Steps 8 - 13

PERFORMANCE DIAGNOSTIC PROCEDURES

8. Exhaust Gas Recirculation (EGR) System Test

Purpose:
The purpose of this test is to make sure the EGR system is operating correctly.

EGR System Test
- Check the EGR actuator connectors.
- Check the EGR actuator circuitry.

Fuel Oil Coolant Electrical Hoses Leaks:

Recommended Procedure:
- Connect the scan tool.
- Engine at operating temperature.
- Key ON, engine OFF.
- Refer to the scan tool operating manual for instructions.
- Access the EGR System Test on the scan tool.
- Carry out the EGR System Test and follow the directions on the scan tool.
- If there are no DTCs present, all tests pass and all PIDs displayed are in range (may appear as green on the scan tool), the system is operating correctly at this time. Clear the DTCs, repeat the self-test.
- If any of the tests do not pass, refer to the pinpoint test that corresponds to the PID that is out of range (may appear as red on the scan tool).

Possible Causes:
- EGR flow related components and circuitry
- PCM

Tools Required:
Scan tool

9. Exhaust Restriction

Purpose:
The purpose of this test is to determine if an exhaust system restriction is causing a performance problem.

Exhaust Restriction

Exhaust Restriction:

- Visually inspect exhaust system for damage.
- Monitor the EP PID with scan tool and the engine temperature greater than 70°C (158°F) at 3,800 rpm with the vehicle in PARK/NEUTRAL.

Recommend Procedure:
Connect the Gauge 0-1,100 kPa (0-160 psi) Bar 014-00761 or equivalent. Access and monitor the RPM PIDS.
- Run engine at 3,800 RPM.
- Record the exhaust gauge pressure value.
- A low RPM or an exhaust pressure greater than 234 kPa (34 psi) indicates a restricted exhaust condition.

Possible Causes:
- Collapsed tail pipe
- Clogged tail pipe
- Clogged catalytic converter
- Damaged muffler
- Turbocharger

Tools Required:
Gauge 0-1,100 kPa (0-160 psi) Bar 014-00761 or equivalent.
Scan tool

10a. Fuel System Delivery

WARNING: AVOID CONTACT WITH FUEL DURING A VISUAL INSPECTION FOR FUEL LEAKS WITH THE ENGINE RUNNING. DO NOT WORK ON THE FUEL SYSTEM UNTIL THE PRESSURE HAS BEEN RELEASED AND THE ENGINE HAS COOLED. FUEL IN THE HIGH-PRESSURE FUEL SYSTEM IS HOT AND UNDER VERY HIGH PRESSURE. HIGH-PRESSURE FUEL MAY CAUSE CUTS AND CONTACT WITH HOT FUEL MAY CAUSE BURNS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

WARNING: WHEN HANDLING FUEL, ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS AND BE PREPARED IN THE EVENT OF FUEL SPILLAGE. SPILLED FUEL MAY BE IGNITED BY HOT VEHICLE COMPONENTS OR OTHER IGNITION SOURCES. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

Note: The Flow Tester, Diesel Fuel 310-193 or equivalent provides a pressure reading while simulating maximum fuel consumption at wide open throttle (WOT) and full load on the fuel system. The Flow Tester, Diesel Fuel 310-193 or equivalent uses a 1.193 mm (0.047 in) calibrated orifice integrated in the tool assembly to simulate the fuel consumption.

Note: Make sure the battery voltage is greater than 12.5 volts at all times throughout this procedure. Fuel pumps will not pass the fuel delivery tests if the battery voltage drops below 12.5 volts during the fuel flow tests. This is especially important if the test is carried out on a non-running vehicle because there are significant electrical loads when operating the fuel pump with the engine off. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Symptom Chart to continue diagnosis.

Purpose:
The purpose of this test is to verify the fuel system pressure and flow.

Fuel System Delivery

Fuel System Delivery Recommended Procedure:

Note: Restrictions in the fuel line may cause continuous aeration.
- Verify there is fuel in the tank.
- Verify the fuel temperature is above 0 �C or 32 �F to prevent testing with gelled fuel. Check for sufficient clean fuel, carry out the Sufficient Clean Fuel test in this section.
- Make sure the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is closed.
- Remove the test port plug from the front of the secondary fuel filter housing. Install the Flow Tester, Diesel Fuel 310-193 or equivalent using two new copper gaskets to seal the banjo bolt and torque to 27 Nm (20 lb-ft).

