SECTION 4: Diagnostic Subroutines. Table of Contents

Transcription

1 SECTION 4: Diagnostic Subroutines Table of Contents Contents PAGE Hard Start/No Start Diagnostic Procedures Visual Engine/Chassis Inspection Check Engine Oil Level Glow Plug System Operation Intake/Exhaust Restriction Test Carry Out The Key On Engine Off (KOEO) On-Demand Self-Test Retrieve Continuous Diagnostic Trouble Codes (DTCs) Fuel Volume Control Valve and Fuel Pressure Control Valve Adaptive Learning Parameter Reset Key On Engine Off (KOEO) Fuel Injector Electrical Self-Test Bleed The High Pressure Fuel System Sufficient Clean Fuel Test Electric Fuel Pump Pressure Test Fuel Conditioning Module Inlet Restriction Test Bleed The High Pressure Fuel System Test Low Pressure Fuel System Validated Combustion Gas In The Fuel Rail Test Check Vehicle Power (VPWR) During Cranking Test Check The CKP And CMP Signal While Cranking Test Monitor The FRP While Cranking Test Glow Plug Mist Test No Start Fuel Injector Return Port Leak Test No Start Monitor FRP Sensor No Start Test Power Balance Test High Pressure Fuel System Test With Valve Covers Off Running Inverse Fuel Injector Leak Test High Pressure Fuel Injection Pump Leak Test High Pressure Fuel System Test Fuel System Leak Test High Pressure Fuel System Test With Valve Covers Off Cranking Fuel System Debris Check Performance Diagnostic Procedures Visual Engine/Chassis Inspection Check Engine Oil Level Sufficient Clean Fuel Test Carry Out The Key On Engine Off (KOEO) On-Demand Self-Test Retrieve Continuous Diagnostic Trouble Codes (DTCs) KOEO Injector Electrical Self-Test Carry Out The Key On Engine Running (KOER) On-Demand Self-Test Power Balance Test High Pressure Fuel System Test Intake Restriction Test Exhaust Gas Recirculation (EGR) System Test Exhaust Restriction Test Electric Fuel Pump Pressure Fuel Conditioning Module Inlet Restriction Test Boost Pressure Test Crankcase Pressure Test

2 4-2 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Hard Start/No Start Diagnostic Procedures F-Super Duty

3 Diagnostic Subroutines 4-3 Hard Start/No Start Diagnostic Procedures

4 4-4 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures 1. Visual Engine/Chassis Inspection Purpose: NOTE:

5 Diagnostic Subroutines 4-5 Hard Start/No Start Diagnostic Procedures For a hard start/no start concern with the engine oil temperature (EOT) below 15 C (60 F) carry out the Glow Plug System Operation Test first. The purpose of this test is to check the general condition of the engine and look for obvious causes of a hard start or no start condition. Visual Engine/Chassis Inspection NOTE: The camshaft position (CMP) sensor, crankshaft position (CKP) sensor and the powertrain control module (PCM) connectors are the most critical electronic components to inspect in no start situations. Verify there are no fluid or pressure leaks. Inspect all wire connections for damage. Inspect the manifold absolute pressure (MAP) sensor, intake air temperature 2 (IAT2) sensor, charge air cooler (CAC) and intake for leaks. Check for aftermarket performance products. Fuel Oil Coolant Electrical Hoses Leaks Method Visual Check Recommended Procedure: Inspect the fuel system, including the fuel tank and the fuel lines for kinks, bends or leakage. Inspect for coolant leaks at the radiator and the heater hoses and check the coolant level. Inspect the MAP sensor, IAT2 sensor, and the CAC for leaks. Inspect wiring for correct routing and make sure no rubbing or chafing has occurred. Inspect the engine harness, PCM, and sensor connectors to make sure they are completely seated and in good condition. Check for aftermarket performance products. If aftermarket performance products are present, return to original equipment manufacturers (OEM) components as necessary. Loose or leaking fuel supply lines cause the fuel system to lose its prime Kinked or blocked fuel supply lines Fuel leaks contribute to no start conditions Coolant leaks indicate engine problems Electronic connectors may be damaged or not correctly installed causing a no start condition Leak around MAP sensor Leak around IAT2 sensor Restricted or open CAC hose Tools Required: Inspection light 2. Check Engine Oil Level WARNING: Smoking or open flame of any type must not be present when working near fuel or fuel vapor. Failure to follow these instructions may result in personal injury. NOTICE: Only use ultra low sulfur diesel fuel that is 5% or less biodiesel with this vehicle. Use of any other fuel type may damage the vehicle or cause an emission concern. Refer to the Owner's Literature for more information. NOTE: If directed here from a pinpoint test, return to the pinpoint test after carrying out this procedure.

6 4-6 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures NOTE: If the engine oil has diesel fuel contamination, the engine oil appears thin and watery, and has a diesel fuel odor. If the engine oil has coolant contamination, the engine oil appears milky white and has an ethylene glycol odor. Purpose: The purpose of this test is to verify the correct engine oil quality and level. Check Engine Oil Level Check for aftermarket performance products. Check for contaminants (fuel, coolant). Correct grade/viscosity. Miles/hours on engine oil, correct level. Method Visual Check Recommended Procedure: Check for aftermarket performance products. If aftermarket performance products are present, return to original equipment manufacturers (OEM) components as necessary. Aftermarket performance products affect the correct operation of the regeneration process which may affect engine oil level. Due to the size of the engine oil system, it is critical when checking the engine oil level, to make sure the vehicle is parked on a level surface and the engine has been turned off for at least 10 minutes to make sure that the engine oil in the upper parts of the engine has returned to the oil pan. Check for the correct engine oil level using the oil level indicator with the vehicle on level ground. If the engine oil level on the oil level indicator is overfull, it is possible the engine was incorrectly repaired or fuel or coolant is diluting the engine oil and filling the crankcase. Recheck the engine oil level. Remove and clean the oil level indicator. Reinsert the oil level indicator into the oil level indicator tube until only the oil level indicator handle touches the top of the oil level indicator tube. Oil Level Indicator Offset If directed to this test from a pinpoint test and the engine oil level is correct, return to the pinpoint test. If not directed to this test from a pinpoint test and the engine oil level is correct, continue to Step 3 Glow Plug System Operation, in this section to continue diagnosis. If the engine oil level is overfull, check the CAC for contamination. If the CAC has engine oil, coolant, fuel or metal contamination, a thorough cleaning of the CAC system is necessary. Refer to the Workshop Manual section for correct cleaning procedures. Clean and mark the oil level indicator.

