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05 07-17

1 05 07-17

SUBJECT DATE
Diagnostic Test May 2017

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

EPA07/10/
DDC-SVC-MAN-0084
GHG14 DD

DDC-SVC-MAN-0191 GHG17 DD Diagnostic Test -


GHG17 Mechanical Cylinder Updated GHG17 Heavy Duty and Medium Duty procedures.
DDC-SVC-MAN-0193 Compression Test
DD5

GHG17
DDC-SVC-MAN-0200
DD8

DiagnosticLink users: Please update the troubleshooting guides in DiagnosticLink with this newest version. To update the
tool troubleshooting guide, open DiagnosticLink and from the Help – Troubleshooting Guides menu, select the appropriate
troubleshooting manual, then click Update.

All information subject to change without notice. 3


05 07-17 Copyright © 2017 DETROIT DIESEL CORPORATION
2 Mechanical Cylinder Compression Test

2 Mechanical Cylinder Compression Test

NOTE: This test should be performed only if directed here by a diagnostic procedure.

Table 1.
Special Service Tools Used in the Procedure
Tool Number Tool Name Tool Graphic
Compression Test Adaptor

J-47411

High Pressure Fuel Rail Test Caps

J-48704 or W470589129100

Perform the following steps for a mechanical compression test on a Heavy Duty DD Platform Engine:
The following are possible causes of low compression:
• Jake Brake ®/piston
• Valve lash/valve train damage
• Camshaft timing
• Cylinder liner/ring damage
• Fuel injector hold-downs
• Blown cylinder head gasket
• Cracked cylinder liner or cylinder head
• Valve or seat damage

WARNING: PERSONAL INJURY


To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.

WARNING: PERSONAL INJURY


To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.

NOTE: First perform the Relative Cylinder Compression Test using DiagnosticLink ®. Refer to section "Relative
Cylinder Compression Test". If results indicate a weak cylinder, perform this mechanical compression test.

1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to 205°F).

4 All information subject to change without notice.


Copyright © 2017 DETROIT DIESEL CORPORATION 05 07-17
05 07-17

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover".
4. Remove both fuel injector harnesses.
For a three-filter fuel system: Refer to section "Removal of the One-Piece Fuel Injector Wiring Harness - Three-Filter
System" and Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Three-Filter System".
For a two-filter fuel system: Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter
System".
a. Disconnect electrical contacts at the fuel injectors.
b. Disconnect the two wiring terminals going to the Jake Brake ® solenoids.
c. Disconnect the 14-pin fuel injector harness connector.
d. Remove the spring clip holding the fuel injector harness connectors to camshaft frame.
e. Remove the fuel injector wiring harnesses.
5. Remove the high pressure fuel injector line from the suspect cylinder.
For a three-filter fuel system: Refer to section "Removal of the High Pressure Fuel Injector Lines - Three-Filter
System".
For a two-filter fuel system: Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System".
6. Remove the fuel injector.
For a three-filter fuel system: Refer to section "Removal of the Fuel Injector - Three-Filter System".
For a two-filter fuel system: Refer to section "Removal of the Fuel Injector - Two-Filter System".
7. Remove excess fuel from cylinder using a vacuum pump.
8. Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder head.
9. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) + 90 degrees.
10. Install the fuel rail plug (J-48704 or W470589129100).
11. Install a hold-down bolt onto the Jake-Brake ® solenoid and snug the bolt.

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

12. Reconnect the batteries; keep the battery charger plugged into the batteries.

NOTE: Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
voltage.

13. With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater using the starter
motor. Record the compression reading on the gauge.
14. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If compression
readings are below specifications, repeat step 13 with a different gauge to be certain of the reading.

NOTE: Fuel injector hold-down bolts are a one-time use item.

15. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test adaptors.
16. Repeat steps for all suspect cylinders.
17. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression".

