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Table of Contents
EGES-305-2
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Follow all warnings, cautions, and notes.
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68 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
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3 DIAGNOSTIC SOFTWARE OPERATION 69
EGES-305-2
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Follow all warnings, cautions, and notes.
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70 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
3 DIAGNOSTIC SOFTWARE OPERATION 71
EGES-305-2
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Follow all warnings, cautions, and notes.
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72 3 DIAGNOSTIC SOFTWARE OPERATION
3. Press and release the top of CRUISE RPM and 3. Count the flashes of the amber lamp in sequence.
RESUME+ switches simultaneously, within 3 After each digit of the code a short pause will
seconds of turning the ignition switch on. occur.
• Example: Two amber flashes, a pause, three
NOTE: The top of CRUISE RPM switch is not
amber flashes, a pause, and two amber
labeled. Pressing the top of CRUISE RPM will
flashes and a pause indicate code 232.
latch the switch and illuminate a small red light at
the top, indicating that cruise is on. 4. For more than one DTC, the red lamp will flash
once indicating the beginning of another active
4. Codes will flash on red warning lamp and amber
DTC.
caution lamp in the instrument panel.
5. After all active DTCs have flashed, the red lamp
will flash twice to indicate the start of inactive
Accessing DTCs (Stripped Chassis) DTCs. Count the flashes from the amber lamp.
If there is more than one inactive code, the red
lamp will flash once between each DTC.
6. After all DTCs have been sent, the red lamp
will flash three times indicating end of DTC
transmission.
To repeat DTC transmission (for CF), press bottom
CRUISE RPM switch to unlatch. Cycle the ignition
switch and press and release the top of CRUISE
RPM and RESUME+ switches simultaneously, within
3 seconds of turning the ignition switch on. The ECM
Figure 62 Cruise switches (Stripped Chassis) will re-send stored DTCs.
4. Codes will flash on red and amber lamps in the 2. Turn ignition switch to ON. (Do not crank the
instrument panel. engine.)
3. Press and hold the top of CRUISE RPM and
RESUME+ switches simultaneously.
Reading DTCs
1. The red lamp will flash once to indicate the NOTE: The top of CRUISE RPM switch is not
beginning of active DTCs. labeled. Pressing the top of CRUISE RPM will
latch the switch and illuminate a small red light at
2. The amber lamp will flash repeatedly, signaling the top, indicating that cruise is on.
active DTCs.
4. Press and release the accelerator pedal three
NOTE: All DTCs are three digits. For DTCs, see times within six seconds of ignition switch on.
Appendix B in this manual or form CGE310-1. 5. Release the RESUME+ switch and press the
Code 111 indicates that no faults were detected. bottom of CRUISE RPM switch to unlatch. The
inactive DTCs will clear.
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 73
NOTE: Completing this procedure within three During the KOEO Standard test, the ECM does
seconds of ignition switch on without turning the an internal test of its processing components and
ignition switch off, will start “Reading DTCs”. memory followed by an Output Circuit Check (OCC).
The OCC evaluates the electrical condition of the
circuits, not the mechanical or hydraulic performance
Clearing DTCs (Stripped Chassis) of the systems. By operating the ECM output circuits
and measuring each response, the Standard test
NOTE: Read and be familiar with all steps and time detects shorts or opens in the harnesses, actuators,
limits in this procedure before starting. and ECM. If a circuit fails the test, a fault is logged
and a DTC is set.
1. Set parking brake.
2. Turn ignition switch to ON. (Do not crank the ECM checks circuits for the following:
engine.)
Injection Pressure Regulator (IPR)
3. Move slide switch from OFF to R/A and hold.
Inlet air heater relay
4. Press and release accelerator pedal three times
Glow plug relay
within 6 seconds.
Horizontal Fuel Conditioning Module (HFCM) fuel
5. Move slide switch from R/A to OFF and codes will pump relay
then clear.
Engine Fan (EFAN) (optional)
Air Conditioning Clutch Control (ACC)
Diagnostic Tests When the OCC is done, the DTC window will display
DTCs, if there are problems.
EGES-305-2
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74 3 DIAGNOSTIC SOFTWARE OPERATION
3. Select Diagnostics from the menu bar. WARNING: To prevent personal injury, use
4. Select Key-On Engine-Off tests from the drop care to prevent contact with the door edge when
down menu. the cab is up and the door is open.
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 75
NOTE: The top of CRUISE RPM switch is not During the Injector test, the ECM requests the IDM
labeled. Pressing the top of CRUISE RPM will actuate the injectors in numerical order (1 through 6),
latch the switch and illuminate a small red light at not in firing order. The IDM monitors the electrical
the top, indicating that cruise is on. circuit for each injector, evaluates the performance
of the injector coils, and checks the operation of the
NOTE: There could be as much as a 60 second electrical circuit. If an electronic component in the
delay from the time switches are pressed to the injector drive circuit fails the expected parameters, the
time DTCs are flashed. IDM sends a fault to the ECM. The ECM logs the fault,
a DTC is set and sent to the EST.
4. Press the bottom of CRUISE RPM switch to
unlatch.
NOTE: The technician can monitor injector operation
by listening to the sound of each injector when
activated by the IDM. During Hard Start and No Start
Standard Test Using Cruise Switches (Stripped
conditions, when oil is very cold and thick, injectors
Chassis)
may be hard to hear.
The DTC window will display DTCs, if there are
problems.
Injector Test
EGES-305-2
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76 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 77
EGES-305-2
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Follow all warnings, cautions, and notes.
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78 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 79
NOTE:
• A Breakout Box or Breakout Harness and a DMM
are required to monitor the suspected circuit or
actuator.
• DTCs are not set by the ECM during this test.
The following actuators are activated when toggled
high during the test:
• Boost Control Solenoid (BCS) (electrical circuit
only) visual inspection of actuator arm movement
when pressurized with regulated air source.
When in low, air is directed to the pneumatic
actuator, air bypasses the pneumatic actuator
when toggled high.
• Horizontal Fuel Conditioning Module (HFCM) fuel
pump
EGES-305-2
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EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 81
3. Select Key-On Engine-Off tests from the drop signal values from the ICP sensor and compares
down menu. those values to the expected values. When the
Standard test is done, the ECM returns the engine to
NOTE: When using the EST to do KOEO or KOER the normal operation and transmits DTCs set during
diagnostic tests, Standard test is always selected the test.
and run first. If the ignition switch is not cycled, the
Standard test does not have to be run again. NOTE: Before doing this test, confirm the following
conditions:
4. From the KOEO Diagnostics menu, select Glow
Plug/Inlet Air Heater and select Run to start the • Problems causing active DTCs were corrected,
test. and active DTCs were cleared.
• Engine coolant temperature must be at least
NOTE: This test can only be run twice for each ignition
70 °C (158 °F).
switch cycle
• Battery voltage must be higher than 10.5 volts.
• Transmission in park or neutral
EGES-305-2
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82 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 83
WARNING: To avoid personal injury, use 5. Wiggle connectors and wires at all suspected
care to prevent contact with the door edge when problem locations. If circuit continuity is
the cab is up and the door is open. interrupted, the EST will display DTCs related to
the condition.
6. Correct problem causing active DTCs.
EGES-305-2
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7. Clear DTCs. 8. When finished with this test, select Session from
menu bar, then Close.