7 Diagnostic Subroutines 4-7 Hard Start/No Start Diagnostic Procedures Engine Oil Level Indication Check for recent fuel system repairs which may have caused fuel leaks into the engine crankcase. If a fuel system repair was made and the engine oil was not changed, change the engine oil, mark the oil level indicator and carry out the Fuel System Leak Test in this section to continue diagnosis. Check the maintenance records for engine idle time, mileage and vehicle usage since the last engine oil change. Oil that has had extended drain intervals has increased viscosity (becomes thicker) and makes engine cranking more difficult and starting less reliable at temperatures below freezing. Refer to the lube oil chart in the Workshop Manual or Owner's Literature for the correct engine oil selection for temperature conditions. If records indicate insufficient engine oil changes, change the engine oil, mark the oil level indicator and carry out the Fuel System Leak Test in this section to continue diagnosis. Check for biodiesel fuel of greater than 5% or high sulphur diesel fuel. Biodiesel fuel concentration of greater than 5% or use of high sulphur content fuel can cause increased fuel dilution. If the engine oil level is overfull, GO to Pinpoint Test AB to continue diagnosis. Engine oil level low engine oil leak, engine oil consumption, incorrect repair Engine oil level high incorrect repair, fuel dilution Engine oil contamination with coolant engine oil cooler, front cover porosity, head gasket, porosity Engine oil contamination with diesel fuel fuel injector leak, high pressure fuel injection pump leak Tools Required: None 3. Glow Plug System Operation NOTE: The wait to start indicator on time (1-10 seconds) is independent from glow plug on time. Purpose: The purpose of this test is to verify the glow plug system operation. Glow Plug System Operation Glow Plug Control Module (GPCM) Operation Glow plug on time is dependent on engine oil temperature and altitude. The GPCM commands the glow plugs on for 1 to 120 seconds. The GPCM does not operate if the engine oil temperature is above 55 C (131 F). Connect the scan tool. Access and retrieve the KOEO and continuous DTCs. If GPCM DTCs are present, GO to Pinpoint Test AF. Verify B+ voltage is supplied to the GPCM. Access and monitor the GPLTM and ECT PIDS to verify sufficient glow plug ON time. Turn the ignition to the ON position and measure the glow plug voltage during the ON time.

8 4-8 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures On Time Specification Measurement 1 to 120 seconds B+ Glow Plug Resistance Disconnect the glow plug bus bar connector. Measure the resistance between the glow plug bus bar connector, component side and battery ground. Disconnect the GPCM. Measure the resistance between the GPCM connector, harness side and the glow plug bus bar connector, harness side. Glow Plug Number Glow Plug to Ground (0.1 to 2 ohms) Glow Plug Bus Bar Connector to GPCM Connector (less than 5 ohms) Recommended Procedure: NOTE: Check for poor connections or loose fitting pins. NOTE: Incorrect measurements result if all glow plug connectors are not disconnected. The glow plug monitor self-test is a KOER functional test of the glow plug system. The self-test is carried out on-demand with the engine running and the A/C off. The PCM activates the GPCM which monitors the glow plugs. The pedal may be used to increase the engine speed to increase voltage if needed. To detect a concern, the self-test requires a concern to be present at the time of testing.

9 Diagnostic Subroutines 4-9 Hard Start/No Start Diagnostic Procedures Item Part Number Description 1 GPCM 2 Black connector 3 Green connector 4 Cylinder 5 glow plug 5 Cylinder 7 glow plug 6 Cylinder 1 glow plug 7 Cylinder 3 glow plug 8 Cylinder 6 glow plug 9 Cylinder 8 glow plug 10 Cylinder 2 glow plug 11 Cylinder 4 glow plug 12 VBAT 13 Glow plug enable (GPE) 14 Diagnostic communication 15 VPWR GPCM power circuits

10 4-10 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Glow plugs Glow plug bus bar GPCM Circuitry Tools Required: Digital Multimeter (DMM) Scan tool 4. Intake/Exhaust Restriction Test Purpose: This purpose of this test is to determine if an intake air or exhaust restriction is contributing to a no start or hard start condition. If the engine starts with a high intake air or exhaust restriction, a considerable amount of black/blue smoke is produced. Intake/Exhaust Restriction Inspect the air filter and inlet ducts. Inspect the exhaust system. Check for illumination of the air filter restriction indicator. Method Visual Check Recommended Procedure: Inspect the air cleaner inlet and ducting to verify no blocks or collapsed ducting. Inspect the air cleaner housing and filter for correct installation. Inspect the air filter restriction gauge to make sure the indicator is in the normal operating range. Inspect the exhaust system for damaged or blocked pipes. Air Filter Restriction Gauge

11 Diagnostic Subroutines 4-11 Hard Start/No Start Diagnostic Procedures NOTE: Reset the air filter restriction gauge after repairing a restriction concern. Snow or foreign material restricting the airflow at the air inlet Misrouted air cleaner ducting On engines recently repaired, rags or cap plugs may have been inadvertently left in an air inlet pipe Tailpipe or muffler may have collapsed or been damaged Tools Required: None 5. Carry Out The Key On Engine Off (KOEO) On-Demand Self-Test Purpose: The purpose of this test is to determine if the PCM has detected any concerns that would cause a hard start or no start condition. Carry Out The KOEO On-Demand Test Use the scan tool. Diagnostic trouble codes (DTCs) set during this test are current concerns. Diagnostic Trouble Codes Recommended Procedure: NOTE: To verify that the DTC is a hard fault, clear continuous DTCs first (be sure to record all DTCs and freeze frame information before clearing). Repeat the KOEO on-demand self-test. If the DTC is set again, a hard fault has occurred. Connect the scan tool. Turn off all accessories. If the vehicle is equipped with a power take-off (PTO) system or auxiliary idle control, it must be turned off to carry out the self-test. Carry out the necessary vehicle preparation and a visual inspection. Refer to Section 2, Quick Test Operation. Refer to the scan tool operating manual for instructions. Ignition ON, engine OFF. Follow the operating instructions from the diagnostic menu. Carry out a KOEO on-demand self-test. Record the DTCs and freeze frame information and refer to the appropriate pinpoint test. The most likely PCM detectable concerns that cause a hard start or no start condition are: CMP sensor inactive concern CKP sensor inactive concern Tools Required: Scan tool 6. Retrieve Continuous Diagnostic Trouble Codes (DTCs) Purpose: The purpose of this test is to determine if the PCM has detected any historical or intermittent concern conditions that would cause a hard start/no start symptom. The condition that caused a continuous DTC may no longer exist. Retrieve Continuous DTCs

