16 MISFIRING CYLINDER

Section Page

16.1 POOR VEHICLE GROUND ..................................................................... 16-3

16.2 AERATED FUEL ..................................................................................... 16-5
16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ..................................................................................... 16-6
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS .................................. 16-9
16.5 FAULTY FUEL INJECTOR ....................................................................... 16-19
16.6 FAULTY ELECTRONIC CONTROL MODULE ......................................... 16-21
16.7 WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ 16-22
 (Rev. 12/05) All information subject to change without notice.
16-2 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

16.1 POOR VEHICLE GROUND

To determine if poor vehicle ground is causing the cylinder to misÞre, perform the following steps:
1. Remove alternator belt.
2. Start the engine.
3. Run the engine through operating range.
4. Listen for engine misÞring.
[a] If the engine is not misÞring, refer to section 16.1.1. Shut down the engine.
[b] If the engine is still misÞring, check for aerated fuel; refer to section 16.2.

16.1.1 Negative Lead Repair

Perform the following steps for negative lead repair:

1. Shut down the engine.
2. Remove negative lead(s) at frame ground stud near battery box.
3. Clean ground stud; refer to OEM guidelines.
4. Clean negative lead(s) terminal lugs with low grit sandpaper.
5. Repair any loose or damaged lead(s), using the splice method or rosin core solder.
6. Install negative lead(s) to frame ground stud; refer to OEM guidelines.
7. Install alternator belt.
[a] If installing a new belt, tighten to 170 N·m (125 lb).
[b] If installing a used belt, tighten to 135 N·m (100 lb).
[c] If a belt tension gage is not available, adjust the belt tension so that a Þrm push with
the thumb, at a point midway between the two pulleys, will depress the belt 12.70
- 19.05 mm (0.500-0.750 in.).

NOTE:
When installing or adjusting an accessory drive belt, be sure the bolt at the accessory
adjusting pivot point is properly tightened, as well as the bolt in the adjusting slot.

NOTE:
Drive belts (Vee and poly-vee) should be replaced every 2,000 hours or 160,000 km
(100,000 miles).

8. Verify negative lead repair; refer to section 16.1.1.1.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-3
16.1 POOR VEHICLE GROUND

16.1.1.1 VeriÞcation of Repair for Negative Lead

Perform the following steps to determine if negative lead repair resolved the misÞring cylinder
condition:
1. Refer to section 16.1 for exhaust caution before preceding. Start engine.
2. Run engine speed up to the occurrence of the misÞring.
3. Listen for misÞring cylinder.
[a] If the engine is not misÞring, no further troubleshooting is required. Shut down
the engine.
[b] If the engine is misÞring, check for aerated fuel. Shut down the engine;
refer to section 16.2.

(Rev. 12/05) All information subject to change without notice.

16-4 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

16.2 AERATED FUEL

To determine if aerated fuel is causing the cylinder to misÞre, perform the following steps:
1. Disconnect the fuel line return hose from the Þtting located at the fuel tank.
2. Place the opened end of fuel line into a suitable container.
3. Start the engine.
4. Run the engine at 1000 rpm.
5. Visually check to see if air bubbles are rising to the surface of the fuel within the container.
[a] If air bubbles are present, refer to section 16.2.1.
[b] If air bubbles are not present, check for improper calibration setting; refer to section
16.3. Shut down the engine.

16.2.1 Aerated Fuel Repair

Perform the following steps for air in fuel repair:

1. Shut down engine.
2. Tighten all fuel line connections between fuel tank and fuel pump; refer to OEM
guidelines.
3. Visually inspect all fuel lines between fuel tank and fuel pump for leaks.
4. Replace any damaged components; refer to appropriate service manual, fuel system
chapter.
5. Verify repair of fuel lines:
[a] If no air in the fuel return, refer to section 16.2.1.1.
[b] If air in the fuel return, locate and repair. Then refer to section 16.2.1.1.

16.2.1.1 Test the Engine with Repair for Aerated Fuel

Perform the following steps to determine if the aerated fuel repair resolved the misÞring cylinder
condition:
1. Refer to section 16.2 for exhaust caution before preceding. Start engine.
2. Run engine at 1000 rpm.
3. Listen for misÞring cylinder.
[a] If the engine is not misÞring, no further troubleshooting is required. Shut down
the engine.
[b] If the engine is misÞring, check for improper injector setting. Shut down the engine;
refer to section 16.3.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-5
16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV ENGINES ONLY)

16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV ENGINES

ONLY)

For troubleshooting DDEC I and DDEC II engines, refer to section 16.4.