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 85
EGES-305-2
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86 3 DIAGNOSTIC SOFTWARE OPERATION
Figure 88 Air Management diagnostic readout for engine rpm, EGR position, and MAF
The ECM commands the EGR valve to close and decrease. If the MAF is not below the expected flow,
increases the engine idle speed to 900 rpm. The ECM DTC 346 is set and the test is cancelled.
allows the Manifold Air Flow (MAF) to stabilize. The
The ECM commands the EGR valve to close, and
ECM monitors and compares the MAF to the expected
allows MAF to stabilize. The ECM monitors MAF and
values; flow is expected to increase. If the MAF does
compares it to the expected flow; flow is expected to
not exceed the expected flow or there is a MAF sensor
increase. If the MAF does not exceed the expected
fault, the test is cancelled and “Engine Not In Testing
flow, DTC 346 is set and the test is cancelled.
Range” is displayed.
The ECM returns engine speed to low idle. If all flow
The ECM commands the EGR valve to open, and
comparisons meet requirements, no DTC is set and
allows MAF to stabilize. The ECM monitors MAF and
the engine is returned to normal operation.
compares it to the expected flow; flow is expected to
EGES-305-2
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Follow all warnings, cautions, and notes.
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3 DIAGNOSTIC SOFTWARE OPERATION 87
EGES-305-2
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88 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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Follow all warnings, cautions, and notes.
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3 DIAGNOSTIC SOFTWARE OPERATION 89
EGES-305-2
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Follow all warnings, cautions, and notes.
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90 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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Follow all warnings, cautions, and notes.
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3 DIAGNOSTIC SOFTWARE OPERATION 91
EGES-305-2
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92 3 DIAGNOSTIC SOFTWARE OPERATION
Figure 98 Example
NOTE: Batteries must be fully charged before doing • Turn ignition switch to ON.
this test. Use battery charger during this test, if • Select Run.
multiple tests are needed; battery drain can be
extensive.
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 93
EGES-305-2
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94 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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3 DIAGNOSTIC SOFTWARE OPERATION 95
EGES-305-2
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96 3 DIAGNOSTIC SOFTWARE OPERATION
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 97
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
EGES-305-2
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98 4 ENGINE SYMPTOMS DIAGNOSTICS
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 99
Causes
Injector sleeve failure
Figure 107 Cutaway of Cylinder Head Showing
Glow plug sleeve failure Glow Plug Sleeve
Head gasket failure
Porous cylinder wall 7. Verify that cooling system is still pressurized at
96 kPa (14 psi).
Combustion leaks can be identified by combustion
gas observed in engine coolant deaeration tank. The 8. Bar engine over by hand and check for coolant
most probable cause of combustion gas leakage to flooding the top of piston and flowing out glow plug
the cooling system is past injector or glow plug sleeves sleeve bore.
in the cylinder head. A failed head gasket or porous
• If leak is slight, pressure may have to be left
cylinder wall is possible, but should not be suspected
on overnight and inspect cooling system for
unless there is evidence of engine overheating or high
leakage in morning. Leave cylinder block
engine mileage without proper coolant.
heater, if available, plugged in.
• If leak is found, go to step 8.
• If no leakage is found, go to “Combustion
Leakage Test using High Pressure (page
100)” in this section.
EGES-305-2
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100 4 ENGINE SYMPTOMS DIAGNOSTICS
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 101
EGES-305-2
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EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 103
EGES-305-2
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104 4 ENGINE SYMPTOMS DIAGNOSTICS
Causes
Glow plug sleeve leak
Injector sleeve leak
Cylinder head cup plug failure
Cylinder head gasket leak
Oil filter base assembly and oil cooler bundle failure
Front cover gasket damage
Figure 113 Cylinder Head Cup Plug Locations
Front cover, cylinder head, or crankcase porosity
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 105
10. Remove oil cooler and oil filter housing from the
engine following the procedures in the Engine
Service Manual.
EGES-305-2
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EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 107
2. Remove turbocharger to exhaust muffler tubing • If no leak is found, continue with step 8.
and the exhaust tube to EGR cooler following the
8. Remove EGR valve and install Intake Manifold
procedures in the Engine Service Manual.
Pressure Test Plug (EGR Valve) (ZTSE4544) and
3. Check for presence of coolant in tubing, exhaust EGR Cooler Test Plate (ZTSE4545) on the EGR
manifolds and EGR cooler exhaust inlet. cooler following the procedures in the Engine
Service Manual.
4. Plug in the cylinder block heater, if available, to
warm coolant. 9. Remove radiator pressure tester from coolant
deaeration tank and fill tank with coolant to a
point above the deaeration inlet line to tank.
Leave radiator cap off.
WARNING: To prevent personal injury or
death from hot coolant or steam scalding, use the
following procedure to remove the pressure cap
from the cooling system. Allow the engine to cool.
Wrap a thick cloth around the cap. Unscrew cap
slowly, then pause to allow pressure to release.
7. Check EGR cooler exhaust inlet for the presence Figure 120 Intake Manifold Pressure Test Plug
of coolant. (EGR Valve) installed
• If coolant is present, replace EGR cooler
following the procedures in the Engine
10. Apply regulated air pressure of
Service Manual.
172 to 414 kPa (25 to 60 psi) at the
• If no leak is found but pressure is dropping EGR Cooler Pressure Test Plate.
rapidly, inspect the exhaust manifolds for
coolant. Repair as necessary following the
procedures in the Engine Service Manual.
EGES-305-2
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108 4 ENGINE SYMPTOMS DIAGNOSTICS
11. Observe coolant deaeration tank for air bubbles. • If air bubbles are observed and EGR cooler
Air pressure must be left on EGR cooler for a passes additional testing, remove and
minimum of 5 minutes. pressure test the intake manifold following
the procedures in the Engine Service Manual.
• If air bubbles are observed in the tank,
remove EGR cooler and retest following the • If no air bubbles are observed or EGR
procedures in the Engine Service Manual to cooler and intake manifold have passed
verify EGR cooler is inoperative. Replace if testing, contact Technical Services for further
necessary. assistance.
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 109
EGES-305-2
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110 4 ENGINE SYMPTOMS DIAGNOSTICS
pressure rises above normal value of deaeration • If thermostat passes test, continue with step
tank cap. 9.
• If pressure is higher than the pressure rating 9. Use vehicle diagnostics manual to review
of the cooling system cap, continue with automatic transmission diagnostics.
“Combustion Leak to Coolant (page 99)” in
10. If over-temperature condition remains, remove
this section.
radiator and have flow checked at radiator shop.
• If pressure gauge reading is below pressure
• Retest engine for over-temperature condition
rating of system, continue with step 8.
with repaired or replaced radiator.
8. Remove and inspect thermostat following the
procedure in the Engine Service Manual. Check
for opening temperature.
• Replace as needed. Retest for condition after
repair.
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 111
Miles driven are not logged if ECM reset occurs • If any chassis DTCs are active when checking
during current key cycle the Electronic System Controller (ESC),
perform appropriate diagnostics and repairs
before continuing.
Causes
2. Do “Test 5. Fuel Supply System Test (page 224)”
An Electronic Control Illuminate the WAIT TO in the “Performance Diagnostics (page 211)”
Module (ECM) reset START lamp section of this manual.
occurs when the ECM
Enable glow plugs See the “Electronic Control Systems Diagnostics
momentarily reboots
or is turned OFF and Enable Inlet Air Heater (page 279)” section of this manual or the applicable
ON while the engine is (IAH) truck Circuit Diagram Manual and Service Manual
operating. when performing the following steps.
