#03-06-04-046: Revised Engine Cranks But Does Not Run - (Sep 26, 2003) Subject: Revised Engine Cranks But Does Not Run Models: 2001-2004 Chevrolet Silverado 2003-2004 Chevrolet Kodiak 2001-2004 GMC Sierra 2003-2004 GMC TopKick with 6.6L Diesel Engine (VIN 1 - RPO LB7) This bulletin is being issued to revise the Engine Cranks But Does Not Run diagnostic in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Circuit Description The Engine Cranks but Does Not Run diagnostic table is an organized approach to identifying a condition that causes an engine not to start. The Engine Cranks but Does Not Run diagnostic table directs the service technician to the appropriate system diagnosis. The Engine Cranks But Does Not Run diagnostic table assumes the following: The batteries are completely charged. Refer to Battery Inspection/Test in Engine Electrical. The cranking speed is within specifications. Refer to Engine Cranks Slowly in Engine Electrical. There is adequate fuel in the fuel tanks. Aids If the cause of an engine cranks but will not run condition has not been found, inspect for the following conditions: Hard starting only in cold ambient temperatures. These may cause an intermittent condition that may not occur in the service bay: - Fuel heater inoperative, refer to Fuel Heater Inoperative. - Ice blockage at the fuel pickup in the fuel tank. This will lead to a high vacuum in the supply lines while cranking, and the problem will disappear after the vehicle is brought in the service bay. It may also exhibit a start and stall condition or a starting condition with no acceleration. The correct cranking speed is 100 RPM cold and 180 RPM hot. A scan tool can be used to inspect cranking speed by pulling the ignition 1 relay and monitoring engine speed on the scan tool while cranking. Water or foreign material in fuel system
A basic engine problem If the crankshaft position (CKP) sensor and the camshaft position (CMP) sensor are disconnected or malfunctioning at the same time, an Engine Cranks But Does Not Run condition will exist. Test Description The numbers below refer to the step numbers on the diagnostic table. 4. This step tests for an ignition 1 voltage supply to the engine control module (ECM). 6. This step tests the 12-volt reference circuit to the CKP sensor and the CMP sensor. The 12-volt reference circuit for the CKP sensor and the CMP sensor is connected internally within the ECM. If the 12-volt reference circuit is shorted to ground, the engine will not start and no engine speed will be indicated on the scan tool. 8. If there is fuel in the engine oil, fuel may be leaking from the fuel injector or fuel injection pump into the crankcase. 9. If the fuel system will not even briefly prime to 10 psi and will not start, the check valve in the fuel filter/heater element housing is stuck open. 10. This step determines if the fuel system is bleeding down causing a no start. The fuel pressure will slowly drop to 0 psi, but should still be above 8 psi 10 seconds after pressurizing the fuel system. 12. This step determines if the problem is a stuck open or broken fuel injector. If fuel vapors come out of any of the glow plug holes, excessive fuel is being sent into a cylinder, and not being distributed to all of the fuel injectors. 13. The engine will not run without an actual fuel rail pressure more than 10 MPa (1,450 psi). 15. If the no-start condition takes place in cold operating temperatures, 2-4 C (35-40 F) or colder, a glow plug system failure may cause the no-start condition. 17. In some cases, no compression, possibly with excessive fuel, in a single cylinder can cause a no start. Step Action Values Yes No 1 2 Did you perform the System Check-Engine Controls? 1. Turn On the ignition, with the engine OFF. 2. Observe the DTC Information with a scan tool. Does the scan tool display DTC P0088, P0089, P0090, P0335, P0336, P0340, P0370, P0374, P0380, P0601, P0602, P0603, P0604, P0611, P0612, P1621, P1626, P1631, P1683, or U1800? Step 2 System Check- Engine Controls Trouble Code (DTC) List Step 3
3 4 5 6 Is the customer's concern with a fuel smell or fuel leak? Observe the Actual Fuel Rail Pressure parameter with a scan tool. Is the pressure within the specified range? Observe the Ignition 1 signal parameter with a scan tool. Is the Ignition 1 signal parameter at the specified value? 1. Attempt to start the engine. 2. Observe the Engine Speed parameter with a scan tool while the engine is cranking. 1.1-1.4 MPa Step 5 B+ 0 RPM Fuel Leaks Step 4 Step 6 Step 18 Step 24 Is the Engine Speed parameter more than the specified value? Step 7 Step 19 7 Important: If there is high resistance in the signal or low reference circuits of the crankshaft position (CKP) sensor the Engine Speed parameter of the scan tool will display a value more than 0. It will not be an accurate measure of engine speed, and can cause an Engine Cranks but does Not Run condition. Test the CKP sensor signal and low reference circuits for high resistance. Refer to Circuit Testing in Wiring Systems. Step 8 Inspect for the following conditions: Excessive fuel in the engine oil Refer to Fuel In Engine Oil in Engine Mechanical. 8 Contaminated fuelrefer to Contaminants-in-Fuel Diagnosis. Fuel specific gravityrefer to Fuel Specific Gravity Testing. Step 9 9 1. Install the J 44638Vacuum Gage to the fuel system service port on the right front side of the engine. 2. Attempt to hand prime the fuel manager 30 times or until the specified pressure is reached. 8 psi Can you prime the system to the specified value? Step 10 Step 31 10 Does the pressure measure more than the specified value for more than 2 minutes? 2 psi Step 11 Step 14