12 4-12 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Use the scan tool. DTCs retrieved during this test are historical concerns. Diagnostic Trouble Codes Recommended Procedure: Connect the scan tool. Turn off all accessories. If the vehicle is equipped with a PTO system or auxiliary idle control, it must be turned off to carry out the self-test. Carry out the necessary vehicle preparation and a visual inspection. Refer to Section 2, Quick Test Operation. Refer to the scan tool operating manual for instructions. Ignition ON, engine OFF. Follow the operating instructions from the diagnostic menu. Record the continuous DTCs and freeze frame information and carry out the appropriate pinpoint test for continuous DTC diagnostics. Clear the continuous DTCs after a repair. Tools Required: Scan tool 7. Fuel Volume Control Valve and Fuel Pressure Control Valve Adaptive Learning Parameter Reset Purpose: If no DTCs are set the PCM stores learned fuel volume control valve and fuel pressure control valve adaptive learning parameters. Reset the fuel volume control valve and fuel pressure control valve adaptive learning parameters and attempt to start the engine. Fuel Volume Control Valve and Fuel Pressure Control Valve Adaptive Learning Parameter Reset Use the scan tool. Clear the fuel injector adaptive tables. Start the engine. Clear Fuel Injector Adaptive Tables Engine Start YES/NO YES/NO Recommended Procedure: Connect the scan tool. Refer to the scan tool operating manual for instructions. Ignition ON, engine OFF. Follow the operating instructions from the diagnostic menu. Clear Fuel Injector Adaptive Tables. Start the engine. If the engine starts and the concern is fixed, verify that the adaptive learning parameter reset fixed the concern. It is possible the adaptive learning parameters were not reset after a new high pressure fuel injection pump was installed. Tools Required: Scan tool 8. Key On Engine Off (KOEO) Fuel Injector Electrical Self-Test NOTE: If unable to carry out KOEO Fuel Injector Electrical Self-Test, disconnect the PCM connector and check the fuel injector for shorts or opens. Purpose:

13 Diagnostic Subroutines 4-13 Hard Start/No Start Diagnostic Procedures The purpose of this test is to determine if the fuel injectors are functioning. KOEO Fuel Injector Electrical Self-Test Use the scan tool. Fuel injector DTCs are displayed after the self-test is completed. Fuel Injector Diagnostic Trouble Codes Cylinder and Fuel Injector Location Recommended Procedure: This test determines if there are any concerns with the operation of the fuel injector circuits. If a concern is detected, a DTC outputs on the data link at the end of the test when requested by a scan tool. Only a hard fault DTC is displayed. Connect the scan tool. Turn off all accessories. If the vehicle is equipped with a PTO system or auxiliary idle control, it must be turned off to carry out the self-test. Carry out the necessary vehicle preparation and a visual inspection. Refer to Section 2, Quick Test Operation. Refer to the scan tool operating manual for instructions. Ignition ON, engine OFF. Follow the operating instructions from the diagnostic menu. Carry out the KOEO Fuel Injector Electrical Self-Test. Record the DTCs and refer to the appropriate pinpoint test to continue diagnosis. Open or short fuel injector circuit Fuel injector connector Fuel injector Tools Required: Scan tool 9. Bleed The High Pressure Fuel System Purpose: Bleed the high pressure fuel system to check if the hard start/no start condition is being caused by air in the fuel system.

14 4-14 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Bleed The High Pressure Fuel System Bleed the high pressure fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. If the fuel is aerated after completing the fuel system bleeding procedure, repeat the fuel system bleed procedure. Fuel Aerated Engine Start YES/NO YES/NO Recommended Procedure: Bleed the high pressure fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. If the fuel is aerated after completing the Fuel System Bleeding procedure, repeat the Fuel System Bleed procedure. If the vehicle starts and runs while the bleed procedure is carried out and fuel is not aerated, the vehicle may have run out of fuel or the fuel filters may have been changed recently. Carry out the High Pressure Fuel System Test in this section to verify correct operation. If the vehicle does not start or the fuel is aerated, carry out the Sufficient Clean Fuel Test in this section to continue diagnosis. Tools Required: Scan tool 10. Sufficient Clean Fuel Test NOTICE: Only use ultra low sulfur diesel fuel that is 5% or less biodiesel with this vehicle. Use of any other fuel type may damage the vehicle or cause an emission concern. Refer to the Owner's Literature for more information. Purpose: The purpose of this test is to verify the fuel quality and sufficient fuel to start the engine. Sufficient Clean Fuel Test Check for illumination of the water in fuel (WIF) indicator. Drain a fuel sample from the fuel conditioning module. Method Visual Check Recommended Procedure: Open the drain valve integrated in the fuel conditioning module and drain fuel into a clear 1 liter container. Close the drain valve. The flow out of the drain valve should be steady and should produce at least 1 liter/1 quart of fuel within 2 minutes. If the volume of the fuel collected within 2 minutes is short of the required 1 liter/1 quart there may be insufficient amount of fuel in the tank and the fuel level may not be correctly indicated on the fuel level gauge. If a fuel level indication concern is suspected, refer to the Workshop Manual Section to continue diagnosis. Observe the WIF indicator. If the indicator is illuminated, the fuel may be contaminated with water. Inspect the fuel in the container. It should be clear, not cloudy. It also should be free of water and contaminants. Dyed red or blue fuel indicates off-highway fuel. The fuel sample should not indicate evidence of waxing or gelling. Waxing or gelling in some fuels in cold weather could clog fuel filters and the fuel pump and cause restrictions in the fuel or low fuel pressure. Some sediment and water may be present in the fuel sample if the fuel filter has not been replaced for a prolonged period of time or if the sediment and water have not been drained recently. If that is the case, a second sample may be required to determine fuel quality.

15 Diagnostic Subroutines 4-15 Hard Start/No Start Diagnostic Procedures Fuel Conditioning Module Drain Valve Biodiesel-water separation, seal degradation, corrosion Corrosion to fuel system components No fuel in the tank Fuel supply line broken or crimped Fuel jelled Fuel quality Pickup tube screen in tank restricted Restricted fuel filters Cloudy fuel indicates that the fuel may not be a suitable grade for cold temperatures. Excessive water or contaminants may indicate that the tank and fuel system may need to be flushed and cleaned. Tools Required: Clear container approximately 0.95 L (1 quart) 11. Electric Fuel Pump Pressure Test NOTE: The fuel pump runs for approximately 30 seconds at initial ignition on and then the pressure decreases. Purpose: The purpose of this test is to verify there is sufficient fuel pressure for starting. Electric Fuel Pump Pressure Test Verify there is fuel in the tank. Check the fuel pump power and ground circuits. Measure the fuel pressure using the Fuel Line Adapter or equivalent. NOTE: If using a scan tool for the fuel pump pressure test, the scan tool value may vary by 10% on the 20.7 kpa (3 psi) specification.

16 4-16 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Instrument Specification Measurement kpa (0-30 psi) gauge kpa (3-8 psi) Recommended Procedure: Verify there is fuel in the tank and battery voltage at the fuel pump. With the ignition ON and engine OFF use a digital multimeter (DMM), and measure the voltage between the fuel pump power and ground circuits. Battery voltage is present for approximately 30 seconds after the ignition is turned to the ON position. If no voltage is present, GO to Pinpoint Test MA to continue diagnosis. Disconnect the fuel line on the outlet side of the fuel conditioning module. Install the Fuel Line Adapter or equivalent and the Magnehelic Gauge kpa (0-30 psi) Bar (part of DSL ENG Pressure Test Kit or equivalent). Measure the fuel pressure with the ignition in the ON position and the engine OFF. If fuel pressure is below 20.7 kpa (3 psi), go to the next step to verify no restriction. If the engine stalls while driving, carry out the Electric Fuel Pump Pressure Test in the Performance Diagnostic Procedures to continue diagnosis.

