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24 Valve, 8.3 Liter Engine

1. Cause Correction Fiel inecion pimpismaltindioninae aean Check CAPS accumulator pressure Refer to pump 9 Procedure 005 077 OK LI EIO l ae Perform ICV solenoid click test Refer to Procedure Fuel injection pump is malfunctioning posees 005 078 LI Waaa ae Perform CAPS plunger cut out test Refer to Procedure Fuel injection pump is malfunctioning potee 005 079 LI E i ae Check for seized distributor rotor Refer to Procedure Fuel injection pump is malfunctioning treet 005 072 J Fill injection pum is miattindionings eie a pump to engine timing Refer to Procedure 005 oe Check the CAPS coupling for wear or failure Refer to Procedure 005 072 ae ee Replace the fuel injection pump Refer to Procedure 005 012 or 005 014 or 005 016 ae Need Check the camshaft tonewheel for tightness Refer to Procedure 001 008 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 29 Engine Difficult to Start or Will Not Start No Exhaust Smoke Continued Cause Correction Disconnect the battery cables for 30 seconds Eeron onkol Modu ECM 5 haked up Connect the battery cables and start the engine Replace the ECM Refer to Procedure 019 031 in the Electronic Control Module ECM is malfunctioning Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines internal enone d n as Analyze the oil and inspect the filters to locate an a
2. 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 83 Intake Manifold Air Temperature Above Specification Continued Cause Correction d Check the fan drive and controls Refer to Procedure Fan drive or fan controls are malfunctioning 008 027 Check the intake manifold pressure sensor Refer to Procedure 019 061 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Verify that the engine and vehicle cooling systems are using the correct components Fan is not an adequate size for the application Verify that the fan is the correct size Intake manifold temperature gauge is malfunctioning if Test the temperature gauge Refer to the vehicle equipped service manual 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 84 Troubleshooting Symptoms Low Idle Adjust Switch Does Not Work This is symptom tree T099 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes The idle adjust switch will not adjust the idle speed outside of the allowable range Refer to Section 1 Operating Instructions Engine idle speed is set at either the minimum or the maximum allowable value Check the idle adjust switch and circuit Refer to Procedures 019 052 and 019 053 in the Fuel Systems Troublesh
3. Check the static injection fiming Refer to Procedure 006 025 or 005 037 Check CAPS accumulator pressure Refer to Procedure 005 077 Perform ICV solenoid click test Refer to Procedure 005 078 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 48 Troubleshooting Symptoms Engine Runs Rough at Idle Continued Cause Correction Fuel iniectioninumo is malfunctioning gt aeei Remove and inspect the rate shape snubber valve pump 9 Refer to Procedure 006 056 OK LI Fuel injection pump is malfunctioning eses oe pump to engine timing Refer to Procedure 005 LI scat oia PER Replace the fuel injection pump Refer to Procedure Fuel injection pump is malfunctioning potee 005 012 or 005 014 or 005 016 moter Check the camshaft tonewheel for tightness Refer to Procedure 001 008 nemaienthedamagess eanet Analyze the oil and inspect the filters to locate an area g g of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 49 Engine Runs Rough or Misfires This is symptom tree T062 Cause Correction Allow the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal symptom tree Engine is cold sd tt tt ees OK ee Refer to Section TF in the Fuel Systems Electronic fault codes
4. Electronic fault codes active or high counts of inactive fault codes View the fault codes and the engine protection data with an electronic service tool Refer to the Engine protection fault code s resulted in power and appropriate electronic service tool user s manual engine speed derate Refer to the corresponding fault code in Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engine Check the time limit on idle and PTO shutdown with an Idle shutdown or PTO shutdown features are activated electronic service tool Refer to the appropriate electronic service tool user s manual Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Moisture in the wiring harness connectors f eee Dry the connectors with an electronic contact cleaner i 7 Isolate the engine protection system Follow the E tect te functi RNR ogy eee vehicle service manual to check for a malfunction Key switch circuit is malfunctioning Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 54 Troubleshooting Symptoms Engine Shuts Off Unexpectedly or Dies During Deceleration Continued Cause Condition Check the battery connections Refer to Procedure 019 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Da Check for air in the