Validate the accelerator
If a reset occurs, the pedal position 3. Check all ECM and IDM related fuses.
engine will momentarily 4. Check all Battery, VIGN and ground connections
stumble and the ECM for the ECM and IDM.
will go through a normal
KEY ON cycle. This 5. Monitor ECM powers and grounds with breakout
includes: box under operator complaint conditions.
If the pedal is not at idle Poor fuse connection 6. Monitor IDM powers and grounds with 12-Pin
position when the reset Breakout Harness under operator complaint
Intermittent open at conditions.
occurs, a DTC is set
connectors
and engine speed goes 7. If root cause has not been identified in previous
to low idle. The ECM Poor battery power feed
steps, continue diagnosis by doing the remaining
will not allow accelerator harness connection
tests in “Performance Diagnostics (page 211)”
pedal authority until Poor ground connection section of this manual.
the Accelerator Pedal
Sensor (APS) is Poor power relay
released. connection
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112 4 ENGINE SYMPTOMS DIAGNOSTICS
Low rear axle ratio 2. Loss of fuel economy is normal if winter blend fuel,
kerosene or No. 1 diesel fuel is being used.
Large frontal area
3. Review vehicle specifications to determine if fuel
Accessory usage consumption is normal for type of application
(Power Takeoff, etc.) and use of vehicle. Compare consumption with
Additional equipment similar vehicles in the same application and
drawing fuel from TCAPE report.
vehicle fuel tanks
4. Do all tests on Performance Diagnostic form or in
Extended idle “Performance Diagnostics(page 211)” section of
applications this manual.
Tire size, tire condition,
These tests will verify the operating condition of
or air pressure
the following engine and chassis systems:
Chassis effects Brake drag
Intake system
Cooling fan clutch
locked ON Exhaust system
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4 ENGINE SYMPTOMS DIAGNOSTICS 113
Fuel in Coolant
Causes
• Leaking or cracked injector sleeve with injector
O-ring failure
• Cracked or porous head casting in fuel rail area
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114 4 ENGINE SYMPTOMS DIAGNOSTICS
4. Plug in the cylinder block heater, if available, to Fuel in Coolant Leakage Test using Low Pressure
warm coolant.
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 115
Fuel In Lube Oil NOTE: When removing the cylinder head connections
from the secondary fuel filter, fuel will leak out. Put in a
Causes
suitable container to collect this leakage. Collect and
• Leaking fuel injector or injector O-ring. A dispose of this fuel according to local regulations.
leaking injector sleeve or injector tip could cause
2. Remove the left and right cylinder head
contaminated engine oil, but would most likely be
connections from the secondary fuel filter
identified as a performance problem.
following the procedures in the Engine Service
• Porous cylinder head (most likely on low mileage Manual. Drain the secondary fuel filter in to the
vehicles) container.
3. Individually pressurize both fuel supply lines to
cylinder heads to 550 to 690 kPa (80 to 100 psi)
Verifying Oil Dilution from Fuel System
using the Fuel Line Test Adapter (ZTSE4607).
1. Verify oil contamination. Oil contaminated with
4. Once a loss of pressure or leak is determined,
diesel fuel will have diesel fuel odor and will cause
remove valve cover at suspected head and
the oil level in engine to rise.
inspect for leak at injector areas.
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116 4 ENGINE SYMPTOMS DIAGNOSTICS
Tools
NOTE: Engine fluids, oil, fuel, and coolant, are a threat
• Clean drain pan, flat with a wide opening
to the environment. Recycle or dispose of engine
fluids according to local regulations. Never put engine
fluids in the trash, on the ground, in sewers, or other
Drain Water from HFCM
bodies of water.
1. Determine if the WIF lamp is on. If the lamp is on,
2. Put a clean flat drain pan under the HFCM drain
the fuel is probably contaminated with water.
plug
3. Wipe down the frame around and under the drain
plug or the HFCM and drain plug.
WARNING: To prevent personal injury or
death, comply with the following:
• Read all safety instructions in the “Safety
Information” section of this manual.
• Dispose of fuel according to local regulations
in a correct container clearly marked DIESEL
FUEL.
• DO NOT smoke.
• Keep away from open flames and sparks.
EGES-305-2
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4 ENGINE SYMPTOMS DIAGNOSTICS 117
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118 4 ENGINE SYMPTOMS DIAGNOSTICS
Excessive water or contaminants may indicate If the WIF lamp is off, the procedure is
that the tank and fuel system need to be complete, do not continue.
flushed and cleaned.
If the WIF lamp is still on, continue with step 9.
Some sediment and water may be present
if the fuel filter has not been replaced for a
NOTE: If the WIF indicator stays on after the water
prolonged period of time, or if the sediment
has been drained, the WIF sensor, the WIF sensor
and water have not been drained recently.
connector, or the cover plate assembly may be
The fuel should be clear, not cloudy. Cloudy corroded, the condition should be corrected and
fuel indicates that the fuel is not a suitable retested.
grade for cold temperatures.
9. Check the WIF sensor connector, do “WIF (Water
The fuel should not be dyed red or blue, these In Fuel) Sensor (page 526)” in “Electronic Control
colors indicate off-highway fuel. Systems Diagnostics (page 279)” section of this
The fuel should not indicate evidence of manual.
waxing or gelling. Waxing or gelling in some 10. Remove the HFCM to service the WIF sensor or
fuels in cold weather could clog fuel filters and check for corrosion on the cover plate assembly.
the fuel pump and cause restrictions in the fuel
or low fuel pressure. 11. Install the HFCM, and redo steps 4, 5, and 6. Turn
the ignition switch to ON to start the HFCM fuel
7. Turn the ignition switch to ON, determine if the pump, determine if the WIF lamp is off.
WIF lamp is off.
If the WIF lamp is off, the procedure is
If the WIF lamp is off, the procedure is complete, do not continue.
complete, do not continue. If the WIF lamp is still on, replace the HFCM.
If the WIF lamp is still on, continue with step 8.
EGES-305-2
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© 2006 International Truck and Engine Corporation
4 ENGINE SYMPTOMS DIAGNOSTICS 119
Causes
Low oil level: oil leak, oil consumption or incorrect WARNING: To prevent personal injury or
servicing death, comply with the following;
High oil level: incorrect servicing, fuel in oil or
• When routing test line do not crimp line, run
coolant in oil
line too close to moving parts, or let line touch
Incorrect oil viscosity hot engine surfaces.
Fuel in oil • Before running engine for diagnostic or
Stuck oil pressure regulator service procedures, set parking brake, shift
transmission to park or neutral, and block
Scored or damaged oil pump wheels.
Engine Oil Pressure (EOP) switch biased
Missing oil gallery cup plugs (front or rear)
Broken, missing or loose piston cooling tube(s)
WARNING: To prevent personal injury or
Missing, damaged or worn bearing inserts or death, do not allow engine fluids to stay on your
camshaft bushings skin. Clean skin and nails with soap and water, or
Lifter missing (will also have performance a good hand cleaner. Wash or properly dispose of
problems) clothing or rags containing engine fluids. Engine
fluids contain elements that may be unhealthy for
Aeration (cracked pickup tube, missing O-ring) skin and could cause cancer.
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120 4 ENGINE SYMPTOMS DIAGNOSTICS
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4 ENGINE SYMPTOMS DIAGNOSTICS 121
10. Reinstall the oil filter, the oil filter cap, the oil pump,
and oil pump cover.
11. Connect regulated shop air line to the ICP system
test adapter in the lube oil filter base.
12. Slowly apply air pressure in 34.5 kPa (5 psi)
increments to 345 kPa (50 psi).
13. Inspect for gross leaks internally.
• If a major leak is observed from the front cover
area, continue with step 14.
• If a major leak is observed from the rear cover
area, continue with step 16.
• If a major leak is not observed, remove
Figure 130 Inspect the lube oil pump engine from vehicle. Disassemble engine
and perform full inspection of all components
1. Gerotor oil pump cover
following procedures in the Engine Service
2. O-ring
Manual.
3. Dowel pin (2)
4. Gerotor assembly 14. Remove the front cover from the engine following
procedures in the Engine Service Manual and
complete inspection of the lube oil pump.
7. Remove and inspect the lube oil pump following
the procedure in the Engine Service Manual.
• Inspect the lube oil pump housing and cover
for gouging or deep scratches.
• Inspect the gerotor gears for excessive wear
or damage.
• If no excessive damage is found continue with
step 8.
8. Drain oil from engine using a clean drain pan.
Inspect oil drain plug magnet, drained oil and oil
filter for foreign debris.
• An oil sample should be taken to determine
level of engine wear metals and contaminants
in the oil.
Figure 131 Main oil gallery cup plug locations
9. Remove both the upper and lower oil pans
following the procedure in the Engine Service
Manual. Inspect for missing, loose or damaged 15. With front cover removed from the engine, verify
oil pickup tube, O-ring, piston cooling tubes, that the front main oil gallery cup plugs are in
bearing inserts, and cam bushings. position and not damaged.
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122 4 ENGINE SYMPTOMS DIAGNOSTICS
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4 ENGINE SYMPTOMS DIAGNOSTICS 123
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124 4 ENGINE SYMPTOMS DIAGNOSTICS
Diagnostics Form. This test will verify the of this manual or on the Performance Diagnostics
functionality of the ICP system. The engine form.
must be at operating temperature 70 °C (158 °F)
to do this test.
10. Do “Test 9. Injector Disable (page 242)” in the WARNING: To prevent personal injury or
“Performance Diagnostics (page 211)” section of death, support the vibration damper during
this manual or on the Performance Diagnostics mounting bolt removal. The damper can slide off
Form. This test will confirm if the ICP system is the nose of the crankshaft very easily.
functioning properly and verify ICP stability.
EGES-305-2
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© 2006 International Truck and Engine Corporation
4 ENGINE SYMPTOMS DIAGNOSTICS 125
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126 4 ENGINE SYMPTOMS DIAGNOSTICS
1. If engine has fuel knock or there is evidence of Coolant leaking into combustion chamber
fuel in the exhaust, remove exhaust manifolds Intake manifold porosity
and inspect for fuel in the exhaust ports. Suspect
a loose injector, missing or damaged O-ring and
gasket on bottom of an injector. White Smoke Diagnostics
2. Inspect air inlet system and exhaust system for 1. In cold ambient temperatures, some white smoke
possible sources of restriction. is possible depending on conditions.
3. Visually inspect turbocharger for oil leakage or • Ensure that engine is up to operating
failure. Some oil carryover is expected due to the temperature 88 °C (190 °F) prior to verifying
closed crankcase ventilation system. a white smoke complaint.
4. Do “Test 1. Diagnostic Trouble Codes (page 213)” • If the engine is unable to obtain
on the Performance Diagnostics Form or in the operating temperature during a road
“Performance Diagnostics (page 211)” section of test, verify thermostat opening temperature
this manual. 88 °C (190 °F).
5. Do “Test 6. Intake and Exhaust Restriction (page 2. On a cold engine, the glow plugs and the inlet
235)” on the Performance Diagnostics Form or in air heater may remain on after the engine starts
the “Performance Diagnostics (page 211)” section to assist in cold smoke cleanup. Do “Tests 14.
of this manual. Glow Plug System (page 192)” and “Test 15. Inlet
Air Heater System (page 199)” in the “Hard Start
6. Do “Test 11. Air Management (page 250)” on and No Start Diagnostics (page 131)” section of
the Performance Diagnostics Form or in the this manual or on the Hard Start and No Start
“Performance Diagnostics (page 211)” section of Diagnostics Form to verify glow plug and inlet air
this manual. heater operation.
3. Do “Test 5. Fuel Supply System (page 224)” in
the “Performance Diagnostics (page 211)” section
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4 ENGINE SYMPTOMS DIAGNOSTICS 127
of this manual or on the Performance Diagnostics • Unfiltered air entering the engine can
Form. Verify quality and quantity of the fuel, cause excessive power cylinder wear and
aeration, and fuel pressure. turbocharger compressor damage. If power
cylinder wear is suspected, identify smoking
4. Do Output State Test Low and High to cycle the
cylinder(s) by removing exhaust manifolds
EGR valve and monitor valve movement with the
and running engine.
Output State Test Continuous Monitor Session.
• If coolant is found in the intake manifold, see
5. If there is coolant loss without engine overheating,
“Coolant Leak to Exhaust” (page 106) in this
check for coolant in exhaust.
section.
• If coolant is leaking from exhaust or can be
smelled in the exhaust, see “Coolant Leak to
Exhaust” (page 106) in this section.
WARNING: To prevent personal injury or
6. Do “Test 8. Injection Control Pressure (page 239)” death, visually inspect the turbocharger with the
in the “Performance Diagnostics (page 211)” engine off, and the turbocharger not spinning.
section of this manual or on the Performance Turbocharger components may be extremely
Diagnostics Form. hot and turbocharger wheels are very sharp
7. Do “Test 9. Injector Disable (page 242)” in the and may spin at high speeds. Visually assure
“Performance Diagnostics (page 211)” section of the turbocharger wheels are not turning before
this manual or on the Performance Diagnostics inserting fingers or other body parts.
Form.
8. Do “Test 10. Relative Compression (page 247)” in 11. Do compression test on cylinders that are white
the “Performance Diagnostics (page 211)” section smoke using the compression test adapter.
of this manual or on the Performance Diagnostics Inspect turbocharger for damage.
Form.
12. If engine is overheating with coolant loss, and
9. If engine has fuel knock or evidence of fuel in cylinder head gasket, injector sleeve, or glow plug
exhaust, remove exhaust manifolds and inspect sleeve is suspected for leaking, see “Combustion
for fuel in the exhaust ports. (Suspect loose Leaks to Coolant Test using High Pressure (page
injectors, missing or damaged O-ring and copper 100)” in this section.
gasket on bottom of injector).
10. Inspect air induction system for evidence of water
ingestion or evidence of unfiltered air entering the
engine.
• Water ingestion could have caused a
hydraulic lock and bent connecting rods. If
water ingestion is suspected, identify smoking
cylinders by removing exhaust manifolds and
running engine.
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© 2006 International Truck and Engine Corporation
128 4 ENGINE SYMPTOMS DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 129
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Diagnostic Form Information EGED-315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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130 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 131
Description
Figure 133 Diagnostic form EGED-315 (Hard Start and No Start Diagnostics side)
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132 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 133
Test Procedures
1. Initial Ignition Key ON (Do not start) WARNING: To prevent personal injury or
death, read all safety instructions in the “Safety
Information” section of this manual.