11 12 13 14 15 Perform the Engine Compression Test. Refer to Engine Compression Test in Engine Mechanical-6.6L. Repair the engine as necessary. Did any of the cylinders emit any fuel vapor during the Engine Compression Test? 1. Crank the engine for 15 seconds. 2. Observe the Actual Fuel Rail Pressure parameter with a scan tool. Is the Actual Fuel Rail Pressure parameter more than the specified value? 1. Reprime the fuel manager to 10 psi. 2. Attempt to start the engine while the prime is still above 8 psi. Does the engine start? Observe the Glow Plug System Type parameter with a scan tool. Is the Glow Plug System Type Federal? Important: Repeat this procedure on both banks of the engine. This test may be repeated as many times as necessary. Step 28 10 MPa (1,450 psi) Step 15 Fuel System Diagnosis Step 16 Step 12 Step 13 Step 14 Fuel System Diagnosis- High Pressure Side Step 17 16 1. Turn OFF the ignition. 2. Connect a test lamp to a glow plug harness connector on one side of the engine. 3. Turn ON the ignition, with the engine OFF. Does the test lamp turn ON and OFF? Step 17 Glow Plug System Diagnosis Inspect for the following conditions: A plugged air filter A collapsed air intake duct 17 The fuel heater is inoperative. If the customer concern is that the engine will not start when ambient temperatures are less than 2-4 C (35-40 F), refer to Fuel Heater Inoperative. A restricted exhaust system Refer to Symptoms-Engine Exhaust in Engine Exhaust. Aids 1. Disconnect the fuel rail pressure sensor.
2. Observe the Actual Fuel Rail Pressure parameter on the scan tool. 18 Does the Actual Fuel Rail Pressure parameter measure more than the specified value? 175 MPa Step 23 Step 22 19 1. Turn OFF the ignition. 2. Disconnect the CKP sensor. 3. Turn ON the ignition, with the engine OFF. 4. Probe the 12-volt reference circuit of the CKP sensor with a DMM connected to a good ground. 10 V Is the voltage more than the specified value? Step 29 Step 20 20 1. Turn OFF the ignition. 2. Disconnect the camshaft position (CMP) sensor. 3. Turn ON the ignition, with the engine OFF. 4. Probe the 12-volt reference circuit of the CMP sensor with a DMM connected to a good ground. 10 V Is the voltage more than the specified value? Step 30 Step 21 21 Test the 12-volt reference circuit of the CKP sensor and the CMP sensor for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Step 33 22 Test the fuel rail pressure sensor signal circuit for a short to ground. Refer to Circuit Testing in Wiring Systems. Step 33 23 Test the fuel rail pressure sensor circuits for high resistance. Refer to Circuit Testing in Wiring Systems. Step 25 24 1. Test the Ignition 1 voltage circuit of the engine control module (ECM) for a short to ground, a high resistance or an open. Refer to Circuit Testing and to Wiring Repairsin Wiring Systems. 2. Replace the fuse if necessary. Step 26 Test for an intermittent or for a poor connection at the fuel rail pressure sensor. Refer to Testing for Intermittent and Poor
25 26 27 28 29 30 31 32 33 34 Connections and to Connector Repairs in Wiring Systems. 1. Clean and tighten the ECM shared ground. Refer topower and Grounding Component Views in Wiring Systems. 2. Attempt to start the engine. Does the engine start? Test for an intermittent and for a poor connection at the ECM. Refer to Testing for Intermittent and Poor Connections and to Connector Repairs in Wiring Systems. Important: When the fuel injector pressure lines are removed, debris will fall on the fuel injector inlet fitting. Vacuum the debris from the area to prevent the debris from falling in the fuel injector. Replace the fuel injectors on the affected cylinders. Refer to Fuel Injector Replace the CKP sensor. Refer to Crankshaft Position (CKP) Sensor Replace the CMP sensor. Refer to Camshaft Position (CMP) Sensor Replace the fuel filter/heater element housing. Refer to Fuel Filter/Heater Element Housing Replace the fuel rail pressure sensor. Refer to Fuel Rail Pressure (FRP) Sensor Replace the ECM. Refer to Engine Control Module (ECM) 1. Clear any DTCs with a scan tool. 2. Attempt to start the engine. Step 32 Step 27 Step 33
Does the engine start and continue to run? Step 35 Step 2 35 1. Allow the engine to idle until normal operating temperature is reached. 2. Observe the DTC Information with a scan tool. Are any DTCs displayed? Trouble Code (DTC) List System OK GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.