To determine if an improper injector calibration setting is causing the cylinder to misÞre, perform
the following steps:
1. Remove the valve rocker cover(s); (one-piece two-piece, three-piece) refer to the
appropriate service manual, engine chapter.
2. Record the injector calibration code of each injector noting the cylinder number;
see Figure 16-1.

NOTE:
Injector calibration and bar codes may be absent from the load plates on Þrst-run
production DDEC III/IV injectors 5235575, 5235580, and 5235550. The correct
calibration code for these units is "01". Load plates on current DDEC III/IV injectors
include the required calibration or bar code information.

Figure 16-1 Injector Calibration Code Location

(Rev. 12/05) All information subject to change without notice.

16-6 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

3. Turn vehicle ignition to the on position, but do not run engine.

4. Install Diagnostic Data Link (DDL) adaptor to the data cable and plug the adaptor into the
DDL connector in the vehicle; refer to OEM guidelines.
5. From the Diagnostic Data Reader (DDR) DDEC III/IV Select Menu, scroll to select
ENGINE and press the ENTER key.
6. Scroll to select FUEL INJECTOR INFO and press the ENTER key.
7. Scroll to select FUEL INJECTOR CAL and press the ENTER key.
8. Scroll to select FUEL INJECTOR CAL. Select VIEW and press the ENTER key.
9. Compare the calibration code(s) shown on the display with the two digit calibration
code(s) on the injector(s).
[a] If the calibration code on the display is different then the calibration code on the
suspect injector for that cylinder, the injector setting must be repaired, see Figure
16-1; refer to section 16.3.1.
[b] If test codes match; refer to section 16.4.

16.3.1 Improper Injector Setting Repair

Perform the following steps to recalibrate improper injector setting:

NOTICE:
Whenever a DDEC III injector is removed from the engine, it
should be reinstalled in its original location to maintain proper
cylinder balance. If reinstalled in a different cylinder head
location, injector calibration must be rechecked with the DDR
and updated. Failure to observe these steps may result in
reduced engine performance.

NOTE:
Injector calibration and bar codes may be absent from the load plates on Þrst-run
production DDEC III/IV injectors 5235575, 5235580, and 5235550. The correct
calibration code for these units is "01''. Load plates on current DDEC III/IV injectors
include the required calibration or bar code information. See Figure 16-1.

1. Scroll to select FUNCTION to return to the FUEL INJECTOR CAL menu on the DDR.
2. Scroll to select FUEL INJECTOR CAL. Select UPDATE and press the ENTER key.
3. Type the four-digit "Update Injector Calibration" password for the DDR and press the
ENTER key. If this feature is not password protected, type "0000" and press the ENTER
key.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-7
16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV ENGINES ONLY)

4. A message will appear telling you to use the scroll keys to select the cylinder (requiring
changes) or select TYPE # (enter the numerical keys to change the CAL (calibration value).

NOTE:
An asterisk (*) will highlight the Þrst cylinder number on the list.

5. Scroll to the cylinder requiring change and type in the required two-digit injector
calibration code number. Press the ENTER key.

NOTE:
The ENTER key must be pressed before the DDR will allow selection of another cylinder
number.

6. Repeat step 5, until all changes have been made.

7. Scroll to select FUNCTION and press the ENTER key.
8. Scroll to select YES and press the ENTER key to reprogram the Electronic Control
Module (ECM) with the revised injector calibration codes.

NOTE:
Turning the ignition to the off position and waiting Þve seconds before starting the engine
is not required.

9. Disconnect the DDR; refer to OEM guidelines.

16.3.1.1 VeriÞcation of Repair for Improper Injector Setting

Perform the following steps to determine if the proper injector setting adjustment resolved the
misÞring cylinder condition:
1. Install the valve rocker cover(s); (one-piece, two piece, three piece) refer to the appropriate
service manual, engine chapter.
2. Start the engine.
3. Run the engine at 1000 rpm.
4. Listen for misÞring cylinder.
[a] If the engine is not misÞring, no further troubleshooting is required. Shut down
the engine.
[b] If the engine is misÞring, shut down the engine. Check for improper valve clearance
and injector height and damaged or worn camshaft lobes and rollers; refer to section
16.4.