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134 5 HARD START AND NO START DIAGNOSTICS
Possible Causes
No injector pre-cycle No key power (vIGN)
Failed IDM ground circuit
No power from main power relay to IDM.
CAN2 link is not working.
IDM failure
WAIT TO START indication does not come on No key power (vIGN)
Failed ECM ground circuit
No power from main power relay to ECM
CAN1 link is not working (will not cause hard start
or no start).
ECM failure
Amber WAIT TO START indication is out (will not
cause hard start or no start).
Electronic fuel pump does not run No key power (vIGN)
Wiring failure from ECM to relay or corrosion
Wiring failure from relay to pump or corrosion
Electronic fuel pump failure (will not cause hard start
or no start)
ECM failure
Water in fuel Water in fuel
Corroded housing or connectors (will not cause hard
start or no start).
Electrical circuit failure (will not cause hard start or
no start).
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5 HARD START AND NO START DIAGNOSTICS 135
2. Engine Cranking
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136 5 HARD START AND NO START DIAGNOSTICS
Possible Causes
Crankshaft will not rotate Low or no battery power
No key power (vIGN)
Insufficient power to ECM
Starting system failure
Circuit fault for Engine Crank Inhibit (ECI)
Cylinder hydraulic lock
Insufficient rpm Low battery power
Starter motor problem
Incorrect oil viscosity
Cold temperature
Excessive exhaust smoke with hard start or no start Glow plug system failure
concern
Failed air heater system
Poor fuel quality
Excessive air inlet or exhaust restriction
Insufficient cylinder temperature
Loose injector
Low compression
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5 HARD START AND NO START DIAGNOSTICS 137
Figure 136
Purpose
• To determine if the ECM has detected Diagnostic
Trouble Codes (DTCs) indicating conditions that
could cause engine problems
• Fill out Diagnostic Form heading.
• Check for abnormal sensor readings.
Tools
• EST with MasterDiagnostics® software
• EZ-Tech® interface cable
Figure 137
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138 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 139
5. Select VIN+ icon to open VIN+ session. VIN (for Information List (cont.)
warranty, ordering parts, and service information).
Engine SN Engine Serial Engine SN (for
The Vehicle Identification Number is also on the
Number ordering parts
door jamb on the operator’s side.
and service
6. Complete the form heading using the on-screen information).
information and the Information List.
The engine serial number is stamped on a
crankcase pad on the rear of the left side
Information List
crankcase below the cylinder head. The engine
Heading VIN+ session Description serial number is also on a separate serial number
Information PID label next to the engine emission label on the left
side valve cover. Compare the Engine SN in the
Miles Odometer For warranty
Vehicle Programming window of the VIN+ session
Hours Engine Hours For warranty with the Engine SN on the engine. The engine
Transmission Transmission Automatic could have been replaced without a programming
Type change to the ECM to upgrade the Engine SN.
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140 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 141
5. Continue with KOEO Standard test. • Inactive: With ignition switch on, inactive
indicates a DTC for a condition during a previous
key cycle. When the ignition switch is turned
Reading DTCs off, inactive DTCs from a previous ignition switch
cycle, are stored in the ECM memory.
ATA code: Codes associated with a Subsystem
Identifier (SID), Parameter Identifier (PID), and • Active/Inactive: With ignition switch on,
Failure Mode Indicator (FMI) active/inactive indicates a DTC for a condition
currently in the system and was present in
DTC: Diagnostic Trouble Code
previous key cycles, if the codes were not cleared.
Status: Indicates active or inactive DTCs
Description: Defines each DTC
• Active: With ignition switch on, active indicates a
DTC for a condition currently in the system. When Possible Causes
the ignition switch is turned off, an active DTC
Electronics failure
becomes inactive. (If a problem remains, the DTC
will be active on the next ignition switch cycle and Failure of the ICP sensor or ICP system
the EST will display active/inactive.) Failure of the Air Management System (AMS)
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142 5 HARD START AND NO START DIAGNOSTICS
Figure 143
Purpose
To determine electrical malfunctions detected by the
ECM self-test and Output Circuit Check (OCC)
Tools
• EST with MasterDiagnostics® software
• EZ-Tech® interface cable
EGES-305-2
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5 HARD START AND NO START DIAGNOSTICS 143
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144 5 HARD START AND NO START DIAGNOSTICS
Figure 145
Purpose
To determine if fuel injectors are working
(electronically) by energizing injectors in a
programmed sequence
The Electronic Control Module (ECM) monitors this
test and transmits DTCs, if injectors or injector circuits
are not working correctly.
Tools
• EST with MasterDiagnostics® software
• EZ-Tech® interface cable Figure 146 KOEO Injector test
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5 HARD START AND NO START DIAGNOSTICS 145
Possible Causes
Injector wiring harness open or shorted
Failed injector wiring harness connector and the
wiring connection to the injector coil
Failed injector coil
Figure 147 Close session Failed Injector Drive Module (IDM)
Failed ECM
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146 5 HARD START AND NO START DIAGNOSTICS
6. Electronic Service Tool (EST) Data List 1. See “Appendix A: VT 275 Performance
Specifications (page 571)” for specifications,
and record on Diagnostic Form.
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5 HARD START AND NO START DIAGNOSTICS 147
• If the EST shows 0 rpm during engine • If the EST indicates low or no injection control
cranking, the ECM may not be receiving pressure, do “Test 13. Low ICP System (page
a signal from the Crankshaft Position (CKP) 177)” in this section.
sensor or Camshaft Position (CMP) sensor.
• If oil pressure is low, the ICP system may not
The ECM will not send the fueling command
be receiving enough oil.
to the IDM without a correct CKP or CMP
signal. See “CKP (Crankshaft Position) • If EGR valve is open at start-up, it can disrupt
Sensor (page 329)” and “CMP sensor (page the air fuel mixture enough to inhibit engine
333)” in the “Electronic Control Systems operation.
Diagnostics (page 279)” section of this
manual.
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148 5 HARD START AND NO START DIAGNOSTICS
Possible Causes
Low battery voltage Failed batteries
High-resistance at battery cable connections or in
wiring to the ECM
Failed ECM power relay
Blown in-line fuse (in battery box) that supplies
voltage to the ECM
Blown fuse in power distribution box
Low cranking rpm Electrical system malfunctions, incorrect oil, or long
oil change intervals in cold ambient temperatures
No rpm indication on the EST while cranking the
engine: Failed CKP sensor, CMP sensor, or circuit
to the ECM. Check DTCs after cranking engine for
20 seconds.
Low Injection Control Pressure A leak in the high-pressure oil system, a Failed ICP
sensor, or inoperative IPR valve
Aerated Oil
Low oil level in the high-pressure oil reservoir
No or low lube oil pressure
Failed high-pressure oil pump or pump drive
Failed IPR valve or electronic controls for the
regulator
Low oil pressure Low oil level: oil leak, oil consumption or incorrect
servicing
High oil level: incorrect servicing, fuel in oil or coolant
in oil
Stuck oil pressure regulator
Failed oil pressure regulator valve
Failed gerotor oil pump
Failed pick-up tube or gasket
Internal lube oil pressure leak
EGR valve Stuck or failed valve
Failed position sensor
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5 HARD START AND NO START DIAGNOSTICS 149
Monitoring Engine Systems using Breakout Box 1. Remove (X-1, X-2) and (X-3, X-4) connectors
from ECM.