5. Crankshaft journals are damaged or outof round ee crankshaft journals Refer to Procedure Main bearings are damaged or worn or the wrong bearings are installed 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 36 Troubleshooting Symptoms Engine Noise Excessive Piston This is symptom tree T051 NOTE Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle users manual Fuel grade is not correct for the application or the fuel quality is poor Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedure 006 026 teen Measure and adjust the overhead settings Refer to Procedure 003 004 ee Remove and inspect the connecting rods Refer to Procedure 001 014 Check for air intake system leaks Refer to Procedure 010 024 Check the pistons and piston rings for wear or damage Refer to Procedures 001 043 and 001 047 Remove the pistons and inspect the piston pin and Piston pin or bushing is loose worn or not installed correctly bushing for damage wear and correct installation Refer to Procedure 001 043 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 37 Engine Noise Excessive Turboch
6. Exhaust system restriction is above specification et ibe Mie OrTausy syst repmiaions Rela 10 y r Procedure 011 009 Fuel grade is not correct for the application or the fuel quality is poor Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 43 Engine Power Output Low Continued Cause Correction Check the oil level Verify the dipstick calibration and Lubricating oil level is above specification oil pan capacity Fill the system to the specified level Refer to the vehicle specifications LI Drive train is not correctly matched to the engine eetet ehork Tor oien gearingang sive train componente Refer to the vehicle specifications LI ekar deie Pun g aae O A esin Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 LI Static injection timing is not corret Teee Check the static injection timing Refer to Procedure 9 006 025 or 005 037 II Fuel iniectin numo is maltunetionina ae Perform a cylinder performance test Refer to Lee ee g Procedure 014 008 J ae ae an Check CAPS gear pump output pressure Refer to Fuel injection pump is malfunctioning Procedure 005 025 Check CAPS accumulator pressure Refer to Procedure 005 077 Ji l mae Remove and inspect the rate shape snubber valve Fuel injection pump is malfunctioning pocece Refer to Procedure 006 056 Continued 7 89351NH Sectio
7. Lubricating Oil Sludge in the Crankcase Excessive This is symptom tree T106 Cause Correction Check the bulk oil supply Drain the oil and replace Bulk oil supply is contaminated with non contaminated oil Replace the oil filters Refer to Procedure 007 025 or 007 013 LI ecg Refer to the Coolant Temperature Below Normal Coolant temperature is below specification symptom tree Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Fuel grade is not correct for the application or the fuel quality is poor Change the oil and filters Refer to Procedure 007 013 Use the oil type recommended in the vehicle operation and maintenance manual eer Verify the correct lubricating oil drain interval Refer to the vehicle operation and maintenance manual eee Refer to the Lubricating Oil Contaminated symptom tree Check for excessive blowby Refer to the Crankcase Gases Blowby Excessive symptom tree Lubricating oil does not meet specifications for operating conditions Crankcase pressure is excessive 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 93 Lubricating Oil Temperature Above Specification This is symptom tree T107 Cause Correction Refer to Secion TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines
8. 002 Lubricating oil pressure switch gauge or sensor is malfunctioning or is not in the correct location 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 71 Engine Will Not Reach Rated Speed RPM This is symptom tree T080 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Compare the calibration stored in the ECM with the Electronic Control Module ECM calibration is not correct engine rating and the Vehicle Parts List If necessary calibrate the ECM Check the programmable parameters and the selected features with an electronic service tool Set the parameters and features again if necessary Refer to the appropriate electronic service tool user s manual Programmable parameters or selected features are not correct Check the percent throtle reading on an electronic service tool Verify that itreads 100 percent with the Accelerator pedal is restricted or malfunctioning accelerator pedal depressed Calibrate the accelerator if possible Replace the accelerator pedal ifnecessary Refer to the vehicle service manual Compare the tachometer reading with a hand tachometer or an electronic service tool reading Calibrate or replace the tachometer as necessary Refer to the vehicle service