(Rev. 12/05) All information subject to change without notice.

16-8 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR

DAMAGED CAMSHAFT LOBES AND ROLLERS

Intake valve clearance and injector height are adjusted by means of an adjusting set screw and
locknut located at the valve (or injector) end of the rocker arm; see Figure 16-2.

1. Exhaust Valve 6. Intake Valve

2. Intake Valve 7. Fuel Injector Follower
3. Locknut 8. Valve Button
4. Adjusting Set Screw 9. Exhaust Valve
5. Exhaust Rocker Arm Assembly

Figure 16-2 Valve and Fuel Injector Height Adjustment Components

NOTE:
On engines equipped with a Jake Brake, measure valve lash and injector height before
removing any brake housings. Only remove the brake housings necessary to provide
access for adjustment.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-9
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR DAMAGED CAMSHAFT LOBES
AND ROLLERS

The injector height is adjusted using the injector timing gage J–39697 (DDEC III/IV) or
J–35637–A (DDEC II and I). On engines equipped with a Jake Brake, move the handle on the
injector height gage to the alternate position, 90 degrees to the shank. A height gage pilot hole
is provided in the fuel injector body on the machined surface contacted by the injector clamp
near the solenoid; see Figure 16-3.

Figure 16-3 Timing Gauge

NOTE:
Be sure the height gage seats on the machined surface with the tip in the pilot hole.
Foreign material in the pilot hole or on the machined surface may prevent accurate
setting of the injector height.

To determine if improper valve clearance, injector height or both are causing the cylinder to
misÞre, perform the following preliminary step 1 through step 3 and repeat step 4 through step
9 for each cylinder to determine if worn or damaged lobes or rollers are causing the engine
to misÞre:
1. Disconnect starting power for engine.
2. Remove the valve rocker cover(s); (one-piece, two piece, three piece) refer to the
appropriate service manual, engine chapter.
3. Insert a 3/4 in. drive breaker bar or ratchet into the square hole in the center of the
crankshaft pulley.

(Rev. 12/05) All information subject to change without notice.

16-10 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

4. Bar the engine over and inspect camshaft and rollers for wear or damage. Stop engine
rotation when any one of the injector followers has just begun its downward stroke;
see Figure 16-4.

1. Injector Follower 4. Injector Cam Lobe

2. Injector Rocker Arm Assembly 5. Point on the Camshaft Lobe that First Produces
Downward Motion of the Injector Follower
3. Injector Roller

Figure 16-4 Injector Followers Downward Stroke

[a] If damage is found on the camshaft lobes or rollers, stop this procedure and replace
damaged components as necessary; refer to the appropriate service manual, engine
chapter. Once complete, refer to section 16.4.1.1.
[b] If no damage was found to camshaft or rollers, continue with task.
5. Using timing chart, see Figure 16-5, determine if the intake valve clearances are acceptable
(listed in Table 16-1), by inserting a feeler gage between the tip of the intake valve stem
and the button; see Figure 16-6.
[a] If the intake valve stem clearance is between 0.127 - 0.280 mm (0.005-0.011 in.),
step 6.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-11
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR DAMAGED CAMSHAFT LOBES
AND ROLLERS

[b] If the intake valve stem clearance is not between 0.127 - 0.280 mm (0.005-0.011 in.),
reset the intake valve(s) to 0.203 mm (0.008 in.); refer to section 16.4.1, step 1.

Figure 16-5 Timing Circle Chart

1. Intake Valve 4. Locknut

2. Valve Button 5. Feeler Gage
3. Intake Rocker Arm Assembly 6. Tip of Intake Valve

Figure 16-6 Intake Valve Clearance

(Rev. 12/05) All information subject to change without notice.