All information subject to change without notice. 5


05 07-17 Copyright © 2017 DETROIT DIESEL CORPORATION
3 Mechanical Cylinder Compression Test

3 Mechanical Cylinder Compression Test

NOTE: This test should be performed only if directed here by a diagnostic procedure.

Table 2.
Special Service Tools Used in the Procedure
Tool Number Tool Name Tool Graphic

J-47411 Compression Test Adaptor

J-48704 or W470589129100 High Pressure Fuel Rail Test Caps

Perform the following steps for a mechanical compression test on a GHG17Heavy Duty DD Platform Engine:
The following are possible causes of low compression:
• Jake Brake ®/piston
• Valve lash/valve train damage
• Camshaft timing
• Cylinder liner/ring damage
• Fuel injector hold-downs
• Blown cylinder head gasket
• Cracked cylinder liner or cylinder head
• Valve or seat damage

WARNING: PERSONAL INJURY


To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.

WARNING: PERSONAL INJURY


To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.

NOTE: First perform the Relative Cylinder Compression Test using DiagnosticLink. Refer to section "Relative
Cylinder Compression Test". If results indicate a weak cylinder, perform this mechanical compression test.

1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to 205°F).

6 All information subject to change without notice.


Copyright © 2017 DETROIT DIESEL CORPORATION 05 07-17
05 07-17

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover".
4. Remove the fuel injector harness.
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System".
a. Disconnect electrical contacts at the fuel injectors.
b. Disconnect the two wiring terminals going to the Jake Brake ® solenoids.
c. Disconnect the 14-pin fuel injector harness connector.
d. Remove the spring clip holding the fuel injector harness connectors to camshaft frame.
e. Remove the fuel injector wiring harness(es).
5. Remove the high pressure fuel line from the suspect cylinder. Refer to section "Removal of the High Pressure Fuel
Injector Lines - Two-Filter System".
6. Remove the fuel injector. Refer to section "Removal of the Fuel Injector - Two-Filter System".
7. Remove excess fuel from cylinder using a vacuum pump.
8. Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder head.
9. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) + 90 degrees.
10. Install the fuel rail plug (J-48704 or W470589129100).
11. Install a hold-down bolt onto the Jake-Brake ® solenoid and snug the bolt.

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

12. Reconnect the batteries; keep the battery charger plugged into the batteries.

NOTE: Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
voltage.

13. With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater using the starter
motor. Record the compression reading on the gauge.
14. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If compression
readings are below specifications, repeat step 13 with a different gauge to be certain of the reading.

NOTE: Fuel injector hold-down bolts are a one-time use item.

15. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test adaptors.
16. Repeat steps for all suspect cylinders.
17. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression".

All information subject to change without notice. 7


05 07-17 Copyright © 2017 DETROIT DIESEL CORPORATION
4 Mechanical Cylinder Compression Test

4 Mechanical Cylinder Compression Test

NOTE: This test should be performed only if directed here by a diagnostic procedure.

Table 3.
Special Service Tools Used in the Procedure
Tool Number Tool Name Tool Graphic
DSN930E16003 Compression Test Adaptor

W936589019100 High Pressure Fuel Rail Test Caps

Check as follows:
The following are possible causes of low compression:
• Valve lash/valve train damage
• Camshaft timing
• Cylinder damage
• Fuel injector hold-downs
• Blown cylinder head gasket
• Cracked cylinder head
• Valve or seat damage
• Engine brake system

WARNING: PERSONAL INJURY


To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.

WARNING: PERSONAL INJURY


To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.

NOTE: First perform the Relative Cylinder Compression Test using DiagnosticLink ®. Refer to section "Relative
Cylinder Compression Test". If results indicate one or more weak cylinder(s), perform this mechanical
compression test.

1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to 205°F).