9. 24 Valve 8 3 Liter Engines Key switch circuit is malfunctioning 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 76 Troubleshooting Symptoms Fuel Consumption Excessive This is symptom tree T087 Cause Correction Verify the engine duty cycle with an electronic service Engine duty cycle has changed fool Refer to the appropriate electronic service tool user s manual Explain the correct engine operation to the operator Operator technique is not correct Refer to the vehicle operation and maintenance manual Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Check the programmable parameters and the selected features with an electronic service tool Set the parameters and features again if necessary Refer fo the appropriate electronic service tool user s manual Programmable parameters or selected features are not correct Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List If necessary calibrate the ECM Electronic Control Module ECM is not calibrated or has incorrect calibration Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 77 Fuel Consumption Excessive Continued Cause Correction Check the boost se
10. Check the oil pressure switch gauge or sensor for correct operation and location Refer to Procedure 007 052 Ll Engine angularity during operation exceeds specification Refer to the vehicle specification sheet Lubricating oil filter is plugged Lubricating oil pressure switch gauge or sensor is malfunctioning or is not in the correct location Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 91 Lubricating Oil Pressure Low Continued Cause Correction Check the lubricating oil pressure sensor and circuit Lubricating oil pressure sensor or circuit is malfunctioning Refer to Procedure 019 066 in the Fuel Systems electronic controlled fuel system Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Main oil pressure regulator is malfunctioning P n pag regulator assembly Check the oil cooler Refer to Procedure 007 003 Remove and inspect the oil pan or suction tube Refer to Procedure 007 025 Inspect the lubricating oil pump Refer to Procedure 007 031 Analyze the lubricating oil Inspect the oil filter Refer to Procedure 007 002 Check the main bearings rod bearings cam bushings and rocker lever bushings for excessive wear Refer to Section 1 Internal engine damage or internal lubricating oil leak 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 92 Troubleshooting Symptoms
11. Replace the ECM Refer to Procedure 019 031 in the Electronic Control Module ECM is malfunctioning Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 75 Fault Code Warning Lamps Do Not Illuminate This is symptom tree T084 Cause Correction Key switch is in the OFF posiion vrereees Turn on the key switch OK Check the warning lamps for voltage Replace the bulbs if necessary Refer to Procedure 019 046 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Fault code warning lamps are burned out Check the battery connections Refer to Procedure 019 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Battery voltage supply to the electronic control ECM is low interrupted or open Check the fault code warning lamp circuit Refer to Procedure 019 047 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Fault code warning lamp circuit is malfunctioning Check the time limit on idle and PTO shutdown with an Idle shutdown or PTO shutdown features are activated electronic service tool Refer to the appropriate electronic service tool user s manual Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC
12. SUPGeS 1M PTO to scicscvetesacsc acsncenssesdaticsactvvsnsseeseandnbanbicss codhepeasi tadnosesizanespeasiasidesissbegseariaiuesaebisateateadbesithiaiscraensd te 64 Engine Starts But Will Not Keep RUNNING cssecssesiasieseeccecisseceseshsacesenetssceatsensnsseensbstsszusnupeaecasdievsvsdened esapidatdasees sbsbsdadaniuseussaeatdaedenrss 65 EngineVibration EXCeSSIVG cise atieasecicianetiitenst ann tnen suacciatbiaidtiadiedhtariacrie sid rahacutiehehidieahmniueranandls 67 Engine Will Not Crank or Cranks Slowly Electric Starter oo cscseesseeseeseeeseeseeeseenssesnsseesseassesseseteeseteassessseseaneansaneasensenenneans 69 Engine Will Not Reach Rated Speed RPM ce ecssessecsssesesseseseseeseseeseceseceeseeeeseceeseetesestesesssuessenaseeseseeseateseaeeaestesseeneaeeteaeates 71 Engine Will Not Shut Off sstvcrscssssecived becuase attersvarscnens qutiesnateanctintahs diated saiedheatentastaddacobandaenatnamonatnerinednieneemeans 74 Fault Code Warning Lamps Do Not Illuminate oo eee eeseeseeseeseeeescsesteeteateatsnseeeeteaneansneeasenesteaneseeetsanesneateateessesnsanensestessntans 75 Fuel Consumption Excessive j s csiv asia niiina sini ariadna araninniaelenidiinendandina sania 76 Fuellin Coolant ionian a dad din A Aaaa atortead ioindaridaddh eh dhe 80 Fuel in the Lubricating Oil prirura aaa aa aaa aa dai aia a aSa 81 Intake Manifold Air Temperature Above Specification c cccseccssseseseseesescsescesesceseeceseeesessatsiseesie