16-12 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

Settings and Models Acceptable Range Recommended Setting

Injector Heights DDEC I and II
(6067GT40, 6067WT40, 6067WU40,
6067GU40, 6063WU00, 6063GU00, 77.9–78.4 mm (3.068–3.088 in.) 78.2 mm (3.078 in.)
6067WU60, 6067GU60, and
6067GU91)
Injector Heights DDEC III
(6067WK60, 6067WK28, 6067GK60,
6067GK28, 6063WK60, 6063WK28, 2.992–3.112 mm (2.992–3.112 in.) 78.8 mm (3.102 in.)
6063GK05 6063GK60, and
6063GK28)
Intake Valve Clearance 0.127 - 0.280 mm (0.005. - 0.011 in.) 0.203 mm (0.008 in.)
Exhaust Valve Clearance "U''
(6067GT40, 6067WT40, 6067WU40, 0.432 - 0.054 mm (0.017 - 0.023 in.) 0.508 mm (0.020 in.)
6067GU40, 6063WU00, 6063GU00)
Exhaust Valve Clearance 0.584 - 0.736 mm (0.023 - 0.029 in.) 0.660 mm (0.026 in.)
"H''(6067WU60, 6067GU60,
6067WK60, 6067GK60, 6067GK28,
6067WK28 6067GU91, 6063WU60,
6063GK05, 6063GK32, 6063GK60,
6063GU41, 6063GU60, 6063WK32,
6063WK60, 6063WU00, 6063WU41,
6063GU00)

Table 16-1 Valve Clearance and Injector Height Settings

6. Using timing chart, see Figure 16-5, determine if the exhaust valve clearances are
acceptable, (listed in Table 16-1) by inserting a feeler gage between the tip of the exhaust
valve stem and the button; see Figure 16-7.
[a] For exhaust valves with a machined groove between the rotator and tip, the exhaust
valve stem clearance should be between 0.584 - 0.736 mm (0.023 - 0.029 in.). If
the exhaust valve stem clearance is between 0.584 - 0.736 mm (0.023 - 0.029 in.),
proceed to step 7. For exhaust valves without a machined groove between the rotator
and tip, the exhaust valve stem clearance should be between 0.432 - 0.584 mm (0.017
- 0.023 in.). If the exhaust valve stem clearance is between 0.432 - 0.584 mm (0.017 -
0.023 in.), perform to step 7 or step 8.
[b] If the exhaust valve stem clearance is not between 0.584 - 0.736 mm (0.023 - 0.029
in.) for exhaust valves with a machined groove between the rotator and tip, reset the
valve(s) to 0.660 mm (0.026 in.); refer to step 7 or step 8.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-13
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR DAMAGED CAMSHAFT LOBES
AND ROLLERS

[c] If the exhaust valve stem clearance is not between 0.432 - 0.584 mm (0.017 - 0.023
in.) for exhaust valves without a machined groove between the rotator and tip, reset
the valve(s) to 0.508 mm (0.020 in.); refer to section 16.4.1. step 2.

1. Location of IdentiÞcation Groove 5. Locknut

2. Valve Button 6. Exhaust Rocker Arm Assembly
3. Allen Wrench 7. Feeler Gage
4. Adjusting Screw 8. Tip of Exhaust Valve

Figure 16-7 Exhaust Valve Clearance

(Rev. 12/05) All information subject to change without notice.

16-14 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

7. If troubleshooting a DDEC III/IV engine, place the small end of J–39697 in the hole
provided in the injector body, with the ßat of the gage toward the fuel injector plunger;
see Figure 16-8.
[a] If the tool is ßush against the follower, the injector height is acceptable; refer to step 9.
[b] If the tool is not ßush, adjust injector height; refer to section 16.4.1, step 3

1. Height Gage Flag 4. Adjusting Screw

2. Height Gage 5. Locknut
3. 3/16 in. Allen Wrench 6. Fuel Injector Follower

Figure 16-8 Fuel Injector Adjustment

8. If troubleshooting a DDEC I or II engine, place the small end of J–35637–A in the hole
provided in the injector body, with the ßat of the gage toward the fuel injector plunger;
see Figure 16-8.
[a] If the tool is ßush against the follower, the injector height is acceptable; refer to step 9.
[b] If the tool is not ßush, adjust injector height; refer to section 16.4.1, step 3.
9. Bar the engine over, clockwise, until the fuel injector for the next cylinder begins its
downward stroke; see Figure 16-4. Repeat step 5 through step 8 and repeat until all six
fuel injectors and sets of valves have been checked and reset as necessary. When all
cylinders have been checked, refer to section 16.4.1, step 4.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-15
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR DAMAGED CAMSHAFT LOBES
AND ROLLERS

16.4.1 Improper Valve Clearance or Injector Height Repair

Perform the following steps to repair improper fuel injector height, intake valve clearance, and
exhaust valve clearance.