- Insert the heavy duty black end of the clear yellow hose into the fuel tank filler pipe to drain the fuel into the fuel tank. Make sure the fuel return hose is not pinched or restricted. Do not substitute any other fuel return hose and do not change the hose length of 6.7 m (22 ft) clear yellow hose with 0.91 m (3 ft) heavy duty black hose end or the internal diameter (ID) of 6.35 mm (0.25 in). The heavy duty black end on the hose is used to reduce pinching between the fuel filler door and the vehicle body.
- Start the engine and let it idle.
- Open the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent.
- Run the engine until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks.
- Verify the battery voltage is greater than 12.5 volts. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Charging System, Symptom Chart to continue diagnosis.
- Record the indicated fuel pressure while the valve is open and fuel is flowing back to the fuel tank.
If the fuel pressure meets the specification, no concern is present at this time.

If the fuel pressure is below the specification, carry out the Fuel Conditioning Module Pressure test in this section.

If the fuel pressure is above the specification, check the fuel return lines for a restriction. If no restriction is present, install a new fuel pressure regulator valve.

Possible Causes:
- Fuel return line restriction
- Fuel pressure regulator valve

Tools Required:

Flow Tester, Diesel Fuel 310-193 or equivalent

Fuel Conditioning Module Pressure
Purpose:

The purpose of this test is to verify that the fuel filters are not restricted.

Fuel Conditioning Module Pressure

Measure the fuel conditioning module outlet fuel system pressure between the fuel conditioning module and the secondary fuel filter.

Use the Flow Tester, Diesel Fuel 310-193 or equivalent to simulate maximum fuel consumption.

Plug the vehicle's fuel return line to isolate the fuel pressure regulator valve.

Fuel Conditioning Module Pressure test Recommended Procedure:

Note: Restrictions in the fuel line may cause continuous aeration.
- Make sure the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is closed.
- Flow Tester, Diesel Fuel 310-193 or equivalent connected.
- Using the male and female tool plugs included with the Flow Tester, Diesel Fuel 310-193 or equivalent, plug the fuel return line between the secondary fuel filter and the fuel conditioning module. Plug the fuel conditioning module fuel return inlet port.
- Install the Fuel Pump Adapter 310-111 or equivalent with the Gauge 0-1,100 kPa (0-160 psi) Bar (part of DSL ENG Pressure Test Kit 014-00761 or equivalent) between the fuel conditioning module outlet port and the fuel supply line leading to the secondary fuel filter.

- Start the engine and let it idle.
- Open the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent.
- Run the engine until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks.
- Verify the battery voltage is greater than 12.5 volts. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Charging System, Symptom Chart to continue diagnosis.
- Record the maximum fuel pressure at the fuel conditioning module outlet while the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is open and fuel is flowing back to the fuel tank.

If the fuel pressure at the fuel conditioning module outlet is below the 344 kPa (50 psi) MIN specification and new primary or secondary fuel filters have not been installed, install new primary and secondary fuel filters. Repeat the Fuel Conditioning Module Pressure test in this section to verify the repair.

If the Fuel Conditioning Module Pressure test has been repeated and the fuel pressure at the fuel conditioning module outlet now meets the 344 kPa (50 psi) MIN specification, remove the fuel return line plugs and connect the fuel return line. Repeat the Fuel System Delivery test in this section to verify the repair.

If the Fuel Conditioning Module Pressure test has been repeated and the fuel pressure at the fuel conditioning module outlet is still below the 344 kPa (50 psi) MIN specification, carry out the Electric Fuel Pump Inlet Restriction test in this section.

If the fuel pressure at the fuel conditioning module outlet is equal to or greater than the 344 kPa (50 psi) MIN specification, carry out the Restricted Secondary Fuel Filter test in this section.

Possible Causes:

- Primary fuel filter
- Secondary fuel filter

Tools Required:

Flow Tester, Diesel Fuel 310-193 or equivalent
Fuel Pump Adapter 310-111 or equivalent
Gauge 0-1,100 kPa (0-160 psi) Bar (part of DSL ENG Pressure Test Kit 014-00761 or equivalent)

Restricted Secondary Fuel Filter
Purpose:

The purpose of this test is to determine the condition of the secondary fuel filter.