13. Troubleshooting Symptoms Smoke White Excessive Continued Cause Correction dian ce sho Check the CAPS coupling for wear or failure Refer to Fuel injection pump is malfunctioning treet Procedure 005 072 OK LI Fueiiniecion pumate malinang ears Replace the fuel injection pump Refer to Procedure t L 9 005 012 or 005 014 or 005 016 LI Coolant is leaking into the combustion chamber J eese Refer to the Coolant Loss Internal symptom tree LI 022 or 006 028 LI of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 99 Smoke Black Excessive This is symptom tree T116 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List Ifnecessary calibrate the ECM Electronic Control Module ECM is not calibrated or has incorrect calibration Check the boost sensor and circuit Refer to Intake manifold pressure boost sensor or circuitis Procedures 019 061 in the Fuel Systems malfunctioning Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the air intake system for restriction Clean or Air intake system restriction is above spe
14. connections and fuel filters for leaks Refer to Procedure 006 024 Check the fuel lines to the supply tanks Refer to vehicle service manual Fuelleak Jett ttt Check the fuel lift pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Remove the injectors and verify the injector shim thickness Refer to Procedure 006 026 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 23 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction i icti Check for fuel inlet restriction Refer to Procedure 006 Fuel inlet restriction 8 oe 020 OK Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedure 006 026 or 014 008 Check the fuel supply line from the fuel pump to the cylinder head for sharp bends which can cause restrictions Jl 006 003 p pa Procedure 011 009 Fill the fuel tank turn off or bypass the fuel heaters Fuel inlet temperature to pump is above specification and check the fuel cooler Refer to the vehicle service manual Fuel supply line restriction between the fuel pump and the injectors Operate the engine fr
15. g 9 of probable damage Refer to Procedure 007 002 Section 10 Chapter 7 Issued 8 2001 7 89351NH 24 Valve 8 3 Liter Engine Page 64 Troubleshooting Symptoms Engine Speed Surges in PTO This is symptom tree T068 Cause Correction Refer to the Engine Speed Surges at Low or High Idle symptom tree in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Engine speed also surges atidle Refer to the Engine Speed Surges Under Load or in Engine speed surges while in the normal operating range Operating Range symptom tree in the Fuel Systems and notin PTO Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Refer to Secon TF in the Fuel Systems Electronic fault codes active or high counts of inactive fault Troubleshooting and Repair Manual for CDC 24 codes Valve 8 3 Liter Engines for fault code troubleshooting for fault code troubleshooting Compare the calibration stored in the ECM with the Electronic Control Module ECM calibration is outdated most recent calibration version available If necessary calibrate the ECM Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List Ifnecessary calibrate the ECM Measure the fuel pressure before and after the fuel filter Refer to Procedure 005 011 Check the vehicle speed sensor and circuit Refer to Procedures 019 090 and 019
16. manual Tachometer is not calibrated or is malfunctioning Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 72 Troubleshooting Symptoms Engine Will Not Reach Rated Speed RPM Continued Cause Correction Check the vehicle speed sensor and circuit Refer to Procedures 019 090 and 019 091 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines p 7 i Check for fuel inlet restriction Refer to Procedure 006 Fuel inlet restriction 020 p Fuel filter is plugged Measure the fuel pressure before and after the fuel pugg filer Refer to Procedure 005 011 Vehicle speed sensor VSS or circuitis malfunctioning Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual Performa cylinder performance test Check CAPS accumulator pressure Refer to Procedure 005 077 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 73 Engine Will Not Reach Rated Speed RPM Continued Cause Correction Fuelinjection
17. performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedures 006 026 or 014 008 Alternately disconnect all other J1939 control devices J1939 control devices are interfering with the engine from the data bus circuit untl communicatons or controls functionality is restored Refer to the vehicle service manual to locate and repair J1939 control devices Compare the drive train specifications to CDC Clutch is malfunctioning or is not correct recommendations Check the clutch for correct operation Refer to the vehicle service manual Remove and inspect the rate shape snubber valve Refer to Procedure 006 056 Fuel injection pump is malfunctioning 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 21 Engine Difficult to Start or Will Not Start Exhaust Smoke This is symptom tree T043 Cause Correction Fuel level low in the tank ttre Fill the supply tank OK Refer to Secon TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Check the batteries and the unswitched battery supply circuit Refer to Procedure 013 009 Procedure 019 Battery voltage is low 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines or the vehicle service manual Check the air intake s