NOTE:
Using the steps below, it will be necessary to bar the engine over only two complete
revolutions. Three cylinders will be adjusted for valves, and three cylinders will be
adjusted for injectors on each revolution.

If required, remove Jake Brake housing necessary to provide access for repair; refer to the
appropriate service manual, engine chapter.

NOTICE:
Never set the valves and injector of the same cylinder at the
same time. Doing this will result in engine damage.

1. Adjust the intake valve clearances as follows:

[a] Insert a 0.203 mm (0.008 in.) feeler gage between the tip of one valve stem and the
valve button; see Figure 16-9.
[b] Loosen the locknut, and turn the adjusting set screw until the feeler gage produces a
snug, smooth pull between the intake valve stem and valve button; see Figure 16-9.

(Rev. 12/05) All information subject to change without notice.

16-16 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION
 SERIES 60 OFF-HIGHWAY SERVICE MANUAL

[c] Torque the locknut to 41 - 47 N·m (30 - 35 lb·ft) and remove the feeler gage. Reinsert
the feeler gage to ensure that the adjustment did not change when the locknut was
tightened. Readjust as necessary.

1. Intake Valve 4. Locknut

2. Valve Button 5. Feeler Gauge
3. Intake Rocker Arm Assembly 6. Tip of Intake Valve

Figure 16-9 Measurement of Intake Valve Clearance

2. Perform the following steps to adjust the exhaust valve clearances:

[a] Insert a 0.660 mm (0.026 in.) feeler gage for valves with a machined groove between
the tip of the valve stem and the valve button. Insert a 0.508 mm (0.020 in.) feeler
gage for valves without machined groove; see Figure 16-7.
[b] Loosen the locknut, and turn the adjusting set screw until the feeler gage produces a
snug, smooth pull between the exhaust valve stem and the valve button.
[c] Torque the locknut to 41 - 47 N·m (30 - 35 lb·ft) and remove the feeler gage. Reinsert
the feeler gage to ensure that the adjustment did not change when the locknut was
tightened. Readjust as necessary.

All information subject to change without notice. (Rev. 12/05)

6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION 16-17
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR DAMAGED CAMSHAFT LOBES
AND ROLLERS

3. Perform the following steps to adjust fuel injector heights.

[a] For DDEC III/IV engines, place the small end of the timing gage (J–39697) in the
hole provided in the fuel injector body, with the ßat of the gage toward the fuel
injector plunger; see Figure 16-3 and proceed to step 3[c].
[b] For DDEC I or II engines, place the small end of the timing gage (J–35637–A) in
the hole provided in the fuel injector body, with the ßat of the gage toward the fuel
injector plunger.
[c] Loosen the locknut and turn the adjusting set screw until the extended part (ßag) of the
gage will just pass over the top of the injector follower. A snug feel is recommended.
The objective is to adjust all six injectors to the same feel; see Figure 16-9.
[d] Torque the locknut to 41 - 47 N·m (30 - 35 lb·ft).
[e] Check the adjustment with J–39697 (DDEC III/IV engines) or J–35637–A (DDEC I
or II engines), and if necessary, readjust the set screw.
4. Install the valve rocker cover(s); refer to the appropriate service manual, engine chapter.
5. Install the Jake Brakes if removed for repair; refer to the appropriate service manual,
engine chapter.
6. Reconnect starting power to the engine.
7. Verify repair of valve clearance or injector height setting. Refer to section 16.4.1.1.

16.4.1.1 VeriÞcation of Repair for Improper Valve Clearance or Injector

Height Setting

Perform the following steps to determine if valve clearance or injector height adjustment resolved
the misÞring cylinder condition:
1. Start the engine.
2. Run the engine at 1000 rpm.
3. Listen for misÞring cylinder.
[a] If the engine is not misÞring, shut down the engine. No further troubleshooting is
required.
[b] If the engine is misÞring, shut down the engine and check for faulty fuel injector;
refer to section 16.5.

(Rev. 12/05) All information subject to change without notice.

16-18 6SE660 0512 Copyright © 2005 DETROIT DIESEL CORPORATION