Engine Surges

ENGINE SURGES






Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. Pre-Diagnostic Troubleshooting Procedure

1. DTC/PRODUCT IMPROVEMENT
1. Check for any TSB's related to customer's complaint or DTC's present.
2. Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB.

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 2

2. FUEL SUPPLY SYSTEM
1. Verify proper fuel quality, grade and level in vehicle.
2. Use scan tool to monitor fuel rail pressure. If pressure does not fluctuate more then ± 500 psi of set point than the fuel system is not the cause of the complaint. Proceed to step3. If condition exist continue.
3. Verify proper low pressure supply to the Injection Pump by performing the IN-TANK FUEL LIFT PUMP FLOW TEST - DIESEL Procedure.
4. Use the HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL to check for failed fuel pump.
5. Perform CHECKING PRESSURE LIMITING VALVE PRESSURE LIMITING VALVE ON THE FUEL - DIESEL.

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 3

3. INJECTION SYSTEM
1. Perform INJECTOR RETURN FLOW TEST. If okay continue. Injector Return Flow Test
2. Check for correct injectors and injector shims.
3. Visually inspect injector wire nuts and pass through connectors for damage or corrosion.

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 4

4. FUEL RETURN
1. Check for kinked or restricted fuel return lines.
2. Check fuel tank venting.

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 5

5. INTAKE SYSTEM
1. Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.
2. Check for air system leaks. Perform INTAKE AIR SYSTEM PRESSURE TEST - DIESEL. Intake Air System Pressure Test
3. Inspect Turbocharger for wheel clearance and proper wastegate operation.

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 6

6. OTHER VEHICLE SYSTEMS
1. Verify proper operation of the Transmission Clutch.
2. Verify proper operation of the Transmission.
3. Verify proper operation of the Vehicle brakes (check for dragging).
4. Verify proper operation of the Cooling fan operation cycle time.
5. Verify proper operation of the Engine driven accessories.
6. Verify proper operation of the Accelerator pedal (restricted or out of calibration).

Is vehicle repaired?

Yes

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test

No

- Go To 7

7. BASE ENGINE
1. Inspect speed indicator ring for damaged/missing teeth.
2. Check for internal engine damage.

Repair Complete.

Repair

- Repair complete.
- Perform the ECM VERIFICATION TEST. Powertrain Verification Test