18. the fuel pump to the cylinder head for sharp bends which can cause restrictions Fuel supply line restriction between the fuel pump and the injectors Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedure 006 026 or 014 008 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedures 006 026 or 014 008 Inspect the air intake and exhaust systems for air leaks Refer to Procedure 010 024 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 18 Troubleshooting Symptoms Engine Acceleration or Response Poor Continued Cause Correction Check the air intake system for restriction Clean or Air intake system restriction is above specification replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Jl a EE e ee Check the exhaust system for restrictions Refer to st sy p Procedure 011 009 Alternately disconnect all other J1939 control devices from the data bus circuit until communications or functionality is restored Refer to the vehicle service manual to locate and repair J1939 control devices J1939 control devices are interfering with the engine controls Check the turbocharger part number and c
19. 049 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 14 Troubleshooting Symptoms Cranking Fuel Pressure is Low This is symptom tree T029 Cause Correction Fuel level low in the tanak streets Fill the supply tank OK Jl Fuel filter is olugged 0 ee Measure before and after the fuel filter Refer to p ugg Procedure 005 011 LI Fuel connections on the suction side of the pump are loose tete Tighter all t6 itngs and connections betwee Ma fuel tanks and fuel pump LI Fuial Suiction stand pide in th fuel inkig broken ameet To check and repair the stand pipe refer to the vehicle service manual Check the fuel lift pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 15 Engine Acceleration or Response Poor This is symptom tree T033 Cause Correction Verify the engine duty cycle with an electronic service Engine duty cycle has changed fool Refer to the appropriate electronic service tool user s manual Explain the correct engine operation to the operator Operator technique is not correct Refer to the vehicle operation and maintenance manual Ll Fuel level low in the tank o ppe Fill the supply tank OK l Check the fuel lines fuel connecti
20. 091 in the Fuel Vehicle speed sensor VSS or circuit is malfunctioning Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Moisture in the wiring harness connectors Dry the connectors with an electronic contact cleaner 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Engine Starts But Will Not Keep Running This is symptom tree T072 Cause Fuel level low in the tank OK Battery voltage supply to the electronic control ECM is low interrupted or open Electronic fault codes active or high counts or inactive fault codes Key switch circuit is malfunctioning Idle shutdown or PTO shutdown features are activated Fuel grade is not correct fr the application or the fuel quality is poor Fuel leak OK Ot Continued 7 89351NH Correction Fill the supply tank Check the battery connections Refer to Procedure 019 087 Refer to Procedure 013 009 Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting for fault code troubleshooting Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Check the time limit on idle and PTO shutdown with an electronic service tool Refer to the appropr
21. 20 Jl White smoke is present 82 J trees Excessive symptom tree 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 104 Troubleshooting Symptoms Engine Noise Diagnostic Procedures General Information NOTE When diagnosing engine noise problems make sure that noises caused by accessories such as the air compressor and power takeoff are not mistaken for engine noises Remove the accessory drive belts to eliminate noise caused by these units Noise will also travel to other metal parts not related to the problem The use of a stethoscope can help locate an engine noise Engine noises heard at the crankshaft speed engine rpm are noises related to the crankshaft rods pistons and piston pins Noises heard at the camshaft speed one half of the engine rpm are related to the valve train A hand held digital tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft speed Engine noise can sometimes be isolated by performing a cylinder cutout test If the volume of the noise decreases or the noise disappears it is related to that particular engine cylinder There is not a definite rule or test that will positively determine the source of a noise complaint Engine driven components and accessories such as gear driven fan clutches hydraulic pumps belt driven alternators air conditioning compressors and turbochargers can contribute to engine noise Use the fo
22. 42 and the vehicle service manual ee Perform the Cooling System Diagnostics Test Refer to Procedure 008 020 eee Check the fan drive and controls Refer to Procedure 008 027 ern Remove and inspect the cooler cores and o rings Refer to the vehicle service manual Vent lines or fill line are restricted obstructed or not routed Check the vent lines and the fill line for correct routing correctly and for restriction Refer to vehicle specifications Charge air cooler CAC fins radiator fins or air conditioner condenser fins are damaged or obstructed with debris 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 11 Coolant Temperature is Below Normal This is symptom tree T024 Cause Correction Coolant temperature gauge or sensor is malfunctioning ates and Bie sengor Repair or replace i Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Electronic fault codes active or high counts of inactive fault codes Check the thermostat for the correct part number and for correct operation Refer to Procedure 008 013 Check for correct coolant fow through the radiator Refer to Procedure 008 042 f S Check the fan drive and controls Refer to Procedure Fan drive or fan controls are malfunctioning 008 027 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 12 Troubleshooting Sym
23. Check the air intake system for restriction Clean or replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Visually inspect the air intake and exhaust systems for air leaks Refer to Procedure 010 024 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 97 Smoke White Excessive Continued Cause Correction Inspect the CAC for air restriction or leaks Refer to Charge air cooler CAC is restricted or leaking Procedure 010 027 OK Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 LI pae tae tane ai rna ae A ras Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 Check the intake manifold for fuel Refer to Procedure Raw fuel in the intake manifold 010 023 Locate the fuel source and repair as necessary Remove the injectors and compare the part numbers Injectors are not correct to the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 aly Check the static injection timing Refer to Procedure 006 025 or 005 037 Fuel injection pump is malfunctioning oo pump to engine timing Refer to Procedure 005 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 98
24. Drive train is not correctly matched tothe engine eetet ee poner ore A na drive marr componens Refer to the vehicle specifications OK Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual Vehicle parasitics are excessive Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Fuel grade is not correct for the application or the fuel quality is poor Perform the automated cylinder performance test Replace injectors as necessary Refer to Procedure 006 026 Check the oil level Verify the dipstick calibration and oil pan capacity Fill the system to the specified level Refer to the vehicle specifications EE E E V E EE Check the exhaust system for restrictions Refer to st sy S p Procedure 011 009 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 79 Fuel Consumption Excessive Continued Cause Correction PEE RY PE ARPS enter Le Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 OK LI Static injection timing is not correct Teee Check the static injection timing Refer to Procedure l g 006 025 or 005 037 LI Fiel miecionbimg is maltuindigana hawe Replace the fuel injection pump Refer to Proced
25. Section 10 Chapter 7 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Identification Note All coding used in the 8 3 Liter and 9 Liter engine manuals are Cummins engine codes These engine codes have no meaning to New Holland warranty codes and should only be used for procedure steps 7 89351NH 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page a Troubleshooting Symptoms Contents Troubleshooting Procedures and Techniques ssssssssssssesssssesssssssessessesseeesessorsessesessensorsnsscsseseesesesasenesseseesesatsatsseeesansatsntsasensseeansansanes 1 Troubleshooting Symptoims Charts casccsccscesesectsisecuscacteesiceecaessensetpctseccecsatterasencosvaceovstindeteseckecdeasrousdveensstcurtayuateeesnburdusedeedeauveavecesnbeeoseucodts 1 Communication Error Electronic Service Tool or Control Device oo cesses eeeeteseseseeseestesessesseeeesteansnssaeeeesneansanenseetessesaneateatensaneans 2 Coolant Loss External wvsic c aia saad atin eared nerve a ene iin eden ann Eia E E TE 4 Coolant Loss Internal Coolant Temperature Above Normal Gradual Overheat c cccescsessessecessesesssesseeceaeseeaceeeseeeeessneesassneassuteaceneecaseceaseneeteceaneceesanees Coolant Temperature Above Normal Gradual Overheat c ccccscceeseseesesesesssessesceaeeceseeeeseeeeesseeesassesassuesneeseeseseceaseseeteceateceesanees Coolant Temperature Above Normal Gradual Overheat cccceesseeeeeees Coolant Temperature is Above N
