replacehousing.
15.14.14 Troubleshooting Procedure for Defective Oil Pump Pressure
Relief Valve
Todetermineif adefectiveoil pumppressurerelief valveiscausinglowoil pressure, perform
thefollowingsteps:
1. Removetheoil pumppressurerelief valve.
2. Inspect theoil pumppressurerelief valve.
[a] If therelief valvemovesfreelyinthevalvebody, reinstall theoil pressurerelief
valve. Check thepickuptubeandscreenassemblyfor defects.
[b] If therelief valvewill not movefreelyinthevalvebody, refer tosection15.14.15.
15.14.15 Oil Pump Pressure Relief Valve Repair
Performthefollowingstepstorepair theoil pumppressurerelief valve:
1. Disassemblethepressurerelief valveandreplacedamagedcomponents.
2. Assembleandinstall thepressurerelief valve.
3. Verifyrepair of thepressurerelief valve; refer tosection15.14.15.1.
15.14.15.1 Test Engine with Repaired Oil Pump Pressure Relief Valve
Performthefollowingstepstodetermineif repairedoil pumppressurerelief valveresolved
lowoil pressure:
1. Install theDDR.
PERSONAL INJURY
2. Start andrunenginespeedat ratedspeed.
3. Visually examinetheDDR for oil pressurereading.
[a] If theDDR indicates241kPa(35psi) or moreat ratedspeed, shut downtheengine
anddisconnect theDDR. Nofurther troubleshootingisrequired.
[b] If theDDR indicateslessthan241kPa(35psi) at ratedspeed, shut downtheengine
anddisconnect theDDR. Check for defectivepickuptubeandscreenassembly;
15.14.16 Troubleshooting Procedure for Defective Pickup Screen Tube and
Screen Assembly
Todetermineif adefectivepickupscreentubeor screenassembly iscausinglowoil pressure,
1. Removepickupscreentubeandscreenassembly. Refer tosection3.3.1.
2. Visually inspect pickupscreentubeandscreenassembly.
[a] If notubestresscracks, twistedscreentube, or crackedangearefound, check for
defectivecrankshaft mainbearingshells; refer tosection15.14.18.
[b] If stresscracks, twistedscreentube, or crackedangearefound, refer tosection
15.14.17.
15.14.17 Pickup Screen Tube and Screen Assembly Replacement
Performthefollowingstepstoreplacethepickupscreentubeandscreenassembly:
1. Replaceall damaged components identied during inspection and install.
2. Verifyreplacement topickupscreentubeandscreenassembly; refer tosection15.14.17.1.
15.14.17.1 Test Engine with Replaced Pickup Screen Tube and Screen
Assembly
Performthefollowingstepstodetermineif areplacedpickupscreentubeor screenassembly
resolvedlowoil pressure:
PERSONAL INJURY
1. Start andruntheenginespeedat ratedspeed.
2. Visually examineoil pressurereading.
[a] If theoil pressureat ratedspeed is 241 kPa(35psi) or more, no further
troubleshootingis required.
[b] If theoil pressureat ratedspeedislessthan241kPa(35psi), check for defective
crankshaft mainbearingshells; refer tosection15.14.18.
15.14.18 Troubleshooting Procedure for Defective Crankshaft Main
Bearing Shells
Todetermineif defectivecrankshaft mainbearingshells arecausinglowoil pressure, check
mainbearingtocrankshaft journal clearances.
1. If mainbearingshell-to-journal clearanceiswithin0.051-0.127mm(0.002-0.005in.),
check for defectiveoil pumpassembly; refer tosection15.14.20.
2. If mainbearingshell-to-journal clearanceisnot within0.051-0.127mm(0.002-0.005in.),
15.14.19 Crankshaft Main Bearing Shell Repair
Performthefollowingstepstorepair crankshaft mainbearingshells:
1. Removeandreplacedefectivecrankshaft mainbearingshells.
2. Verifycrankshaft mainbearingshellsrepair; refer tosection15.14.19.1.
15.14.19.1 Test Engine with New Crankshaft Main Bearing Shells
Performthefollowingstepstodetermineif newcrankshaft mainbearingshellshaveresolved
lowoil pressure:
PERSONAL INJURY
1. Start andrunengineat ratedspeed.
2. Visually examinetheoil pressurereading.
[a] If theoil pressureat ratedspeedis 241kPa(35psi) or more, no further
Check theoil pumpassembly; refer tosection15.14.20.