Tools
2. Install breakout box connectors (X-1, X-2) and
• Breakout Box
(X-3, X-4) to ECM.
• Digital Multimeter (DMM)
3. Install wiring harness connectors to breakout box
headers (X-1, X-2) and (X-3, X-4).
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150 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 151
Monitoring ICP using Pressure Sensor Breakout 1. Remove engine harness connector from ICP
Harness sensor.
Tools 2. Connect Pressure Sensor Breakout Harness to
engine harness and ICP sensor.
• Pressure Sensor Breakout Harness
• DMM
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152 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 153
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154 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 155
Possible Causes
Low oil level Oil leak
Oil consumption
Incorrect servicing
High oil level Incorrect servicing
Fuel in oil
Coolant in oil
Incorrect oil level gauge
Coolant in oil Cylinder head gasket leak
Cylinder head cup plug leak
Injector sleeve leak
Glow plug sleeve leak
Front cover gasket leak
Failed oil cooler or seals
Front cover, cylinder head, or crankcase porosity
Fuel in oil Injector seal leak
Cylinder head porosity
Inoperative injector
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156 5 HARD START AND NO START DIAGNOSTICS
Figure 156
Purpose
To determine if intake or exhaust restriction is causing
hard start or no start conditions
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 157
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158 5 HARD START AND NO START DIAGNOSTICS
10. Fuel Supply System NOTE: Breaking any fuel system joints will induce air
in the fuel system.
Tools
• 0-160 psi gauge (on Gauge Bar Tool)
• ICP System Test Adapter
• In-line shut off valve
• 3/8 inch clear sample line
• Clear container with a wide opening
(approximately 1 liter or 1 quart US)
Purpose NOTE: Engine fluids, oil, fuel, and coolant, are a threat
to the environment. Recycle or dispose of engine
• To check the fuel supply system for efficient fluids according to local regulations. Never put engine
engine operation fluids in the trash, on the ground, in sewers, or other
• To check for fuel aeration bodies of water.
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5 HARD START AND NO START DIAGNOSTICS 159
10.1. Pressure, Quality, and Aerated Fuel 5. Remove air inlet duct on the engine to aid in plug
removal and system testing.
1. See “Appendix A: VT 275 Performance
Specifications (page 571)” for fuel pump pressure
specification and record on Diagnostic Form.
CAUTION: To prevent damage to the engine, take
2. Verify there is fuel in the fuel tank(s). Check fuel precautions to prevent foreign materials from entering
in fuel tank(s) for odors other than diesel fuel, for the air intake system when the air inlet duct is
example: kerosene, alcohol, or gasoline. removed.
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160 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 161
7. Install the ICP System Test Adapter and assemble Sample should be clear, free of debris, water
and attach Fuel Pressure Gauge. and other contaminates. Sample should not be
cloudy or dyed (blue or red).
• The Fuel Pressure Gauge (Figure 248) is
available through the tool supplier. It is If air bubbles stop with sample flowing, the fuel
recommend this tool be used for pressure is not aerated and if there is no contamination,
and sampling. continue with step 15.
• If the Fuel Pressure Gauge can not be If the air bubbles do not clear before the
obtained. Test setup can be made using tools sample container is almost full, a second
from the dealer supplied Essential Tool Kits sample needs to be taken to determine if air
(Figure 250). bubbles have cleared, continue with step 13.
8. Run the clear test line to clear container If fuel is contaminated with water, debris or
other contaminates, take a second sample.
9. Turn ignition switch to ON (do not crank the Some sediment and water may be present in
engine). 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, continue with step 13.
WARNING: To prevent personal injury or
death: If the fuel sample is cloudy in colder
temperatures, this indicates waxing or gelling.
• Dispose of fuel according to local regulations
Summer fuels are not suitable in colder
in the correct container clearly marked
temperatures. Change to the recommended
DIESEL FUEL.
fuel grade. See “Fuel Requirements” in the
• DO NOT smoke. Engine Operation and Maintenance Manual
(for engine’s model number and model year).
• Keep away from open flames and sparks.
If the fuel sample is dyed, either blue or red,
this indicates off-road use fuel and could
10. Open the in-line shut off valve, drain sample in the cause a performance problem. Change
clear container. As filling, observe the clear test to a recommended fuel grade. See “Fuel
line for indication of air bubbles. Requirements” in the Engine Operation and
Maintenance Manual (for engine’s model
NOTE: Breaking any fuel system joints will induce air number and model year).
in the fuel system, it should clear shortly.
11. Close in-line shut off valve. 13. If a second sample is needed, cycle the ignition
switch to restart the fuel pump, drain sample and
12. Check for contamination and record results on check for air bubbles and contamination in the
Diagnostics Form. fuel.
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162 5 HARD START AND NO START DIAGNOSTICS
14. Record the results on the Diagnostic Form. NOTE: Any residue or microbial growth in the
tank(s) will compound with the use of biodiesel.
If air bubbles did not clear, check the fuel This can cause serious plugging of filters and
supply system from the fuel tank(s) to the deposits in the fuel system. Fuel tanks should be
HFCM inlet for leaks. Correct the condition thoroughly cleaned and dried before operating
and retest. The check should include wiggling with any biodiesel blends. Adding biocides will
all fuel line connections, checking the primary help minimize growth.
fuel filter cover and the HFCM drain plug for
15. Cycle ignition switch to OFF and back to ON.
leaks with the fuel pump turned off. With the
fuel pump off, the primary fuel filter cover and 16. Check fuel pressure on the fuel pressure gauge
the drain plug may show a slow drip of fuel when the pump starts. Pressure should increase
indicating cover or plug is loose or seals are to specification quickly.
worn, cracked, or broken.
17. Turn ignition switch to OFF.
Excessive water or contaminants may indicate
18. Record the results on the Diagnostic Form.
that the tank and fuel system may need to be
flushed and cleaned. Take a sample from the • If fuel pressure is within specification, do “Test
HFCM drain plug for verification. See “Drain 11. Main Power Relay Voltage to ECM (page
Water from HFCM (page 116)” in the “Engine 169)” in this section.
Symptoms Diagnostics (page 99)” section of
• If fuel pressure is below specification, replace
this manual.
both the primary and secondary fuel filters
If fuel doesn’t clear up, the system may have and retest.
to be flushed to correct the condition. Replace
the primary and secondary fuel filters and verify • If fuel pressure is still below specification,
fuel is the recommended grade and clean. after replacing both primary and secondary
fuel filters, measure fuel pump discharge
pressure. Do “Test 10.2. Fuel Pump
Discharge Pressure (page 165)” in this
section.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 163
Possible Causes
Contaminated Fuel Water or contaminants in fuel tank
Ice in fuel lines
Debris in fuel tank(s)
Fuel colored, cloudy, or colored
Fuel is waxy or gelled
Off road fuel red colored or blue colored
Aeration Low or no fuel level in fuel tank(s).
Failed seals for fuel lines between fuel tank(s) and
the HFCM, fuel supply line broken or crimped.
A cracked or restricted pickup tube screen or pickup
tube.
HFCM fuel filter cap seal damaged, HFCM drain plug
loose, or HFCM drain plug O-ring broken or missing
A loose fuel line or fuel line connector on the suction
side of the fuel pump
No Fuel Low or no fuel level in fuel tank(s).
Failed fuel tank transfer pump
A restricted, kinked, bent, loose, cracked, or broken
fuel pickup tube or screen.
Failed seals for fuel lines between fuel tanks, ice
in fuel lines, fuel supply line broken or crimped, or
restriction in the fuel line from the fuel tank to the
HFCM.
Low fuel pressure Debris in tank
Restriction from the fuel tank to the HFCM
A kinked or bent fuel supply line or a blocked pickup
tube screen
A loose fuel line or fuel line connector on the suction
side of the fuel system
Dirty or plugged fuel filters
Failed fuel pump
Debris in the fuel regulator valve
Failed or stuck fuel pressure regulator valve.
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© 2006 International Truck and Engine Corporation
164 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 165
10.2. Fuel Pump Discharge Pressure NOTE: Use existing copper gaskets for testing.
Replace the copper gaskets on the banjo bolt when
NOTE: This procedure should only be performed testing is over and repairs have been made.
when directed by “Test 10.1. Pressure, Quality, and
Aerated Fuel (page 159)” when fuel pressure is still
below specification or slow to build, after replacing
both primary and secondary fuel filters.
Purpose
To measure fuel pump discharge pressure
1. Remove the banjo bolt from fuel supply from fuel 3. Connect the Fuel Pressure Gauge to the Fuel
pump (item 2) at the bottom of the secondary fuel Pressure Test Adapter.
filter housing. 4. Turn ignition switch to ON (do not crank the
engine).
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© 2006 International Truck and Engine Corporation
166 5 HARD START AND NO START DIAGNOSTICS
5. Check fuel pressure on the test gauge 6. Record the results on the Diagnostic Form.
immediately when the pump starts. The fuel
• If the discharge pressure is within
pressure should increase to specification quickly.
specification, turn ignition switch to OFF,
continue with step 7.
• If the discharge pressure is not within
specifications, turn ignition switch to OFF.
Reconnect the fuel line and banjo bolt to
the secondary fuel filter housing, do “Test
10.3. Fuel Inlet Restriction (page 167)” in this
section.
7. Remove the Fuel Pressure Test Adapter.
8. Remove, clean, and inspect the fuel pressure
regulator, see the Engine Service Manual.
9. After reinstallation of the secondary fuel filter
housing and all fuel line. Attach the filter pressure
gauge to the secondary fuel filter test port, and
retest fuel pressure.
Figure 168 Replace two copper gaskets
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 167
Purpose
To measure fuel pump inlet restriction
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© 2006 International Truck and Engine Corporation
168 5 HARD START AND NO START DIAGNOSTICS
NOTE: Inspect the drain plug O-ring for damage from 7. Record results on Diagnostic Form.
removal. Care must be taken when installing drain
• If vacuum indication is above the
plug to prevent damaging the O-ring.
specification, check for restrictions in
5. Connect to 0-30 in Hg gauge on the gauge bar the fuel supply lines from the fuel pickup tube
tool through an in-line shut off valve. Make sure in the fuel tank to the HFCM. Visually inspect
the shut off valve is in the closed position. for bent, crimped, or damaged fuel supply
lines and connections from the fuel tank(s)
NOTE: The fuel pump runs for 60 seconds when to the HFCM. Correct any restrictions and
ignition switch is turned on. The in-line shut off valve retest fuel pressure at the secondary fuel
must be closed before the fuel pump shuts off. This filter housing test port.
will prevent the gauge from filling with fuel.
• If vacuum indication is below the specification
6. Turn ignition switch to ON. Open the in-line shut and fuel pump discharge pressure is low,
off valve and check for restriction indication on the replace the fuel pump and retest fuel pressure
test gauge. Close the in-line shut off valve. Turn at the secondary fuel filter housing test port.
ignition switch to OFF.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 169
Figure 171
Purpose
To determine correct power supplied to operate the
ECM. The ECM requires 7 volts minimum for correct
operation.
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© 2006 International Truck and Engine Corporation
170 5 HARD START AND NO START DIAGNOSTICS
Possible Causes
Low battery voltage Corroded or loose connections
Failed batteries
High-resistance at battery cable connections
Wiring to the ECM
Low or no battery voltage to the ECM The ECM main power circuit fuse in the power test
center may be open.
Corroded or loose connections
High-resistance or an open power feed circuit to the
ECM or ECM power relay.
ECM main power relay may have failed.
Ignition switch circuit problem or fuse
Failed ECM
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5 HARD START AND NO START DIAGNOSTICS 171
Voltage Measurement at ECM with Breakout Box 2. Remove two white connectors (X3 and X4) from
ECM.
Tools
• Breakout Box
• DMM
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172 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 173
Figure 177
Purpose
To determine correct power supplied to operate the
IDM
The IDM requires 7 volts minimum to operate.
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© 2006 International Truck and Engine Corporation
174 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 175
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176 5 HARD START AND NO START DIAGNOSTICS
Possible Causes
Low battery voltage Failed batteries
High-resistance at battery cable connections
Wiring to the IDM
Low or no battery voltage to the IDM The IDM power circuit fuse in the power test center
may be open.
Corroded or loose connections
High-resistance or an open power feed circuit to the
IDM or IDM power relay.
IDM power relay may have failed.
Ignition switch circuit problem or fuse
Failed IDM
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 177
Purpose
To determine the cause of low injection control
pressure that prevents engine starting
Tools
• EST with MasterDiagnostics® software
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178 5 HARD START AND NO START DIAGNOSTICS
13.1. System Function NOTE: Do not connect the engine wiring harness
to the Actuator Breakout Harness.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 179
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180 5 HARD START AND NO START DIAGNOSTICS
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5 HARD START AND NO START DIAGNOSTICS 181
12. Record results on Diagnostic Form. • If a leak is still heard after replacing the IPR
valve, continue with “13.3. Under Valve Cover
• When the IPR valve is energized, the air leak
Leaks (page 182).”
should stop.
• If an air leak is not heard when the IPR
• If a faint air leak is still heard, replace the IPR
valve is energized, continue with “13.5.
valve. Follow the procedures in the Engine
High-pressure Pump (page 189).” This test
Service Manual. Repeat step 11 to verify if
result indicates no leaks in the high-pressure
the IPR valve is functioning correctly.
oil system.
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© 2006 International Truck and Engine Corporation
182 5 HARD START AND NO START DIAGNOSTICS
13.3. Under Valve Cover Leaks 7. Use the Actuator Breakout Harness to apply B+
and ground to the IPR valve.
NOTE: Before doing this test, inspect the D-rings
for the ICP Sensor Adapter and ICP Leak Test Plug.
Replace D-rings if worn, cracked or cut. CAUTION: Do not leave IPR valve energized
1. Close shutoff valve in test hose before longer than 120 seconds. This can damage the
disconnecting shop air. IPR valve.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 183
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184 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 185
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186 5 HARD START AND NO START DIAGNOSTICS
24. Listen for air leaks in both O-ring areas under the
high-pressure pump,
• If an air leak is not detected in the area under
the high-pressure cover, but an air leak is
heard, replace the Branch Tube Assembly.
• If an air leak is located or detected, repair or
replace as required.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 187
13.4. Cylinder Head Isolation 1. Remove the case-to-head tube plug from the rear
of the oil rail. Install the ICP Leak Test Plug in this
NOTE: Before doing this test, inspect the D-rings for port.
the ICP Leak Test Plug. Replace D-rings if worn,
cracked or cut. NOTE: Understand and comply with the following:
Depending on which rail is being tested, the complete • This will block air flow to the oil rail and
test setup must be on the same side. injectors.
