Steps 1 - 5
Hard Start/No Start Diagnostic Procedures
1. Visual Engine/Chassis Inspection
Purpose:
Visual Engine/Chassis Inspection:
This is a visual inspection to check the general condition of the engine and lock for obvious causes of hard start or no start conditions.
Recommended Procedure:
Inspect fuel system including fuel tank and fuel lines for kinks, bends and/or leakage. Check oil lines and high pressure pump in engine V for major oil leaks. Inspect for coolant leaks at radiator and heater hoses and check coolant level. Inspect MAP sensor and intercooler for pinched hoses and leaks. Inspect wiring for correct routing and make sure no rubbing or chafing has occurred. Inspect the in-line 42-way, Injector Driver Module (IDM), Powertrain Control Module (PCM) and sensor connectors to make sure they are completely seated and in good condition.
Possible Causes:
^ Loose or leaking fuel supply lines could cause fuel system to lose prime.
^ Kinked or blocked fuel supply lines will create fuel restriction.
^ Massive fuel or oil leaks could contribute to no start conditions.
^ Coolant leaks could indicate serious engine problems.
^ Electronic connectors may be damaged or not installed properly causing a no start condition. The Camshaft Position (CMP) sensor and the Injection Pressure Regulator (IPR) are the two most critical electronic sensors/actuators to inspect in no start situations.
^ Pinched or open MAP sensor hose.
^ Pinched or open intercooler hose.
Tools Required:
Inspection light
2. Check Engine Oil Level
Purpose:
Check Engine Oil Level:
To determine if there is enough oil or oil of sufficient quality to operate the injectors.
Recommended Procedure:
Check oil level with dipstick when vehicle is on level ground. If there is no oil or very little oil in the crankcase, the injectors will not operate.
If the oil level on the dipstick is overfull it is possible the engine was incorrectly serviced or fuel/coolant is diluting the oil and filling the crankcase. Usually, if a substantial amount of fuel is in the oil, it will have a fuel odor.
Inspect oil for color. A milky white oil indicates possible coolant contamination and will have an ethylene glycol odor.
Check service records for correct oil type and viscosity for the vehicle operating temperature. Single weight or 15W-40 oil is not recommended for cold ambient temperatures. 10W-30 oil is recommended for cold ambient temperatures. Oil that has had extended drain intervals will have increased viscosity (become thicker) and will make engine cranking more difficult and starting less reliable at temperatures below freezing. Refer to the lube oil chart in the Owner's Guide for the correct oil selection for temperature conditions.
The level in the oil reservoir should also be checked. Remove the inspection plug in top of reservoir and check to see if the oil reservoir is full. (A reservoir that drains back after the engine has not been operated for a period of time can cause a hard start and die condition.) Filling the reservoir will allow the system to prime faster facilitating starting. If a drainback condition is present, determine cause and repair as necessary.
Possible Causes:
^ Loss of lube oil pressure
^ Oil level low - oil leak, oil consumption, incorrect servicing
^ Oil level high - incorrect servicing, fuel dilution from tandem fuel pump, fuel dilution from injector O-rings
^ Oil contamination with coolant - oil cooler, head gasket, porosity
^ Low reservoir level - engine built dry (not pressure lubed), prolonged period of not running, excessive cranking without starting
Tools Required:
1/4-inch drive ratchet or breaker bar to remove inspection plug
3. Intake/Exhaust Restriction
Purpose:
Intake/Exhaust Restriction:
This is a visual inspection to determine if an air intake or exhaust restriction is contributing to a no start or hard start condition. If the engine does start with a high air intake or exhaust restriction, a considerable amount of black/blue smoke is produced.
Recommended Procedure:
Inspect the air cleaner inlet and ducting to assure that it is not blocked or collapsed. Inspect the air cleaner housing and filter for proper installation. Inspect the filter minder to assure intake restriction is below the red marks.
Inspect the exhaust back pressure device bellcrank during cranking and assure that it is not closing. Inspect the exhaust system for damaged or blocked pipes. When the tang is against the stop, the valve is fully open.
Possible Causes:
^ Snow, plastic bags or other foreign material may restrict airflow at the air inlet.
^ Misrouted air cleaner ducting.
^ On engines recently repaired, rags or cap plugs may have been inadvertently left in an air inlet pipe.
^ Exhaust back pressure device may be closing during cranking or stuck closed.
^ Tailpipe or muffler may have collapsed or been damaged.
Tools Required:
None
4. Sufficient Clean Fuel
Purpose:
Sufficient Clean Fuel:
The purpose of this test is to see if the fuel system is getting sufficient clean fuel to start and run.
Recommended Procedure:
Route a hose from the fuel drain line to a clear container and open the drain. When the key is turned to the on position, the fuel pump will run for 20 seconds. Turn the key on and observe the fuel flowing into the container. Turn the key off when the container is half full.
Observe the WATER IN FUEL lamp. If the lamp is illuminated, the fuel is probably contaminated with water.
Flow out of the drain should be a steady stream. Insufficient flow could indicate fuel supply or fuel system problems.
Inspect fuel in the container. It should be clear, not cloudy. It also should be free of water and contaminants.
If engine oil is present in the fuel it may indicate an injector O-ring leak and subsequent loss of rail pressure. If that is suspected, check rail pressure during engine cranking (Hard Start/No Start Diagnostic Procedures Step 9C).
Some sediment and water may be present in the fuel sample if the fuel filter has not been serviced for a prolonged period of time and/or if the sediment and water have not been drained recently. If that is the case, a second sample may be required to determine fuel quality.
Possible Causes:
^ No fuel in tank.
^ Fuel supply line could be broken or crimped.
^ Fuel could be jelled (most likely in cold weather with No.2 fuel).
^ Pickup tube screen in tank could be clogged.
Cloudy fuel indicates that the fuel may not be a suitable grade for cold temperatures; excessive water or contaminants may indicate that the tank and fuel system may need to be flushed and cleaned.
Tools Required:
Clear container - approximately 0.95L (1-quart)
5. Electric Fuel Pump Pressure
Purpose:
Electric Fuel Pump Pressure:
To determine if there is sufficient fuel pressure for starting.
Recommended Procedure:
First verify that there is fuel in the tank and battery voltage going to the fuel pump, using a digital multimeter connected between the two circuits going to the pump. Battery voltage will be present for approximately 20 seconds after the ignition key is turned on. If no voltage is present, GO to Pinpoint Test FK. Tests FK: Fuel Pump Monitor/Control
E-Series
Remove the doghouse cover and remove the 1/8-inch pipe plug from the top rear of left head. Install Gauge 0-1.1 MPa (0-160 psi) Bar 014-00761 or equivalent. Measure pressure in crank or run. If pressure measures below specification 310 kPa (45 psi), perform test step 8a in Performance Diagnostic Procedures. Performance Diagnostic Procedures
F-Series
Remove the 1/8-inch pipe plug from the top front of the right head. Install Gauge 0-1.1 MPa (0-160 psi) Bar 014-00761 or equivalent. Measure pressure in crank or run. If pressure measures below specification 310 kPa (45 psi), perform test steps 8a-d in Performance Diagnostic Procedures. Performance Diagnostic Procedures