Restricted Secondary Fuel Filter

Measure the fuel pressure difference between the fuel inlet and fuel outlet sides of the secondary fuel filter.

Restricted Secondary Fuel Filter test Recommended Procedure:

Note: Restrictions in the fuel line may cause continuous aeration.
- Make sure the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is closed.
- Flow Tester, Diesel Fuel 310-193 or equivalent connected.
- Fuel Pump Adapter 310-111 or equivalent with Gauge 0-1,100 kPa (0-160 psi) Bar (part of DSL ENG Pressure Test Kit 014-00761 or equivalent) connected.
- Male and female tool plugs included with the Flow Tester, Diesel Fuel 310-193 or equivalent installed between the secondary fuel filter and the fuel conditioning module. Fuel conditioning module fuel return inlet port plug installed.
- Start the engine and let it idle.
- Open the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent.
- Run the engine until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks.
- Verify the battery voltage is greater than 12.5 volts. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Charging System, Symptom Chart to continue diagnosis.
- Record the indicated fuel pressure difference while the valve is open and fuel is flowing back to the fuel tank.

If the fuel pressure difference is greater than the specification, install new primary and secondary fuel filters.

If the fuel pressure difference is within the specification, install a new fuel pressure regulator valve.

Remove the fuel return line plugs and connect the fuel return line to the fuel conditioning module, repeat the Fuel System Delivery test in this section to verify the repair.

Possible Causes:

- Secondary fuel filter
- Fuel pressure regulator valve

Tools Required:

Flow Tester, Diesel Fuel 310-193 or equivalent
Fuel Pump Adapter 310-111 or equivalent
Gauge 0-1,100 kPa (0-160 psi) Bar (part of DSL ENG Pressure Test Kit 014-00761 or equivalent).

10b. Electric Fuel Pump Inlet Restriction

WARNING: AVOID CONTACT WITH FUEL DURING A VISUAL INSPECTION FOR FUEL LEAKS WITH THE ENGINE RUNNING. DO NOT WORK ON THE FUEL SYSTEM UNTIL THE PRESSURE HAS BEEN RELEASED AND THE ENGINE HAS COOLED. FUEL IN THE HIGH-PRESSURE FUEL SYSTEM IS HOT AND UNDER VERY HIGH PRESSURE. HIGH-PRESSURE FUEL MAY CAUSE CUTS AND CONTACT WITH HOT FUEL MAY CAUSE BURNS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

WARNING: WHEN HANDLING FUEL, ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS AND BE PREPARED IN THE EVENT OF FUEL SPILLAGE. SPILLED FUEL MAY BE IGNITED BY HOT VEHICLE COMPONENTS OR OTHER IGNITION SOURCES. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

Note: The Flow Tester, Diesel Fuel 310-193 or equivalent provides a pressure reading while simulating maximum fuel consumption at wide open throttle (WOT) and full load on the fuel system. The Flow Tester, Diesel Fuel 310-193 or equivalent uses a 1.193 mm (0.047 in) calibrated orifice integrated in the tool assembly to simulate the fuel consumption.

Note: Make sure the battery voltage is greater than 12.5 volts at all times throughout this procedure. Fuel pumps will not pass the fuel delivery tests if the battery voltage drops below 12.5 volts during the fuel flow tests. This is especially important if the test is carried out on a non-running vehicle because there are significant electrical loads when operating the fuel pump with the engine off. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Charging System, Symptom Chart to continue diagnosis.

Purpose:

To detect concerns with the fuel conditioning module inlet, fuel filters or fuel pump.

Electric Fuel Pump Inlet Restriction

Measure the fuel inlet vacuum on the fuel tank side of the fuel conditioning module.

Recommended Procedure:

Note: Restrictions in the fuel line may cause continuous aeration.

