Visual Inspection

A visual inspection for loose, disconnected, damaged, or misrouted wires and/or hoses should be made prior to diagnosing or servicing the fuel injection system. A thorough visual inspection will help find these faults and save unnecessary testing and diagnostic time.

VISUAL INSPECTION

1. Check that the battery connections are clean, tight, and not corroded.

Battery Connections:

2. Check that the 60-way engine controller electrical connector is fully pressed into the engine controller, and that the connector mounting screw is tight.

Single Board Engine Controller (SBEC):

3. Check that the connectors at the air intake heater relays are tight and not corroded.

Air Intake Heater Relays:

4. Check that the starter motor and solenoid electrical connections are tight and not corroded.

Starter Motor Connections:

5. Check that the electrical connectors are properly connected to the charge air temperature sensor and the [1][2]air temperature switch. Check that there is no corrosion in the connectors and that the wires are not damaged.

CAT Sensors And Air Temperature Switch:

6. Check that the WATER-IN-FUEL electrical connector is connected to the sensor. Check that the WATER-IN-FUEL connector has no damaged wires or corrosion.

Water-In-Fuel (WIF) Sensor:

7. Place a drain pan under the drain tube from the water/fuel separator. With the engine not running, hold the drain valve open until all water and contaminants have been removed and clean fuel exits the drain. Dispose of contents in drain pan according to applicable regulations.

Water-In-Fuel (WIF) Sensor:

8. Check that the fuel solenoids electrical connector is securely attached to the fuel solenoid on the injection pump. Check that there is no corrosion or damaged wires.

Fuel Solenoid And KSB Solenoid:

9. Check that the KSB solenoids electrical connector is securely attached to the KSB solenoid on the injection pump. Check that there is no corrosion or damaged wires

Fuel Solenoid And KSB Solenoid:

10. Check that the air intake heater electrical connections are tight and free of corrosion.

Air Intake Heater:

11. Check that the throttle and accelerator linkage aren't binding. Check that the throttle return spring is connected.

Throttle And Accelerator Cable Linkage:

12. Inspect all fuel lines for signs of damage, restriction, or leakage.



13. Check that the ground cable mounted at the front of the cylinder head is tight and not corroded.

Ground Strap:

14. Inspect the air cleaner element for restrictions.

Air Cleaner Element:

15. Check that the turbo-charger output hose is securely attached to the intercooler inlet tube and the turbo-charger. Check that the intercooler output hose is securely attached to the cooler and the intake manifold.

Intercooler:

16. Check that the power brake vacuum hose is securely attached to the vacuum pump and that it is not leaking.
17. Check that the accessory belt that drives the vacuum pump is not slipping or damaged.
18. Check that the throttle position sensors 3-way electrical connector is fully pushed into the sensor. Check that there is no corrosion or damaged wires.

Throttle Position Sensor:

19. Check distance (speed) sensor's 2-way electrical connection for proper installation.
20. Check neutral/safety switch for proper installation (Automatic Transmission only).
21. Check the torque converter lockup solenoid electrical connection (Automatic Transmission).
22. If vehicle has overdrive, check that the overdrive solenoid electrical connection is completely pushed into the solenoid (Automatic Transmission).

Transmission Electrical Connections (4 Speed Overdrive):

Transmission Electrical Connections: