Engine Surges

*ENGINE SURGES







Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.

Diagnostic Test


1. DTC/PRODUCT IMPROVEMENT

Check for any TSB's related to customer's complaint or DTC's present.

Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB.

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 2


2. FUEL SUPPLY SYSTEM

Verify proper fuel quality, grade and level in vehicle.

Use scan tool to monitor fuel rail pressure. If pressure does not fluctuate more then ± 500 psi of setpoint than the fuel system is not the cause of the complaint. Proceed to step3. If condition exist continue.

Verify proper low pressure supply to the Injection Pump by performing the "*IN-TANK FUEL LIFT PUMP FLOW TEST - DIESEL" Procedure. In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure

Use the "*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL" to check for failed fuel pump.

Perform "*CHECKING PRESSURE LIMITING VALVE ON THE FUEL - DIESEL". Pressure Limiting Valve Test

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 3

3. INJECTION SYSTEM

Perform "*INJECTOR RETURN FLOW TEST". Injector Return Flow Test

If okay continue.

Check for correct injectors and injector shims.

Visually inspect injector wire nuts and pass through connectors for damage or corrosion.

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 4

4. FUEL RETURN

Check for kinked or restricted fuel return lines.

Check fuel tank venting.

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 5

5. INTAKE SYSTEM

Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.

Check for air system leaks. Perform "*INTAKE AIR SYSTEM PRESSURE TEST - DIESEL". Intake Air System Pressure Test

Inspect Turbocharger for wheel clearance and proper wastegate operation.

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 6

6. OTHER VEHICLE SYSTEMS

Verify proper operation of the Transmission Clutch.

Verify proper operation of the Transmission.

Verify proper operation of the Vehicle brakes (check for dragging).

Verify proper operation of the Cooling fan operation cycle time.

Verify proper operation of the Engine driven accessories.

Verify proper operation of the Accelerator pedal (restricted or out of calibration).

Is vehicle repaired?

Yes

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test

No

- Go To 7

7. BASE ENGINE

Inspect speed indicator ring for damaged/missing teeth.

Check for internal engine damage.

Repair Complete.

Repair

- Repair complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test