8 All information subject to change without notice.


Copyright © 2017 DETROIT DIESEL CORPORATION 05 07-17
05 07-17

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover".
4. Remove the fuel injector harness.
5. Disconnect electrical contacts at the fuel injectors.
6. Disconnect the fuel injector harness connector.
7. Remove the fuel injector wiring harnesses.
8. Remove high pressure fuel line from the suspect cylinder. Refer to section "Removal of the High Pressure Fuel
Injector Lines".
9. Remove the fuel injector. Refer to section "Removal of the Fuel Injector".
10. Remove excess fuel from cylinder using a vacuum pump.
11. Install the compression test adaptor into the fuel injector bore in the cylinder head.
12. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) plus 90 degrees.
13. Install the W936589019100 High Pressure Fuel Rail Test Cap.

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

14. Reconnect the batteries; keep the battery charger plugged into the batteries.

NOTE: Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
voltage.

15. Using DiagnosticLink ®, start the Mechanical Compression Test routine; this will disable fuel from the Quantity
Control Valve.
16. With the batteries fully charged, crank the engine over five compression strokes to 150 rpm or greater, using the
starter motor. Record the compression reading on the gauge.
17. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If compression
readings are below specifications, repeat step 16 with a different gauge to be certain of the reading.

NOTE: Fuel injector hold-down bolts are a one-time use item.

18. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test adaptors.
19. Repeat steps for all suspect cylinders.
20. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression".

All information subject to change without notice. 9


05 07-17 Copyright © 2017 DETROIT DIESEL CORPORATION
5 Mechanical Cylinder Compression Test

5 Mechanical Cylinder Compression Test

NOTE: This test should be performed only if directed here by a diagnostic procedure.

Table 4.
Special Service Tools Used in the Procedure
Tool Number Tool Name Tool Graphic
DSN930E16003 Compression Test Adaptor

W936589019100 High Pressure Fuel Rail Test Caps

Check as follows:
The following are possible causes of low compression:
• Valve lash/valve train damage
• Camshaft timing
• Cylinder damage
• Fuel injector hold-downs
• Blown cylinder head gasket
• Cracked cylinder head
• Valve or seat damage
• Engine brake system

WARNING: PERSONAL INJURY


To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.

WARNING: PERSONAL INJURY


To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.

NOTE: First perform the Relative Cylinder Compression Test using DiagnosticLink ®. Refer to section "Relative
Cylinder Compression Test". If results indicate one or more weak cylinder(s), perform this mechanical
compression test.

1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to 205°F).

10 All information subject to change without notice.


Copyright © 2017 DETROIT DIESEL CORPORATION 05 07-17
05 07-17

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover".
4. Remove the fuel injector harness.
5. Disconnect electrical contacts at the fuel injectors.
6. Disconnect the fuel injector harness connector.
7. Remove the fuel injector wiring harnesses.
8. Remove the high pressure fuel lines from the suspect cylinder. Refer to section "Removal of the High Pressure Fuel
Injector Lines".
9. Remove the fuel injector. Refer to section "Removal of the Fuel Injector".
10. Remove excess fuel from cylinder using a vacuum pump.
11. Install the compression test adaptor into the fuel injector bore in the cylinder head.
12. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) plus 90 degrees.
13. Install the W936589019100 High Pressure Fuel Rail Test Cap.

CAUTION: ELECTRICAL SHOCK


To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.

14. Reconnect the batteries; keep the battery charger plugged into the batteries.

NOTE: Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
voltage.

15. Using DiagnosticLink ®, start the Mechanical Compression Test routine; this will disable fuel from the Quantity
Control Valve.
16. With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater, using the starter
motor. Record the compression reading on the gauge.
17. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If compression
readings are below specifications, repeat step 16 with a different gauge to be certain of the reading.

NOTE: Fuel injector hold-down bolts are a one-time use item.

18. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test adaptors.
19. Repeat steps for all suspect cylinders.
20. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression".

All information subject to change without notice. 11


05 07-17 Copyright © 2017 DETROIT DIESEL CORPORATION