15.14.20 Troubleshooting Procedure for Defective Oil Pump Assembly
Todetermineif adefectiveoil pumpiscausinglowoil pressure, performthefollowingsteps:
1. Removetheoil pumpassembly; refer tosection3.3.1.
2. Manually rotatetheoil pumpdrivegear.
[a] If thedrivegear rotatesfreelyinthepumphousing, call Detroit Diesel Customer
[b] If thedrivegear doesnot rotatefreely, replacetheoil pumpassemblyandverify
repair; refer tosection15.14.20.1.
15.14.20.1 Test Engine with Replaced Oil Pump Assembly
Performthefollowingstepstodetermineif oil pumpreplacement resolvedlowoil pressure:
PERSONAL INJURY
1. Start andruntheenginespeedat ratedspeed.
2. Visually examinetheoil pressurereading.
[a] If theoil pressureat ratedspeed is 241 kPa(35psi) or more, no further
[b] If theoil pressureat ratedspeedislessthan241kPa(35psi), shut downtheengine
andcall Detroit Diesel Customer Support Center at 313-592-5800.
15.15 HIGH ENGINE COOLANT TEMPERATURE
Thereareseveral causesfor highenginecoolant temperature. Theseprobablecausesare:
Improper EngineCoolant Level
Insufcient Radiator Air Circulation
Faulty PressureControl Cap
DefectiveCoolant Hoses
Incorrectly AdjustedFanBelt
InoperativeThermo-ModulatedFan
Faulty Thermostats
Faulty Water Pump
CombustionGases inCoolant
Abnormal Radiator Coolant Flow
15.15.1 Troubleshooting Procedure for Improper Engine Coolant Level
To determineif improper enginecoolant level is causinghighenginecoolant temperature,
visuallyinspect theradiator coolant level; refer toOEM guidelines.
1. If theradiator coolant level iswithinapproximately50mm(2.0in.) of theradiator ller
neck, check for insufcient radiator air circulation; refer tosection15.15.3.
2. If theradiator coolant level isnot withinapproximately 50mm(2.0in.) of theradiator
ller neck, refer tosection15.15.2.
15.15.2 Improper Coolant Level Resolution
Performthefollowingstepstoresolveimproper coolant level:
1. Fill coolant systemtocorrect level; refer tosection4.4.1.
2. Verifycoolant level resolution; refer tosection15.15.2.1.
15.15.2.1 Test Engine with Proper Coolant Level
Performthefollowingto determineif proper coolant level resolvedhighenginecoolant
temperature:
PERSONAL INJURY
2. Runtheenginethroughitsoperatingrangewithno-loadfor approximatelyveminutes,
allowingtheenginecoolant toreachnormal operatingrange.
[a] If theenginecoolanttemperatureis82-105C(180-221F), nofurther troubleshooting
[b] If theenginecoolant temperatureisnot 82-105C(180-221F), shutdowntheengine.
Check for insufcient radiator air circulation; refer tosection15.15.3.
15.15.3 Troubleshooting Procedure for Insufcient Radiator Air
Circulation
Todetermineif insufcient radiator air circulationiscausinghighenginecoolant temperature,
visually examinetheradiator andradiator shrouding.
1. If theradiator is absent of clogging, debris, anddirt, check thepressurecontrol cap;
2. If theradiator hasexcessiveclogging, debris, or dirt, refer tosection15.15.4.
3. If theradiator shroudingisnot damaged, incorrectlypositioned, or inadequate, check the
pressurecontrol cap; refer tosection15.15.6.
4. If theradiator shroudingisdamaged, incorrectlypositioned, or inadequate, refer tosection
15.15.5.
15.15.4 Exterior Radiator Repair
Performthefollowingfor exterior radiator repair:
1. Cleantheexterior radiator of all clogging, debris, or excessivedirt; refer to OEM
guidelines.