17 Diagnostic Subroutines 4-17 Hard Start/No Start Diagnostic Procedures Dirty or restricted fuel filters Fuel pump relay Inertia switch Leak in the low pressure supply line Tools Required: Magnehelic Gauge kpa (0-30 psi) Bar (part of DSL ENG Pressure Test Kit or equivalent) Fuel Line Adapter or equivalent 12. Fuel Conditioning Module Inlet Restriction Test Purpose: The purpose of this test is to isolate the cause of low fuel pressure. Fuel Conditioning Module Inlet Restriction Measure the restriction at the fuel pump inlet. Instrument Specification Measurement 0-30 in-hg Vacuum Gauge 6 in-hg maximum Recommend Procedure: Disconnect the fuel line to the inlet side of the fuel conditioning module. Install the Fuel Line Adapter or equivalent and the Vacuum Gauge 0-30 in-hg vacuum. Measure the restriction at wide open throttle (WOT) (maximum engine speed out of gear with the brakes set and the wheels blocked). If restriction is greater than 6 in-hg, there is a restriction between the fuel pump and the fuel tank. If the restriction is less than 6 in-hg, inspect both fuel filters. If the filters are OK, install a new fuel conditioning module. Refer to the Workshop Manual Section , Fuel Charging and Controls.

18 4-18 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Fuel line restriction Fuel filters Fuel conditioning module Tools Required: Fuel Line Adapter or equivalent Vacuum Gauge (part of DSL ENG Pressure Test Kit or equivalent) 13. Bleed The High Pressure Fuel System Test Low Pressure Fuel System Validated Purpose: Bleed the high pressure fuel system after validating the low pressure fuel system is providing the fuel volume and flow required by the high pressure fuel system. Bleed The High Pressure Fuel System Test Low Pressure Fuel System Validated Bleed the high pressure fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. If the fuel is aerated after completing the fuel system bleeding procedure, carry out the Combustion Gas In The Fuel Rail Test in this section to continue diagnosis. Fuel Aerated Engine Start YES/NO YES/NO Recommended Procedure: Bleed the high pressure fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. If the vehicle does not start, the fuel stays aerated and the correct fuel flow and volume in the low pressure fuel system has been validated, check the secondary fuel filter. Repair as necessary. If the fuel continues to stay aerated, carry out the Combustion Gas In The Fuel Rail Test in this section to continue diagnosis.

19 Diagnostic Subroutines 4-19 Hard Start/No Start Diagnostic Procedures If the vehicle starts, the fuel stays aerated and does not stall after the bleed tool is removed, carry out the High Pressure Fuel System Test in this section to continue diagnosis. If the vehicle stalls during the High Pressure Fuel System Test, carry out the Combustion Gas In The Fuel Rail Test in this section to continue diagnosis. If the vehicle still has a hard start or no start condition and the fuel is not aerated, carry out the Check Vehicle Power During Cranking Test in this section to continue diagnosis. Tools Required: Scan tool 14. Combustion Gas In The Fuel Rail Test Purpose: The purpose of this test is to check if any combustion gas leaks past the combustion gasket. Combustion Gas In the Fuel Rail Test Bank 1 Bank 2 Cylinder 1 (YES/NO) Cylinder 3 (YES/NO) Cylinder 5 (YES/NO) Cylinder 7 (YES/NO) Cylinder 2 (YES/NO) Cylinder 4 (YES/NO) Cylinder 6 (YES/NO) Cylinder 8 (YES/NO) Recommended Procedure: NOTE: The compression pulses in the latex balloon indicate the combustion gas is leaking into the fuel rail. NOTE: Additional DTCs may result during this procedure. Disconnect the low pressure fuel pump electrical connector. Disconnect the fuel injector return line at the check valve located near the left cylinder head. Refer to the Workshop Manual Section , Fuel Charging and Controls. Install a latex balloon over the fuel return line and secure with a tie strap. Remove the glow plugs from cylinder numbers 2 through 8, leaving the cylinder number 1 glow plug installed. Crank the engine and observe the latex balloon for compression pulses. Refer to the Workshop Manual Section , Glow Plug system. If no compression pulses are present, remove the cylinder number 1 glow plug and install the glow plug in cylinder number 2. Crank the engine and observe the latex balloon for compression pulses. Repeat the test moving the glow plug to cylinder numbers 3 through 8 and continue testing all cylinders. Record the cylinder numbers that indicate compression pulses in the latex balloon. For cylinders that leak combustion gas into the fuel return line as indicated by compression pulses in the latex balloon, remove the fuel injector and install new O-rings, combustion gasket and fuel injector hold down clamp assemblies. Refer to the Workshop Manual Section , Fuel Charging and Controls. Carry out the Combustion Gas In The Fuel Rail Test in this section to verify the repair. After the repair is verified, carry out the High Pressure Fuel System Test in this section. Fuel injector combustion gasket Fuel injector O-rings Fuel injector loose Fuel injector Tools Required:

20 4-20 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Latex balloons Tie straps 15. Check Vehicle Power (VPWR) During Cranking Test Purpose: The purpose of this test is to verify PCM power during cranking. Scan Tool Data List Monitoring NOTE: The 8 volt specification represents the minimum battery voltage required for engine starting. Greater than average crank times are encountered if the battery voltage is less than 9.5 volts. If excessive crank time is a concern, verify battery voltage is greater than 9.5 volts. NOTE: An outside power source may be needed for the scan tool. The scan tool may reset below 9.5 volts. Select the parameters indicated from the scan tool parameter list and monitor while cranking the engine. Parameter Specification Measurement VPWR 8 volts minimum If a low voltage condition is present, check the battery, charging system or power and ground circuits to the PCM. Recommended Procedure: Connect the scan tool. Ignition ON, engine OFF. Access and monitor the VPWR PID while cranking the engine. Battery cables Low battery voltage Charging system Power and ground circuits to the PCM PCM relay GO to Pinpoint Test A to diagnose a voltage concern. Tools Required: Scan tool 16. Check The CKP And CMP Signal While Cranking Test Purpose: The purpose of this test is to verify the CMP and CKP sensors and circuits are functioning. Scan Tool Data List Monitoring The scan tool may reset below 9.5 volts. Select the parameters indicated from the scan tool parameter list and monitor while cranking the engine. NOTE: An outside power source may be needed for the scan tool.

21 Diagnostic Subroutines 4-21 Hard Start/No Start Diagnostic Procedures Parameter Specification Measurement RPM SYNC 150 RPM minimum YES Low RPM may be caused by starting or charging system concerns. No RPM indicated while cranking may indicate a CKP concern. Recommended Procedure: Connect the scan tool. Ignition ON, engine OFF. Access and monitor the RPM PID while cranking the engine. If RPM is above 150 RPM, GO to Pinpoint Test V and diagnose the CMP sensor. If RPM is 0 RPM, GO to Pinpoint Test D and diagnose the CKP sensor. Refer to Section 6, Typical Diagnostic Reference Values for normal operating values. Weak battery or starter Circuitry CKP sensor CMP sensor Tools Required: Scan tool 17. Monitor The FRP While Cranking Test Purpose: The purpose of this test is to determine if the high pressure fuel system generates minimum fuel pressure to sustain starting. Scan Tool Data List Monitoring The scan tool may reset below 9.5 volts. Select the parameters indicated from the scan tool parameter list and monitor the fuel pressure. Parameter Specification Measurement FRP FRP Ignition ON 0.49 volts 0 MPa (0 psi) Cranking MPa (4,000 psi) minimum A reading above the FRP sensor specification indicates high fuel rail pressure with the engine OFF. Check for exhaust gas in the fuel rail, air in the fuel rail, a biased FRP sensor or an electrical concern. A reading below the minimum FRP sensor specification indicates low fuel rail pressure during crank. Check the fuel rails and high pressure fuel lines for leaks. Recommended Procedure: Connect the scan tool. Ignition ON, engine OFF. Access and monitor the FRP volts PID. Record the FRP sensor value with the engine OFF. Access and monitor the FRP pressure PID. Record the FRP sensor value while the engine is cranking.

22 4-22 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Fuel pressure greater than 0.49 volts 0 MPa (0 psi) with the ignition ON, pressure may read high due to exhaust gas in the fuel rail, air in the fuel rail, a biased FRP sensor or an electrical concern. If no concerns are found and the engine does not start, carry out the Glow Plug Mist Test No Start in this section to continue diagnosis. If the engine has a hard start condition, carry out the Power Balance Test in this section to continue diagnosis. Fuel pressure less than MPa (4,000 psi) during cranking indicates that the fuel pressure is too low to sustain engine starting. Check the fuel injectors, high pressure fuel injection pump, high pressure fuel supply line to the fuel rails and left and right bank fuel rails for leaks. If any leaks are present, repair as necessary. High pressure fuel injection pump Fuel volume control valve or circuitry Fuel pressure control valve or circuitry Fuel injectors Tools Required: Scan tool 18. Glow Plug Mist Test No Start Purpose: WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury. The purpose of this test is to find a fuel injector with a leaking nozzle for a no start condition. For a hard start condition, continue to the Power Balance Test in this section to continue diagnosis. Glow Plug Mist Test No Start Glow Plug Mist Test No Start Bank 1 Bank 2 Cylinder 1 (YES/NO) Cylinder 3 (YES/NO) Cylinder 5 (YES/NO) Cylinder 7 (YES/NO) Cylinder 2 (YES/NO) Cylinder 4 (YES/NO) Cylinder 6 (YES/NO) Cylinder 8 (YES/NO) Recommended Procedure: NOTE: This test is intended to diagnose a leaking fuel injector tip for vehicles with a no start condition only. If the engine runs, do not carry out this test, a fuel injector may be misdiagnosed as the leak may be to small to be visually detected. Excessive engine oil in a cylinder can mislead to multiple fuel injectors being suspected for leaks. Disconnect the 15-pin inline connector on the left hand valve cover harness. Disconnect the 15-pin inline connector on the right hand valve cover harness. Remove all glow plugs. Crank the engine 15 seconds 2 times to clear the cylinders. Crank the engine 15 seconds while checking for a mist from the glow plug holes.

23 Diagnostic Subroutines 4-23 Hard Start/No Start Diagnostic Procedures If a mist is visible from one glow plug hole, install a new fuel injector at the cylinder in question and repeat the test to verify the repair. Verify the engine oil level and quality after the repair, change the engine oil and check the charge air cooler (CAC) for contamination. Refer to the Workshop Manual Section , Charge Air Cooler Repairs, for the correct cleaning procedures. If a mist is visible from all glow plug holes or one bank of glow plug holes then carry out the Inverse Fuel Injector Leak Test in this section to continue diagnosis. If no mist is visible from any glow plug holes, carry out the Fuel Injector Return Port Leak Test - No Start in this section to continue diagnosis. Fuel injectors Tools Required: None 19. Fuel Injector Return Port Leak Test No Start Purpose: WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. This screening test is only for a no start condition with the correct engine oil level. If the engine runs, do not carry out this test. The purpose of this test is to check for leaks from the fuel injector return port. The result only verifies that there is a leak on the fuel return port from the fuel injector, not which bank or fuel injector is affected. For a hard start condition, continue to the Power Balance Test in this section to continue diagnosis. Fuel Injector Return Port Leak Test No Start Fuel Flow Return YES/NO Recommended Procedure: Remove the fuel cooler to bracket fasteners, remove the exhaust back pressure (EBP) tube and the return/supply line bracket to get access to the cylinder head/fuel injector fuel return line. Disconnect the fuel return line at the check valve before the fuel return at the fuel cooler. The check valve maintains fuel flow from the high pressure fuel injection pump fuel return line to the fuel cooler. Connect one end of a clear hose to the cylinder head fuel return lines and the place the other end into a container. Disconnect the 15-pin inline connector on the left hand valve cover harness. Disconnect the 15-pin inline connector on the right hand valve cover harness. Crank the engine for 15 seconds 2 times. If there is no fuel return flow, carry out the Monitor FRP Sensor No Start Test in this section to continue diagnosis. If there is fuel return flow, the return port is leaking, carry out the Inverse Fuel Injector Leak Test in this section to continue diagnosis of which fuel injector is leaking. Tools Required: Clear hose

24 4-24 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures 20. Monitor FRP Sensor No Start Test Purpose: NOTICE: This test is only to be carried out if the vehicle has a no start condition, the engine oil level is correct and the fuel injectors are confirmed to not have any fuel injector nozzle leaks. If any of these conditions are present while this test is being carried out, cylinder damage may occur. If the engine runs, do not carry out this test. For a hard start condition, continue to the Power Balance Test in this section to continue diagnosis. The purpose of this test is to determine if the required fuel pressure to start the vehicle is present and the FRP sensor is reading correctly. Monitor FRP Sensor No Start Test Access and monitor the FRP PID while cranking the engine. Disconnect the FRP sensor electrical connector. Crank the engine. FRP Below 20 MPa (2,900 PSI) Cranking Engine Start YES/NO YES/NO Recommended Procedure: Connect the scan tool. Ignition ON, engine OFF. Access and monitor the FRP PID while cranking the engine. If the FRP is greater than 20 MPa (2,900 psi), do not continue with this test, GO to Pinpoint Test ME. If the FRP is below 20 MPa (2,900 psi), continue with this test. Disconnect the FRP sensor electrical connector. Crank the engine. If the engine starts, the FRP value is equal to or greater than 20 MPa (2,900 psi). Connect the FRP sensor electrical connector and attempt to start the engine. If the engine does not start with the FRP sensor reconnected, install a new FRP sensor and bleed the fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. If the engine does not start, reassemble the engine and bleed the fuel system. Refer to the Workshop Manual Section , Fuel System, Fuel System Bleeding High Pressure, Diesel Engine. GO to Pinpoint Test ME. Tools Required: Scan tool 21. Power Balance Test Purpose: NOTE: Before carrying out the power balance test, allow the engine to stabilize at the temperature necessary to recreate the symptom. Access the PCM and record the freeze frame data. The freeze frame data contains information which can be used to recreate original conditions that caused the symptom. Refer to Section 2, Freeze Frame Data for more information. NOTE: The contributing power cylinders that immediately follow the non-contributing power cylinders in the firing order may be affected. The affected power cylinders may not be able to fully recover the crankshaft speed, causing them to display below average contributing power cylinders and to be incorrectly identified as the non-contributing power cylinder. Therefore, only the cylinders that deviate the most from the average should be identified as the non-contributing power cylinder. Single or inconsistent non-contributing power cylinder traces may be caused by a natural variation in the crankshaft speed and should be ignored. The purpose of this test is to determine if the fuel injectors are operating correctly by observing individual cylinder contribution while carrying out the power balance test.