26. Valve 8 3 Liter Engine Troubleshooting Symptoms Page 27 Engine Difficult to Start or Will Not Start No Exhaust Smoke Continued Cause Correction i eet Isolate the engine protection system Follow the vonie endine poten eyes Meneoing vehicle service a fo check i a malfunction Check the fuel lift pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Moisture in the wiring harness connectors ss tres Dry the connectors with an electronic contact cleaner Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Ll e Check for air in the fuel system Refer to Procedure Air in the fuel system 006 003 Check for fuel inlet restriction Refer to Procedure 006 020 er j Remove the injectors and verify the injector shim ees Mieke evenness thickness Refer to Procedure 006 026 L ae A Check CAPS gear pump output pressure Refer to Fuel inject lfuncti uel injection pump is malfunctioning Procedure 005 025 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 28 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start No Exhaust Smoke Continued
27. active or high counts of inactive fault Troubleshooting and Repair Manual fr CDC 24 codes Valve 8 3 Liter Engines for fault code troubleshooting Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List If necessary calibrate the ECM Measure the fuel pressure before and after the fuel filter Refer to Procedure 005 011 Check for air in the fuel system Refer to Procedure 006 003 Check for fuel inlet restriction Refer to Procedure 006 020 Electronic Control Module ECM is not calibrated or has incorrect calibration Check the fuel lit pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 50 Troubleshooting Symptoms Engine Runs Rough or Misfires Continued Cause Correction Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedures 006 026 Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedu
28. al depressed Calibrate the accelerator if possible Replace the accelerator pedal ifnecessary Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 60 Troubleshooting Symptoms Engine Speed Surges Under Load or in Operating Range Continued Cause Correction Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Check the vehicle speed sensor and circuit Refer to Procedures 019 090 and 019 091 in the Fuel Vehicle speed sensor VSS or circuit is malfunctioning Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Dry the connectors with an electronic contact cleaner Check for air in the fuel system Refer to Procedure 006 003 Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Check for fuel inlet restriction Refer to Procedure 006 020 Perform the automated cylinder performance test Replace injectors as necessary Refer to Procedures 006 026 or 014 008 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troublesho
29. al for CDC 24 Valve 8 3 Liter Engines LI naea Ba Check the main oil pressure regulator assembly Main oil pressure regulator is malfunctioning Refer to Procedure 007 029 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 90 Troubleshooting Symptoms Lubricating Oil Pressure Low This is symptom tree T105 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Check the oil level Add or drain oil if necessary Lubricating oil level is above or below specification Refer to Procedure 007 025 Check the dipstick calibration Refer to Procedure 007 009 Inspect the engine for external oil leaks Tighten the capscrews pipe plugs and fitings Replace gaskets if necessary Refer to the vehicle operation and maintenance manual for specifications Lubricating oil leak external Change the oil and filters Refer to Procedure 007 013 Use the oil type recommended in the vehicle operation and maintenance manual Lubricating oil does not meet specifications for operating conditions Change the oil and filter Refer to Procedures 007 025 and 007 013 Review the oil change interval Refer to the vehicle operation and maintenance manual Lubricating oil is contaminated with coolant or fuel ag Set CUD anna Corie Mee Sipon
30. arger This is symptom Tree T052 NOTE Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Check the air intake system for restriction Clean or Air intake system restriction is above specification replace the air filter and inlet piping as necessary Refer to Procedure 010 031 thet es Inspect the air piping chassis and cab for contact points oo Check the exhaust system for restrictions Refer to Procedure 011 009 Check the turbocharger part number Replace the turbocharger if necessary Refer to Procedure 010 033 Check the turbocharger for damage Measure the Turbocharger is worn or damaged turbine and compressor wheel clearances Refer to Procedure 010 038 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 38 Troubleshooting Symptoms Engine Power Output Low This is symptom tree T057 Cause Correction Refer to Secion TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes View the fault codes and the engine protection data with an electronic service tool Refer to the Engine protection fault code s resulted in power and appropriate electronic service tool user s manual engine speed derate Refer to the corresponding fault code in Section TF in the Fuel Sys