- Verify there is fuel in the tank.
- Verify the fuel temperature is above 0 �C or 32 �F to prevent testing with gelled fuel. Check for sufficient clean fuel, carry out the Sufficient Clean Fuel test in this section.
- Make sure the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is closed.
- Remove the test port plug from the front of the secondary fuel filter housing. Install the Flow Tester, Diesel Fuel 310-193 or equivalent using two new copper gaskets to seal the banjo bolt and torque to 27 Nm (20 lb-ft).

- Using the male and female tool plugs included with the Flow Tester, Diesel Fuel 310-193 or equivalent, plug the fuel return line between the secondary fuel filter and the fuel conditioning module. Plug the fuel conditioning module fuel return inlet port.
- Start the engine and let it idle.
- Open the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent.
- Run the engine until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks.
- Verify the battery voltage is greater than 12.5 volts. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to Charging System, Symptom Chart to continue diagnosis.
- Record the indicated vacuum reading while the valve is open and fuel is flowing back to the fuel tank.

If the vacuum reading is greater than the specification, correct the restriction between the fuel tank pickup and the fuel conditioning module, remove the fuel return line plugs and connect the fuel return line. Repeat the Fuel System Delivery test in this section to verify the repair.

If the vacuum reading is within the specification, check the primary fuel filter. If the primary fuel filter is OK, install a new fuel conditioning module, refer to the workshop manual section 310-01, Fuel Tank and Lines, Fuel Conditioning Module. Remove the fuel return line plugs, connect the fuel return line and repeat the Fuel System Delivery test in this section to verify the repair.

Possible Causes:

- Fuel supply line restriction
- Fuel conditioning module
- In tank fuel pickup

Tools Required:

Flow Tester, Diesel Fuel 310-193 or equivalent
Fuel Pump Adapter 310-111 or equivalent
0-30 in-Hg Vacuum Gauge (part of DSL ENG Pressure Test Kit 014-00761 or equivalent)

10c. Fuel Aeration Test

Purpose
To determine if the fuel is aerated and causing a poor idle condition.

Fuel Aeration Test

Fuel Aeration Test:

Install a clear hose on the fuel return line at the fuel conditioning module.

Refer to Engine.

Run at the engine at WOT for 2 minutes.

Return fuel should be free of bubbles.

1. Remove the fuel return line at the fuel conditioning module.
2. Attach a 1/4-inch diameter hose (clear) to the fuel conditioning module and place the other end of the hose into Rotunda tool 034-00005 or the equivalent.
3. Turn the ignition on. The fuel pump will cycle on, then off. Diesel fuel may not flow out through the attached hose after only one key cycle. Repeat the key cycle until fuel flows from the attached hose.
4. Start the engine.
5. Run at WOT for 2 minutes. Return fuel should be free of bubbles.
6. If the fuel has air in it, the fuel returning to the tank will appear white, foamy or non-transparent. If no or very little air is present in the fuel, the fuel will appear clear/transparent.
7. If air is present in the return fuel, inspect the fuel system for leaks.

Possible Causes:

NOTE: Air can enter the fuel system at any point where there is suction in the fuel system.

- Fuel pickup in the fuel tank
- Fuel supply line entering the fuel module from the fuel tank
- Fuel return line entering the fuel module from the engine

Tools Required:
Rotunda tool 034-00005 or equivalent

11. Perform KOER On-Demand Self Test

Purpose:
The purpose of this test is to determine if the PCM has detected any fault conditions that would cause a performance problem while the engine is running. The KOER self-test will perform step tests on the injection control pressure system and the exhaust back pressure system.

Step tests are PCM controlled tests where the PCM commands a specific exhaust back pressure or injection control pressure and then measures the result. If a predetermined threshold is not reached, a DTC will be generated. This test can be performed at any engine temperature.

Perform KOER On-Demand Self Test

KOER On-Demand Self Test:

NOTE: Before performing the KOER On-Demand Self-Test make sure the high-pressure oil passages are free of air. A recent repair to the system may allow air to enter the oil passages. To remove the air, drive the vehicle (with deceleration and acceleration cycles) at highway speeds for 32 km (20 miles).

- The self-test will verify the ICP, EGR and VGT systems performance.

Recommended Procedure:

NOTE: Engine will run rough during this test.