25 Diagnostic Subroutines 4-25 Hard Start/No Start Diagnostic Procedures Power Balance Test NOTE: Disregard any DTCs set as a result of the Power Balance Test. Use the scan tool to carry out the Power Balance Test. Monitor individual cylinder contribution and record the consistently non-contributing power cylinders. Non - Contributing Power Cylinders At Engine Idle Speed Non - Contributing Power Cylinders Off Engine Idle Speed or Under Load Recommended Procedure: Cylinder and Fuel Injector Location At Engine Idle Speed Test NOTE: The cylinder contribution test or enhanced power balance test must be carried out while the vehicle is stationary and not in motion. At no time should manual input through the accelerator pedal occur during these tests. Do not carry out this test while driving. NOTE: This procedure is to be carried out at engine idle speed. Concerns that are experienced at off engine idle speed or under load conditions are addressed in the Off Engine Idle Speed or Under Load Test. Connect the scan tool. Ignition ON, engine Running. Access the Power Balance Test. Evaluate each cylinders performance and compare to specification plus or minus 15 RPM. If the performance of all cylinders are within plus or minus 15 RPM, select the manual fuel injector balance test on the scan tool and evaluate each cylinders performance while comparing to specification plus or minus 15 RPM. If the performance of all cylinders are within plus or minus 15 RPM, no concern is present. If the performance of any cylinders are not within plus or minus 15 RPM, record the consistently non-contributing power cylinders and carry out the Off Engine Idle Speed or Under Load Test in this section to continue diagnosis. Off Engine Idle Speed or Under Load Test

26 4-26 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures NOTE: This procedure is to be carried out for concerns that are experienced at off engine idle speed or under load. NOTE: Disregard any DTCs set as a result of the Power Balance test. Connect the scan tool. Ignition ON, engine Running. Access the FRP_DSD PID and increase the fuel pressure to between MPa (15,000 to 16,000 psi). Access the Power Balance Test. Evaluate each cylinders performance and compare to specification plus or minus 15 RPM. Select the manual fuel injector balance test on the scan tool. Evaluate each cylinders performance while comparing to specification plus or minus 15 RPM. Record the consistently non-contributing power cylinders. Tools Required: Scan tool 22. High Pressure Fuel System Test With Valve Covers Off Running Purpose: The purpose of this test is to inspect for leaks under the valve covers at the fuel lines, connections, FRP sensor and fuel injector body. High Pressure Fuel System Test With Valve Covers Off Running Carry out the High Pressure Fuel System Test on the scan tool. Check the fuel lines, fuel line connections and fuel injectors for leaks, cracks and correct installation during the test. Fuel System Leaks YES/NO Recommended Procedure: NOTE: This test is only carried out when there is an engine oil level overfull condition due to fuel contamination. Connect the scan tool. Remove the right hand and left hand valve covers. Refer to the Workshop Manual Section , Engine, Valve Cover. Use a black light under the valve covers to check for residual black light dye (luminescence) which is present in new engines. If there are signs of black light dye (luminescence) under the valve covers, use shop air to clean off the fuel injectors paying close attention to jam nut on tops of the fuel injectors and fuel line connections. Once cleaned, check the areas again with the black light to make sure the areas are clean as well as areas under the fuel lines, fuel injectors and fuel line connections. Add 1-2 packages (30-50 ml) of black light dye (luminescence) to the fuel filter housing. If there is no signs of black light dye (luminescence), add black light dye (luminescence) to the fuel filter housing. Ignition ON, engine Running. Carry out the High Pressure Fuel System Test on the scan tool with the valve covers removed. Check the fuel lines, fuel line connections and fuel injectors for leaks or cracks during the test using the black light. If a concern is present, repair as necessary. Pay close attention to the tops of the fuel injectors and fuel line connections. If a concern is present, it may take up to 10 minutes for any black light dye (luminescence) to become visible. Check the CAC for contamination. If the CAC has engine oil, coolant, fuel or metal contamination, a thorough cleaning of the CAC system is necessary. Refer to the Workshop Manual section for correct cleaning procedures. Check the turbocharger bearings. Refer to the Workshop Manual section , Turbocharger, Bearing Clearance Check. If no leaks are present, carry out the Inverse Fuel Injector Leak Test in this section to continue diagnosis. Tools Required: Scan tool

27 Diagnostic Subroutines 4-27 Hard Start/No Start Diagnostic Procedures 23. Inverse Fuel Injector Leak Test Purpose: WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. NOTICE: If the fuel system is not bled, a fuel injector may be incorrectly diagnosed. The purpose of this test is to check for leaks from the fuel injector at the nozzle or the return port. Inverse Fuel Injector Leak Test NOTE: Additional DTCs may result during this procedure. Carry out the Inverse Fuel Injector Leak Test. Bank 1 Bank 2 Cylinder 1 (YES/NO) Cylinder 3 (YES/NO) Cylinder 5 (YES/NO) Cylinder 7 (YES/NO) Cylinder 2 (YES/NO) Cylinder 4 (YES/NO) Cylinder 6 (YES/NO) Cylinder 8 (YES/NO) Ignition in the OFF position. Remove the right hand and left hand valve covers. Refer to the Workshop Manual Section , Engine, Valve Cover. Release the fuel pressure. Refer to the Workshop Manual Section Fuel System, for the Fuel System Pressure Release Diesel Engine procedure. Disconnect the 15-pin inline connector on the left hand valve cover harness. Disconnect the 15-pin inline connector on the right hand valve cover harness. Disconnect all the fuel injector connectors. Refer to the Workshop Manual Section , Fuel Charging and Controls. Remove all the fuel injector supply tubes, fuel injector hold down clamp assemblies and the fuel injectors. Refer to the Workshop Manual Section , Fuel Charging and Controls. Assemble all fuel injectors except the cylinder number 1 fuel injector to the fuel rail using the original fuel injector supply tubes. Position the fuel injectors so the fuel nozzle and drain hole are visible and the nozzle is directed towards the valvetrain. Connect the open end of the hose from the Air Purge Adapter to the fuel injector supply tube, put the other end of the hose in a fuel container and crank the engine for 15 seconds. Attach the cylinder number 1 fuel injector to the fuel injector supply tube with the fuel injector positioned so the fuel nozzle and drain hole are visible. Disconnect the cylinder number 2 fuel injector from the fuel injector supply tube and put the other open end of the tube in a fuel container and crank the engine for 15 seconds. Attach the cylinder number 2 fuel injector to the fuel injector supply tube with the fuel injector positioned so the fuel nozzle and drain hole are visible. This must be done or a leaking fuel injector may not be detected. Install the Fuel Injector Cups or equivalent to the fuel injectors to contain any side spray from the fuel nozzles. Ignition ON, engine OFF. Crank the engine for 10 seconds. Check for fuel injectors that are leaking fuel from the fuel nozzles or drain holes. Ignition in the OFF position.