2. Verifyexterior radiator repair; refer tosection15.15.5.1.
15.15.5 Radiator Shroud Repair
Performthefollowingfor radiator shroudrepair:
1. Repair or replacedamagedradiator shrouding; refer toOEM guidelines.
2. Verifyexterior radiator repair; refer tosection15.15.5.1.
15.15.5.1 Test Engine with Repaired Exterior Radiator and Shrouding
Performthefollowingtodetermineif exterior radiator andshroudingrepair resolvedhighengine
coolant temperature:
PERSONAL INJURY
Check thepressurecontrol cap; refer tosection15.15.6.
15.15.6 Troubleshooting Procedure for Faulty Pressure Control Cap
Todetermineif afaultypressurecontrol capiscausinghighenginecoolant temperature, perform
coolant pressurecontrol captests.
1. If thecoolingsystempressureislessthanor equal to62kPa(9psi), check thecoolant
hoses; refer tosection15.15.8.
2. If thecoolingsystempressureisgreater than62kPa(9psi), refer tosection15.15.7.
15.15.7 Pressure Control Cap Resolution
Performthefollowingstepstoresolvefaulty pressurecontrol cap:
1. Removeandreplacepressurecontrol cap; refer toOEM guidelines.
2. Install anewpressurecontrol cap; refer toOEM guidelines.
3. Verifypressurecontrol caprepair; refer tosection15.15.7.1.
15.15.7.1 Test Engine with Replaced Pressure Control Cap
Performthefollowingto determineif exterior radiator repair resolvedhighenginecoolant
temperature:
PERSONAL INJURY
[a] If theenginecoolant temperatureisnormal, nofurther troubleshootingisrequired.
Shut downtheengine.
[b] If theenginecoolant temperatureisnot normal, shut downtheengine. Checkcoolant
hoses; refer tosection15.15.8.
15.15.8 Troubleshooting Procedure for Defective Coolant Hoses
Todetermineif defectivecoolant hosesarecausinghighenginecoolant temperature, visually
examinecoolingsystemhoses; refer toOEM guidelines.
1. If coolingsystemhosesarenot soft, deteriorated, collapsed, or haveleakingconnections,
check thefanbelts; refer tosection15.15.10.
2. If coolingsystemhosesaresoft, deteriorated, collapsed, or haveleakingconnections,
15.15.9 Coolant System Hoses Replacement
Performthefollowingstepstoresolvewornor damagedcoolant systemhoses:
1. Removeandreplacedamagedor worncoolant hoses as necessary; refer to OEM
guidelines.
2. Install newcoolant hosesasnecessary; refer toOEM guidelines.
3. Verifyreplacedcoolant systemhoses; refer tosection15.15.9.1.
15.15.9.1 Test Engine with Replaced Coolant Hoses
Performthefollowingto determineif thenewcoolant hoses resolvedhighenginecoolant
temperature:
PERSONAL INJURY
allowingtheenginecoolant to reachnormal operatingrange, andvisually examine
replacedhoses for any leaks.
[a] If theenginecoolant temperatureis82-105C (180-221F) andnoleaksarefound,
nofurther troubleshootingisrequired.
[b] If theenginecoolant temperatureis 82-105C (180-221F) andleaks arefound,
repair theleaks; refer tosection15.15.9. Shut downtheengine.
[c] If theenginecoolant temperatureis not 82-105C (180-221F) andno leaks are
found, shut downtheengine. Check fanbelt; refer tosection15.15.10.
15.15.10 Troubleshooting Procedure for Incorrectly Adjusted Fan Belt
Todetermineis amisadjustedfanbelt is causinghighenginecoolant temperature, perform
thefollowingsteps:
1. Check theautotensioner for springloading.
2. Comparetensiontobelt specications.
[a] If thebelt tensionis normal, check thethermo-modulatedfan; refer tosection
15.15.12.
[b] If thebelt tensionisnot normal, refer tosection15.15.11.
15.15.11 Belt Tension Resolution
Performthefollowingstepstoresolveincorrect belt tension:
1. Replacetheautotensioner as required.
2. Verifybelt tensionresolution; refer tosection15.15.11.1.
15.15.11.1 Test Engine with Correct Belt Tension
Performthefollowingtodetermineif belt tensionresolvedhighenginecoolant temperature:
PERSONAL INJURY
Check thermo-modulatedfan; refer tosection15.15.12.
15.15.12 Troubleshooting Procedure for Inoperative Thermo-Modulated
Fan
Todetermineif aninoperativethermo-modulatedfaniscausinghighenginecoolant temperature,
test thethermo-modulatedfan. Refer toOEM guidelines.
1. If thethermo-modulatedfanisfunctioningcorrectly, check thermostats; refer tosection
15.15.14.
2. If thethermo-modulatedfanisnot functioningcorrectly, refer tosection15.15.13.
15.15.13 Thermo-Modulated Fan Replacement
Performthefollowingstepstoreplaceinoperativethermo-modulatedfan:
1. Replaceinoperativethermo-modulatedfan; refer toOEM guidelines.
2. Verifythermo-modulatedfanreplacement; refer tosection15.15.13.1.
15.15.13.1 Test Engine with Replaced Thermo-Modulated Fan
Performthefollowingstepstodetermineif thermo-modulatedfanreplacement resolvedhigh
enginecoolant temperature:
PERSONAL INJURY
Check thermostats; refer tosection15.15.14.
15.15.14 Troubleshooting Procedures for Faulty Thermostats
Todetermineif faulty thermostatsarecausinghighenginecoolant temperature, performthe
following:
1. Removethermostat fromthethermostat housing; refer tosection4.6.1.
2. Inspect thermostat for correct operation; refer tosection4.6.1.1.
[a] If thermostat isfully openat 95C (203F), check water pump; refer to section
15.15.16.
[b] If thermostat isnot fullyopenat 95C (203F), refer tosection15.15.15.
15.15.15 Thermostat Replacement
Performthefollowingstepstoreplacethermostats:
1. Install newthermostat; refer tosection4.6.2.
2. Verify replacedthermostat; refer tosection15.15.15.1.
15.15.15.1 Test Engine with New Thermostat
Performthefollowingstepstodetermineif thermostat replacement resolvedhighenginecoolant
temperature:
PERSONAL INJURY
Check water pump; refer tosection15.15.16.
15.15.16 Troubleshooting Procedure for Faulty Water Pump
Todetermineif afaultywater pumpis causinghighenginecoolant temperature, performthe
following:
1. Removethewater pumpandinspect pumpfor failedshaft or rotor. For Non-EGR engines
refer tosection4.2.1; for EGR enginesrefer tosection4.3.1.
2. Replacewater pumpif damaged. For Non-EGR enginesrefer tosection4.2.2; for EGR
engines refer to section4.3.2.
15.15.16.1 Test Engine with Replaced Water Pump
Performthefollowingstepstodetermineif thermo-modulatedfanreplacement resolvedhigh
PERSONAL INJURY
Check combustiongasesincoolant; refer tosection15.15.17.
15.15.17 Troubleshooting Procedure for Combustion Gases in Coolant
Todetermineif combustiongasesincoolant iscausinghighenginecoolant temperature, perform
acylinder compressiontest. Refer tosection1.2.2.2.
1. If test resultsaretospecications; check radiator coolant ow; refer tosection15.15.19.
2. If test resultsarenot tospecications, refer tosection15.15.18.
15.15.18 Cylinder Head Gasket Replacement
Performthefollowingstepstoreplacecylinder headgasket:
1. Removeandreplacecylinder headgasket; refer tosection1.2.2.
2. Verifynewcylinder headgasket replacement; refer tosection15.15.18.1.
15.15.18.1 Test Engine with Replaced Cylinder Head Gasket
Performthefollowingtodetermineif cylinder headgasket replacement resolvedhighengine
PERSONAL INJURY
Check radiator coolant ow; refer tosection15.15.19.