Connect the scan tool. Turn off all accessories. If the vehicle is equipped with an auxiliary powertrain control module (APCM), it must be turned off to perform the self-test.
- Perform the necessary vehicle preparation and visual inspection. Refer to Quick Test Operation. Quick Test Operation
- Refer to the scan tool operating manual for instructions.
- Key on, engine running.
- Follow the operating instructions from the diagnostic menu.
- Perform a KOER On Demand Self-Test. Key On Engine Running (KOER) On-Demand Self Test
- Record the DTCs and refer to the appropriate pinpoint test.

Tools Required:
Scan tool

12a. Low Idle Stability (ICP Pressure)

Purpose:
The purpose of this test is to determine if idle stability or low power is caused by a stuck or dirty IPR or faulty ICP signal.

Low Idle Stability (ICP Pressure)

Low Idle Stability (ICP Pressure):

- Check at low idle and EOT above 70°C (158°F)
- Monitor the ICP and RPM PIDS with the scan tool.

If engine rpm is unstable, disconnect the ICP sensor.
- ICP will default to 5.0 MPa (725 psi) when disconnected.
- If rpm smooths out, the ICP sensor is suspect.
- If rpm is still unstable, reconnect the ICP sensor and GO to 12b.

Recommended Procedure:

NOTE: The engine must be at operating temperature.

- Connect the scan tool.
- Key on, engine running.
- Access and monitor the ICP and RPM PIDS.
- Operate the engine at 670 RPM.

If engine does not stabilize, disconnect the ICP sensor. If low idle speed stabilizes with the ICP sensor disconnected, the problem is most likely in the ICP sensor circuit. GO to Pinpoint Test Q. Test Q If RPM does not stabilize, reconnect the sensor and GO to 12b.

Possible Causes:
- Debris stuck in the IPR
- ICP sensor
- Circuitry

Tools Required:
Scan tool

12b. Injection Pressure Regulator Test

Purpose:
The purpose of this test is to determine if idle stability or low power is caused by a stuck or dirty IPR.

Low Idle Stability (ICP Pressure)

Low Idle Stability (ICP Pressure):

- Check at low idle and EOT above 70°C (158°F)
- Monitor the IPR PID with the scan tool.

Recommended Procedure:

NOTE: The engine must be at operating temperature.

- Connect the scan tool.
- Key on, engine running.
- Access and monitor the IPR and RPM PIDS.
- Operate the engine at 670 RPM.

If the IPR duty cycle is less than the MAX specification, go to the next step. If the IPR duty cycle is greater than the MAX specification, GO to Test 10e of the Hard Start/No Start Diagnostics No-Start Testing and check for an injection control system leak.

Possible Causes:
- Debris stuck in the IPR
- Injection control system leak

Tools Required:
Scan tool

13. Boost Pressure Test

Purpose:
The purpose of this test is to determine if the engine can develop sufficient boost to obtain specific power.

Boost Pressure Test

- Carefully inspect the intercooler tubes/connections, turbocharger connections, and MAP hose for signs of damage or leaks.
- Carry out the boost pressure test at 1,200 RPM.
- Monitor the EGR duty cycle, MGP, RPM, and VGT duty cycle PIDS with the scan tool.
- Control the engine speed to 1,200 RPM and EGR duty cycle to 0% with the scan tool.
- Control the VGT duty cycle to 0% and 85% with the scan tool.

Recommended Procedure:

NOTE: If test fails, go to Pinpoint Test KA. Tests KA

Boost pressure will level out after 3,300 rpm. This is best accomplished either climbing a hill or with the vehicle fully loaded.
- Key on, engine running.
- Access and monitor the MGP, EGR_DC, RPM, and VGTDC PIDS.
- Control the RPM_DSD PID to 1,200 RPM and EGRDC PID to 0%.
- Degrease the VGTDC PID to 0% and record the MGP PID value.
- Increase the VGTDC PID to 85% and record the MGP PID value.
- Decrease the VGTDC PID to 0% and record the MGP PID value.

If the MGP PID values are within specifications, go to the next step. If the MGP PID values are not within specifications, GO to Pinpoint Test KA. Tests KA

Possible Causes:
- MAP hose pinched or open
- Leaking intake, hoses or fittings
- Leaking exhaust system
- Turbocharger
- Base engine
- Intercooler hoses leaking
- Intercooler
- EGR sticking

Tools Required
Scan tool