28 4-28 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Install a new fuel injector for any identified fuel injectors that are leaking fuel from the fuel nozzles or drain holes. Refer to the Workshop Manual Section , Fuel Charging and Controls. Remove the Fuel Injector Cups or equivalent from the ends of the fuel injectors. Install all the fuel injectors. Install new fuel injector supply tubes, O-rings and combustion washers for all fuel injectors that were removed. Refer to the Workshop Manual Section , Fuel Charging and Controls. Reassemble the engine. Bleed the high pressure fuel system. Refer to the Workshop Manual Section Fuel System for the Fuel System Bleeding High Pressure, Diesel Engine procedure. For a no start condition with no leaks present and the engine oil level is correct, carry out the Monitor FRP Sensor No Start Test in this section to continue diagnosis. For a hard start condition with no leaks present and the engine oil level is correct, check for electrical harness chafes. GO to Pinpoint Test ME. If entering this test from pinpoint test AB, no leaks are present and the engine oil level did not increase, there is no fuel system concern. Refer to Section 3, No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index and follow the diagnosis for Exhaust System Concerns. If no leaks are present and the engine oil level increased when carrying out the High Pressure Fuel System Test and Fuel System Leak Test, install a new high pressure fuel injection pump. Clear the fuel injector adaptive tables using the scan tool. Damaged fuel injector Leaking fuel injector nozzle or fuel injector Fuel lines Fuel rail Tools Required: Scan tool Air Purge Adapter Fuel Injector Cups or equivalent 24. High Pressure Fuel Injection Pump Leak Test Purpose: The purpose of this test is to determine if the high pressure fuel injection pump is leaking. High Pressure Fuel Injection Pump Leak Test Carry out the High Pressure Fuel Injection Pump Leak Test. Fuel Drain From Oil Drain Plug Hole YES/NO Recommended Procedure: NOTICE: Do not start the engine. Damage to the engine may occur. Ignition in the OFF position. Drain the engine oil. Do not install the oil drain plug. Install a battery charger to maintain battery voltage during this test. Turn the ignition to the ON position. ow the low pressure fuel pump to run until it stops. Cycle the ignition to the OFF position then to the ON position after the low pressure pump stops. Repeat this step 10 times. Visually check for fuel leaking during this test. Fuel drains from the oil drain plug hole if the high pressure fuel injection pump is leaking. If visible fuel leaks are present, install a new high pressure fuel injection pump. Refer to the Workshop Manual Section , Fuel Charging and Controls, Fuel Injection Pump High Pressure. Check the intake air system and related components for engine oil residue

29 Diagnostic Subroutines 4-29 Hard Start/No Start Diagnostic Procedures caused from the engine oil overfull condition and repair as necessary. Check the turbocharger bearings. Refer to the Workshop Manual Section , Turbocharger, Bearing Clearance Check. Clear the fuel injector adaptive tables using the scan tool. If no visible fuel leaks are present and the engine oil level was overfull in the Check Engine Oil Level test, install the oil drain pan plug and fill the engine with liters (15 quarts) of the correct engine oil. For a no start condition, carry out the Glow Plug Mist Test No Start in this section to continue diagnosis. For a hard start condition, carry out the Power Balance Test in this section to continue diagnosis. High pressure fuel injection pump Fuel pressure control valve Fuel volume control valve High pressure fuel system leak Tools Required: Scan tool 25. High Pressure Fuel System Test NOTE: Disregard any DTCs set as a result of the High Pressure Fuel System Test. NOTE: Carry out the Electric Fuel Pump Pressure Test before carrying out the High Pressure Fuel System Test. Purpose: The purpose of this test is to determine if the high pressure fuel system is able to reach and maintain the requested desired fuel pressure for a calibrated amount of time. This procedure may be used to assist in diagnosing hard start/no start or driveability concerns. This test can also be run to check for engine oil level increase due to leaks. High Pressure Fuel System Test NOTE: Depending on the engine state the fuel rail pressure may vary at idle from MPa (5,000 PSI) to MPa (7,500 PSI). Use the scan tool to carry out the High Pressure Fuel System Test. Visually check for engine compartment fuel leaks during this test. Commanded Pressure Measured Pressure Specification Measured Variation MPa (5,000 PSI) +/- 2.0 MPa (+/- 290 PSI) MPa (10,000 PSI) +/- 2.0 MPa (+/- 290 PSI) MPa (15,000 PSI) +/- 3.0 MPa (+/- 435 PSI) MPa (20,000 PSI) +/- 3.0 MPa (+/- 435 PSI) MPa (24,650 PSI) +/- 3.0 MPa (+/- 435 PSI) Recommended Procedure: NOTE: Follow the scan tool directions when carrying out the high pressure fuel system test. This test determines if the high pressure fuel system is able to maintain the requested fuel pressure for a calibrated amount of time. Turn off all accessories. If the vehicle is equipped with a PTO system or auxiliary idle control, it must be turned off to carry out the high pressure fuel system test.

30 4-30 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Refer to the scan tool operating manual for instructions. Ignition in the OFF position. Carry out the High Pressure Fuel System Test. Wait a minimum of 10 minutes and recheck the engine oil level. If the measured variation is outside of the specifications, no visible fuel leaks are present, and the engine oil level was correct in the Check Engine Oil Level test, GO to Pinpoint Test ME. If the measured variation is outside of the specifications, no visible fuel leaks are present, and the engine oil level was overfull in the Check Engine Oil Level test, carry out the Fuel System Leak Test in this section to continue diagnosis. If the measured variation is outside of the specifications or the engine oil level has increased during this test, carry out the High Pressure Fuel System Test With Valve Covers Off Running in this section to continue diagnosis. Tools Required: Scan tool 26. Fuel System Leak Test Purpose: The purpose of this test is to check for fuel injector leakage. This test can also be run to check for an engine oil level increase due to leaks. Fuel System Leak Test Carry out the Fuel System Leak Test. Method Visual Check Recommended Procedure: NOTICE: While carrying out this procedure, at the first sign of a fuel leak immediately abort the test. Refer to the scan tool manufacturers manual for instructions. NOTE: Verify the high pressure fuel system has no trapped air before continuing with this procedure. For additional information, refer to the Workshop Manual Section , Fuel System. NOTE: Do not carry out this test unless directed here from another procedure or DTC. NOTE: Additional DTCs may result during this procedure. Bleed the high pressure fuel system. Refer to the Workshop Manual Section Fuel System for the Fuel System Bleeding High Pressure, Diesel Engine procedure. If air bubbles are present, complete the Fuel System Bleeding High Pressure, Diesel Engine and retest. If the concern or DTC is still present continue with this test. Ignition ON, engine running. Access the PCM and monitor the RPM, FRP and FRP_DSD PIDs. Access the PCM and command the RPM to 1,500. Access the PCM and command the FRP_DSD to MPa (24,650 PSI). Maintain the RPM and FRP_DSD for 10 minutes. Ignition in the OFF position. ow the engine to remain OFF for 10 minutes. Check for the correct engine oil level using the oil level indicator with the vehicle on level ground. If entering this test directly from the Check Engine Oil Level test and the engine oil level increased, GO to Pinpoint Test AB to continue diagnosis.

31 Diagnostic Subroutines 4-31 Hard Start/No Start Diagnostic Procedures If the engine oil level increased, carry out the High Pressure Fuel System Test With Valve Covers Off Running in this section to continue diagnosis. If the engine oil level did not increase in this test and did not increase in the High Pressure Fuel System Test, refer to Section 3, No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index and follow the diagnosis for Exhaust System Concerns. Tools Required: Scan tool 27. High Pressure Fuel System Test With Valve Covers Off Cranking Purpose: The purpose of this test is to inspect for leaks under the valve covers at fuel lines, FRP sensor and fuel injector body. High Pressure Fuel System Test With Valve Covers Off Cranking Check the fuel lines, fuel line connections and fuel injectors for leaks, cracks and correct installation during the test. Fuel System Leaks YES/NO Recommended Procedure: Remove the right hand and left hand valve covers. Refer to the Workshop Manual Section , Engine, Valve Cover. Use a black light under the valve covers to check for residual black light dye (luminescence) which is present in new engines. If there are signs of black light dye (luminescence) under the valve covers, use shop air to clean off the fuel injectors paying close attention to jam nut on tops of the fuel injectors and fuel line connections. Once cleaned, check the areas again with the black light to make sure the areas are clean as well as areas under the fuel lines, fuel injectors and fuel line connections. Add 1-2 packages (30-50 ml) of black light dye (luminescence) to the fuel filter housing. If there is no sign of black light dye (luminescence), add black light dye (luminescence) to the fuel filter housing. If the engine does not start, crank the engine for 15 seconds and check the fuel lines, fuel line connections and fuel injectors for leaks or cracks during the test using the black light. If a concern is present, repair as necessary. Pay close attention to the tops of the fuel injectors and fuel line connections. If a concern is present, it may take up to 10 minutes for any black light dye (luminescence) to become visible. If the engine starts, start the engine and carry out the High Pressure Fuel System Test on the scan tool with the valve covers removed. Check the fuel lines, fuel line connections and fuel injectors for leaks or cracks during the test using the black light. If a concern is present, repair as necessary. Pay close attention to the tops of the fuel injectors and fuel line connections. If a concern is present, it may take up to 10 minutes for any black light dye (luminescence) to become visible. Check the turbocharger bearings. Refer to the Workshop Manual section , Turbocharger, Bearing Clearance Check. If no concern is present, carry out the Fuel Injector Return Port Leak Test No Start in this section to continue diagnosis. Fuel leaks Tools Required: None 28. Fuel System Debris Check Purpose: This test determines if there is debris in the high pressure fuel system requiring the replacement of the entire high pressure fuel system (fuel rails/fuel lines/fuel injectors) when a new high pressure fuel injection pump is installed. To be carried out if the high pressure fuel injection pump did not have a solenoid concern, no electrical concerns and no leaks found. Fuel System Debris Check Carry out the Fuel System Debris Check.

32 4-32 Diagnostic Subroutines Hard Start/No Start Diagnostic Procedures Fuel System Debris YES/NO Recommended Procedure: NOTICE: Do not cut the secondary fuel filter open to determine if there is debris in the fuel system. The purpose of the fuel filter is to collect debris and may be indicating that it is correctly functioning. Raise the rear tires of the vehicle 6 to 8 inches. Disconnect the cylinder number 1 fuel injector from the jumper tube, connect a rubber hose, crank engine over and drain the fuel through a coffee filter or paint strainer. Disconnect the cylinder number 2 fuel injector from the jumper tube, connect a rubber hose, crank engine over and drain the fuel through a coffee filter or paint strainer. If there is metallic material in the fuel, install a new high pressure fuel injection pump, a new fuel cooler, new fuel injectors, new LH and RH high pressure fuel system rails, new primary and secondary fuel filters, new fuel rail pressure (FRP) sensor, new high pressure fuel lines, new low pressure fuel supply line and new secondary fuel filter housing. If there is no metal debris, rust or corrosion present in the fuel conditioning module, clean any fuel residue and reinstall. Install a new fuel conditioning module if metal debris, rust or corrosion is present. Flush the low pressure fuel return lines until they are free of any metal debris. Install all new low pressure fuel return lines if rust or corrosion is present. Inspect the fuel tank for metal debris and flush any metal debris found. Water in fuel Gasoline Tools Required: Coffee filter or paint strainer

33 Diagnostic Subroutines 4-33 Performance Diagnostic Procedures Performance Diagnostic Procedures F-Super Duty

34 4-34 Diagnostic Subroutines Performance Diagnostic Procedures 1. Visual Engine/Chassis Inspection Purpose: The purpose of this test is to check the general condition of the engine and chassis.

35 Diagnostic Subroutines 4-35 Performance Diagnostic Procedures Visual Engine/Chassis Inspection Verify there are no fluid or pressure leaks. Inspect all wire connections for damage. Inspect the manifold absolute pressure (MAP) sensor, intake air temperature 2 (IAT2) sensor, charge air cooler (CAC), and intake for leaks. Fuel Oil Coolant Electrical Hoses Leaks Method Visual Check Recommended Procedure: Inspect for a leak around the MAP sensor. Inspect for a leak around the IAT2 sensor. Inspect the fuel system, including the fuel tank, fuel pump, fuel filter housing and fuel lines, for kinks, bends or leakage. Inspect for coolant leaks at the radiator and coolant hoses. Check the coolant level. Inspect wiring for correct routing, and verify no rubbing or chafing has occurred. Inspect all sensors, and verify the connectors are properly secured. Inspect the CAC hoses for leaks. Loose or leaking fuel lines Kinked or blocked fuel lines Fuel or oil leaks Coolant leaks Restricted or open CAC hose Incorrect connections Tools Required: Inspection light 2. Check Engine Oil Level WARNING: Smoking or open flame of any type must not be present when working near fuel or fuel vapor. Failure to follow these instructions may result in personal injury. NOTICE: Only use ultra low sulfur diesel fuel that is 5% or less biodiesel with this vehicle. Use of any other fuel type may damage the vehicle or cause an emission concern. Refer to the Owner's Literature for more information. NOTE: If directed here from a pinpoint test, return to the pinpoint test after carrying out this procedure. NOTE: If the engine oil has diesel fuel contamination, the engine oil appears thin and watery, and has a diesel fuel odor. If the engine oil has coolant contamination, the engine oil appears milky white and has an ethylene glycol odor. Purpose: The purpose of this test is to verify the correct engine oil quality and level.