15.15.19 Troubleshooting Procedure for Abnormal Radiator Coolant Flow
Todetermineif abnormal radiator coolant owis causinghighenginecoolant temperature,
1. Install asight glasswithstring(bothends) totheradiator outlet hosenear radiator and
beforell andheater returnlines; seeFigure15-26.
Figure 15-26 Radiator Flow Check
PERSONAL INJURY
2. Start andruntheengineat full load.
3. Observethestringfor owanddirectionaswell as thell andbleedlines. Continue
observationwhilevaryingtheenginespeedbetween1800-2400rpm.
[a] If abalancedcoolant owisobservedinthesight glass, call Detroit Diesel Customer
Support Center at 313-592-5800. Shut downtheengine.
[b] If abalancedcoolant owisnot observedinthesight glass, refer tosection15.15.20.
Shut downtheengine.
15.15.20 Abnormal Radiator Coolant Flow Resolution
Performthefollowingsteps, asnecessary, toresolveabnormal radiator coolant ow:
1. Correct bleedlinesize; refer toOEM guidelines.
2. Correct ll linesizeor connector ttingsize; refer toOEM guidelines.
3. Correct restrictivetoptank opening; refer toOEM guidelines.
4. Correct locationof standpipe; refer toOEM guidelines.
5. Verifyrepairsmadetocorrect abnormal radiator coolant ow; refer tosection15.15.20.1.
15.15.20.1 Test Engine with Resolved Radiator Coolant Flow
Performthefollowingtodetermineif abnormal radiator coolant owrepair resolvedhighengine
PERSONAL INJURY
Call theDetroit Diesel Customer Support Center at 313-592-5800.
15.16 LOW COOLANT TEMPERATURE
Thereareseveral causesfor lowcoolant temperature. Theseprobablecausesare:
Faulty Thermostats
Insufcient Radiator Air Circulation
15.16.1 Troubleshooting Procedure for Faulty Thermostats
Todetermineif faulty thermostats arecausinglowenginecoolant temperature, performthe
followingsteps:
1. Removethermostat fromthethermostat housing; refer tosection4.6.1.
2. Inspect thermostat for correct operation; refer tosection4.6.1.1.
[a] If thethermostat is fully openat 95C (203F), check insufcient radiator air
circulation; refer tosection15.16.3.
[b] If thethermostat isnot fullyopenat 95C (203F), refer tosection15.16.2.
15.16.2 Thermostat Replacement
Performthefollowingstepstoreplacethermostats:
1. Install newthermostat; refer tosection4.6.2.
2. Verifyreplacedthermostat; refer tosection15.16.2.1.
15.16.2.1 Test Engine with New Thermostat
Performthefollowingstepstodetermineif thermostat replacement resolvedlowenginecoolant
temperature:
PERSONAL INJURY
Check insufcient radiator air circulation; refer tosection15.16.3.
15.16.3 Troubleshooting Procedure for Insufcient Radiator Air
Circulation
Todetermineif insufcient radiator air circulationiscausinglowenginecoolant temperature,
visually examinetheradiator andradiator shrouding.
1. If theradiator hasexcessiveclogging, debris, or dirt, refer tosection15.16.4.
2. If theradiator shroudingisnot damaged, incorrectlypositioned, or inadequate, andif the
radiator isabsent of clogging, debris, anddirt, thencall Detroit Diesel Customer Support
Center at 313-592-5800.
3. If theradiator shroudingisdamaged, incorrectlypositioned, or inadequate, refer tosection
15.16.5.
15.16.4 Exterior Radiator Repair
Performthefollowingsteps for exterior radiator repair:
1. Cleantheexterior radiator of all clogging, debris, or excessivedirt; refer to OEM
guidelines.
2. Verify exterior radiator repair; refer tosection15.16.5.1.
15.16.5 Radiator Shroud Repair
Performthefollowingsteps for radiator shroudrepair:
1. Repair or replacedamagedradiator shrouding; refer toOEM guidelines.
2. Verify exterior radiator repair; refer tosection15.16.5.1.
15.16.5.1 Test Engine with Repaired Exterior Radiator and Shrouding
Performthefollowingstepstodetermineif exterior radiator or shroudingrepair resolvedthelow
PERSONAL INJURY
2. Runtheenginethroughitsoperatingrangewithno-loadconditionfor approximatelyve
minutes, allowingtheenginecoolant toreachnormal operatingrange.
Call Detroit Diesel Customer Support Center at 313-592-5800.
15.17 POOR FUEL ECONOMY
Customer expectationsof fuel economyareusuallybasedonpast experiences, recommendations
fromcolleagues or salesstaff, andwishful thinking. It isparamount that theenduser attain
reasonableexpectations, basedonsoundpredictions. Fuel economy management canbe
accomplishedwiththeaidof Detroit Diesel'sSpecManagercomputer program. Theprogram
takesintoconsiderationanumber of factorssuchasvehicledesign, dutycycle, androuteprole
as it predictsreal worldfuel economy. Contact thelocal Detroit Diesel distributor for Spec
Manager support, prior tocontactingthefactory. Makesurethat thereissoundbasisfor thepoor
fuel economycomplaint. Theseprecautionsappliestobothnewandin-servicevehicles.
Therearemany variableswhichmayaffect fuel economy. Includedare:
VehicleFrontal Area
VehicleWeight
RollingResistance(Static androlling)
Air Resistance(Excessiveadd-onsincreaseair resistance; trailer gaptoolarge)
EngineSpeed
TireSize(Revs/mile)
AxleRatio
TransmissionGear Ratios
RoadSurface(Cement, blacktop, gravel)
Duty Schedule(Highway, stop-and-go, excessiveidling)
VehicleMaintenance(Pluggedair lter, lowtirepressure, poor wheel alignment, brakes
dragging)
VehicleCruiseSpeed
Driver Habits
Weather Conditions
NOTE:
If any of these variables is not optimized, a serious penalty in fuel economy will result.
Many of these items are out of the operator's control. However, there are factors that can
be controlled and have a major impact on fuel economy.
15.17.1 Troubleshooting Guidelines for Vehicle Cruise Speed
Oneof themost commonfactorsthat reducesfuel economyisvehiclecruisespeed.
15.17 POOR FUEL ECONOMY
Maintainas slowacruisingspeedas possible. ListedinTable15-43aretheapproximate
percentagesof fuel economyreductionbasedonvehiclecruisingspeed.
Vehi cl e Cruise Speed (mph) Approxi mate Reducti on i n Fuel Economy (%)
5051 2
5152 3
5253 4
5354 5
5455 10
5565 10
75 20
Table 15-43 Fuel Economy Reduction based on Cruising Speed
15.17.2 Troubleshooting Guidelines for Excessive Engine Idling
Another factor toconsider isexcessiveengineidling. Asidefromthefact that theoperator is
getting0mpgduringidling, combustionislessthanideal. Poor combustioncancompromise
theefciency of theturbocharger. Regardingthenotionthat idlingmaintains cabheat inthe
winter, sometestshaveshownthat duringtherst hour after full loadoperation, theengine
actuallycoolsdownat afaster ratewhenidlingthanwhenturnedoff. Therefore, toincreasefuel
economy minimizeengineidling.
15.17.3 Troubleshooting Guidelines for Fuel Economy in Cold Weather
It is not uncommonto experiencealoss infuel economy duringthewinter. Coldambient
conditionsbringonmoreengineidlingandincreasedresistanceinmovingpartssuchasengine,
transmission, andaxle, duetouidviscosityincrease. Thereisalsotheissueof winter-blended
fuel. Blendedfuel typicallydoesnot containasmuchenergyassummer fuel. Therefore, it takes
morefuel tomovetheequipment. Testshaveshownthat therecanbeasmuchasa7%penaltyin
fuel economyduetoblendedfuels. Therefore, tosaveonfuel economy, comparisonsmust be
madefor thesameyearly timeframe.

1 Mbe900 05a

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

1 Mbe900 05a

Transféré par

Droits d'auteur :

Formats disponibles

15 TROUBLESHOOTING

15.5.23 Troubleshooting Procedure for Aerated Fuel

Vous aimerez peut-être aussi