• When case-to-head tube plug is removed,
the case-to-head tube may be still attached.
Remove tube from plug. A new case-to-head
tube assembly must be installed, to leak test
plug or sensor adapter.
If case-to-head tube plug has a square drive,
the replacement case-to-head tube is no
longer supported. A case-to-head tube with
a hex drive in the plug must be used as a
replacement.
Both the left and right side case-to-head tubes
and plugs must be replaced.
• If the wrong diagnostic tool is used, a
misdiagnosis will result. If the case-to-head
tube plug has a hex drive in the head, use
Figure 197 ICP Leak Test Plug and ICP System
ICP Adapter/Plug Kit (ZTSE4690) only.
Test Adapter (right cylinder head)
2. Install ICP System Test Adapter into ICP sensor
1. ICP Leak Test Plug
port.
2. In-line shutoff valve
3. ICP System Test Adapter • ICP sensor removed from right cylinder head
• Plug removed from left cylinder head
3. Connect the shop air supply line to the ICP
System Test Adapter. Make sure the shutoff
valve is closed.
4. Apply 689 kPa (100 psi) of pressure, open shutoff
valve, and listen for an air leak.
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© 2006 International Truck and Engine Corporation
188 5 HARD START AND NO START DIAGNOSTICS
5. Record results on Diagnostic Form • If an air leak is detected, repair as needed and
verify the integrity of the repairs.
• If an air leak is not detected, the air leak may
be coming from the crankcase or opposite
cylinder head. Verify previous test results and
repeat procedure for opposite cylinder head.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 189
NOTE: Do this test only if Test 13.2 did not have leaks
and Test 6 had low ICP.
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190 5 HARD START AND NO START DIAGNOSTICS
NOTE: Understand and comply with the following: 6. Connect the engine wiring harness to the ICP
sensor. Use the Pressure Sensor Breakout
• This will block oil flow to the right oil rail and
Harness as an extension, if needed.
injectors.
• When case-to-head tube plug is removed,
the case-to-head tube may be still attached.
Remove tube from plug. A new case-to-head
tube assembly must be installed, to leak test
plug or sensor adapter.
If case-to-head tube plug has a square drive,
the replacement case-to-head tube is no
longer supported. A case-to-head tube with
a hex drive in the plug must be used as a
replacement.
Both the left and right side case-to-head tubes
and plugs must replaced.
• If the wrong diagnostic tool is used, a
misdiagnosis will result. If the case-to-head
tube plug has a hex drive in the head, use Figure 202 ICP Leak Test Plug (left cylinder
ICP Adapter/Plug Kit (ZTSE4690) only. head)
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5 HARD START AND NO START DIAGNOSTICS 191
CAUTION: Do not leave IPR valve energized 11. Crank the engine and monitor the ICP pressure
longer than 120 seconds. This can damage the (right side isolation).
IPR valve.
• If unable to build ICP pressure above
3.45 MPa (500 psi) (0.82 volts), the problem
9. Crank the engine and monitor ICP pressure. is on left side. Do “Test 13.4. Cylinder Head
Isolation (page 187)” and check for leaks.
10. Record results on Diagnostic Form.
• If able to build ICP pressure above
• If unable to build the ICP pressure above
3.45 MPa (500 psi) (0.82 volts), remove
3.45 MPa (500 psi) (0.82 volts), check branch
ICP Test Adapter from right side oil rail and
tube, case-to-head tubes use of proper
re-install case-to-head-tube plug. Re-install
diagnostic tools or faulty high pressure pump.
ICP sensor. Reconnect ICP sensor to engine
Follow the procedure in the Engine Service
wiring harness. Continue with step 12.
Manual. Retest to verify repairs.
12. Crank the engine and monitor ICP pressure.
• If able to build ICP pressure above
3.45 MPa (500 psi) (0.82 volts), check • If unable to build the ICP pressure above
previous test results. Remove the ICP Leak 3.45 MPa (500 psi) (0.82 volts), the problem
Test Plug from the left side oil rail and re-install is on the right side. Do “ 13.4. Cylinder Head
case-to-head-tube plug. Continue with step Isolation (page 187)” and check for leaks.
11.
• If able to build pressure the engine should
start and run. Install valve covers, following
procedures in the Engine Service Manual.
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192 5 HARD START AND NO START DIAGNOSTICS
Tools
EST with MasterDiagnostics® software
EZ-Tech® interface cable
DMM
Amp clamp
Glow Plug Test Lead
Possible causes
Poor wiring harness connection
Poor ground connection
Failed glow plug relay
Failed glow plugs
Failed ECM
Figure 203
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5 HARD START AND NO START DIAGNOSTICS 193
Figure 205 Output State Test Session NOTE: The Glow Plug/Inlet Air Heater Output
State Test will command the glow plugs on for
120 seconds. Both sides can be tested during
3. Select D_OutputStateTest.ssn in the Open this time. The Glow Plug/Inlet Air Heater Output
Session File window, select Open to detect State Test is limited to two requests per key cycle.
possible DTCs. 7. After 40 seconds, measure amperage.
8. Record the amperage reading for the left side on
Diagnostic form.
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© 2006 International Truck and Engine Corporation
194 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 195
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196 5 HARD START AND NO START DIAGNOSTICS
14.4. Engine Harness 3-pin to Relay 1. Use DMM to measure resistance of wire between
the glow plug relay and all three circuits in the
3-pin connector.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 197
1. Connect DMM positive lead to battery supply 6. Turn ignition switch to ON. (Do not start engine.)
terminal (battery to glow plug relay).
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© 2006 International Truck and Engine Corporation
198 5 HARD START AND NO START DIAGNOSTICS
NOTE: When using the EST to do the KOEO or KOER 13. When finished with this test, select Session from
diagnostic tests, Standard Test is always selected menu bar, then Close.
and run first. If the ignition switch is not cycled, the
Standard Test does not have to be run again.
10. From the KOEO Diagnostics menu, select Glow
Plug/Inlet Air Heater, then select Run to start the
test.
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 199
Figure 216
Purpose
To determine if the Inlet Air Heater system is operating
correctly
Tools
EST with MasterDiagnostics® software
Figure 217 Amp Clamp
EZ-Tech® interface cable
DMM
1. Install Amp Clamp around feed wire next to
Amp Clamp element.
2. Turn ignition switch to ON. (Do not start engine.)
Possible causes
Poor wiring harness connection
Poor ground connection
Failed relay
Failed element
Failed ECM
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© 2006 International Truck and Engine Corporation
200 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 201
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202 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 203
8. Record result on Diagnostic Form. • If voltage is not B+, do “Test 15.4. Wiring
Harness Continuity and Resistance (page
• If voltage is B+, do “Test 15.3. Resistance of
205).”
Element (page 204).”
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© 2006 International Truck and Engine Corporation
204 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 205
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206 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation
5 HARD START AND NO START DIAGNOSTICS 207
NOTE: When using the EST to do the KOEO or KOER Figure 231 Close session
diagnostic tests, Standard Test is always selected
and run first. If the ignition switch is not cycled, the
Standard Test does not have to be run again. 13. When finished with this test, select Session from
menu bar, then Close.
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208 5 HARD START AND NO START DIAGNOSTICS
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© 2006 International Truck and Engine Corporation