Visual Inspection

VISUAL INSPECTION

NOTE:

A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made before attempting to diagnose or service the fuel injection system. A visual check will help find these conditions. It also saves unnecessary test and diagnostic time. A thorough visual inspection of the fuel injection system includes the following checks:

PROCEDURE

Battery Disconnect:

1. Be sure that the battery connections are tight and not corroded.

Engine Controller:

2. Be sure that the 60-way connector is fully engaged with the engine controller. Verify that the connector mounting screw is tight.

Air Intake Heater Relays:

3. Be sure that the electrical connections at the air intake heater relays are tight and not corroded.

Starter Motor Connections:

4. Inspect the starter motor and starter solenoid connections for tightness and corrosion.

Charge Air Temp. Sensor And Air Temp. Switch:

5. Verify that the electrical connectors are connected to the charge air temperature sensor and [1][2]air temperature switch. Inspect the connectors for corrosion or damaged wires.

6. Verify that the electrical connector is connected to the [1][2]air temperature switch.

Water In Fuel (WIF) Sensor:

7. Verify that the Water-in-Fuel (WIF) sensor electrical connector is connected to the sensor. Inspect the connector for corrosion or damaged wires.

8. Place a drain pan under the drain tube. With the engine not operating, hold the drain open until all water and contaminants have been removed and clean fuel exits the drain. Dispose of mixture in drain pan according to applicable regulations.

Fuel Solenoid And KSB Solenoid:

9. Verify that the electrical connector is connected to the fuel solenoid on the injection pump. Inspect the connector for corrosion or damage.

10. Verify that the electrical connector is connected to the KSB solenoid on the injection pump. Inspect the connector for corrosion or damage.

Air Intake Heater:

11. Be sure that the air intake heater electrical connections are tight and free of corrosion.

Throttle And Accelerator Cable Linkage:

12. Inspect the throttle linkage and accelerator linkage for binding.

13. Be sure that the throttle return spring is connected.

14. Inspect all fuel lines for signs of leakage.

Ground Strap:

15. Be sure that the ground cable connection at the front of the cylinder head is tight and free of corrosion.

Air Cleaner Element:

16. Inspect the air cleaner element for restrictions.

Intercooler:

17. Be sure that the turbo-charger output hose is connected to the intercooler inlet tube. Verify that the intercooler output hose is connected to the cooler and the intake manifold.

18. Be sure that the vacuum pump-to-brake booster hose is connected and not damaged.