31. assseseaseneceeteceateeeaeeseaseneesentees 82 Low Idle Adjust Switch Does Not Work ccsccccecssesectseceesesesssescsesceesseesnseesceseeceaeeceaeeceaseneasensassnsasensasensaseneaseneceateceateneaeeesentes Intake Manifold Pressure Boost is Below Normal Lubricating Oil Consumption EXCESSIVE iccc5 csiesccacvastavtssviesteuneasiabeesegesndncasvasrosd a igusttincseraejecctsbunsatducdunsdbatt A ATAN EAR Lubricating Oil Contaminated Lubricating Oil Pressure High Lubricating Oil Pressure Low Lubricating Oil Sludge in the Crankcase Excessive oe essessesessesseseesesstesseesnssneenensesteasssssseeateatsanesneaneatsessseneaneansanenseneeneaneans 92 Lubricating Oil Temperature Above Specification ceccsceseecssesesessesecseseesesscseeceseeceaeeceseessesiseessaesseseaseneasensceeneceateceateeeeseneesenees 93 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page b Troubleshooting Symptoms Lubricating or Transmission Oil in the Coolant ooo scsseseesessesessesseeseeesssseesssseeansatsncssensateaneassaesissessssnsateaseatsassnseneaneatsateseneeens 94 Smoke Whites Excessive rieren rrtt a aaa aar aa toast edsidldls aaa aaea a aa deh deed ete 95 Smoke Black EXCESSIVE naene aeaa aaae ar aE aaa a a aaa a aaa 99 Turbocharger Leaks Engine Oil or F el siisii iaaiiai antradieniais aiis 103 Engine Noise Diagnostic Procedures General Information ssssssssssrrunnsuunnnnnnnnnnnonunnnnnnnnnnnnenunnnnnnnnnnnnnnnnnnnnennnnunennn
32. ation leaks Repair if necessary Add coolant Refer to the vehicle specifications Refer to Secion TF in the Fuel System Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting J Check the fan drive belt Replace the belt if PAAA DANE Pion necessary Refer to Procedure 008 002 Test the temperature gauge Repair or replace the Electronic fault codes active or high counts of inactive fault codes Coolant temperature gauge is malfunctioning gauge if necessary Refer to Procedure 008 004 and the vehicle service manual Ll Radiator cap is not correct is malfunctioning or has low Check the radiator pressure cap Refer to Procedure pressure rating 008 047 p Radiator hose is collapsed restricted or leaking i a Mb tagiaDr Nope Robi rrogdure NOA Therinoshatis not corrector is iraluncionin Check the thermostat for the correct part number and 9 for correct operation Refer to Procedure 008 013 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 10 Troubleshooting Symptoms Coolant Temperature is Above Normal Sudden Overheat Continued Cause Correction Check the water pump using the diagnostic test in Water pump is malfunctioning Procedure 008 020 Replace the water pump if necessary Refer to Procedure 008 062 Inspect the CAC air conditioner condenser and radiator fins Clean if necessary Refer to Procedures 010 027 and 008 0
33. bable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 26 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start No Exhaust Smoke This is symptom tree T044 Cause Correction Fuel level low in the tank Juste Fill the supply tank OK Electronic fault codes eos counts of inactive fault Refer to Secion TF for fault code troubleshooting Check the batteries and the unswitched battery supply circuit Refer to Procedure 019 087 in the Fuel Battery voltage is low Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines and the vehicle service manual Check the battery connections Refer to Procedure 019 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Battery voltage supply to the electronic control ECM is low interrupted or open Measure the fuel pressure before and afer the fuel filter Refer to Procedure 005 011 Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List If necessary calibrate the ECM Electronic Control Module ECM is not calibrated or has incorrect calibration Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Key switch circuit is malfunctioning Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24
34. causes a loud double knock which is usually heard when the engine is idling When the injector to this cylinder is cut out a noticeable change will be heard in the sound of the knocking noise However on some engines the knock becomes more noticeable when the vehicle is operated on the road at steady speed condition 7 89351NH Section 10 Chapter 7 Issued 8 2001
35. cification replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Visually inspect the air intake and exhaust systems for air leaks Refer to Procedure 010 024 Inspect the CAC for air restriction or leaks Refer to Procedure 010 027 Ll pad POR Check the exhaust system for restrictions Refer to Exhaust system restriction is above specification Procedure 011 009 Continued Charge air cooler CAC is restricted or leaking 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 100 Troubleshooting Symptoms Smoke Black Excessive Continued Cause Correction Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedure 006 026 Remove the injectors and compare the part numbers Injectors are not correct to the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 J T rbocharasr dilseaiisieakina raia Check the turbocharger compressor and turbine seals 9 9 Refer to Procedures 010 040 or 010 049 Check the radial bearing clearance and axial clearance Inspect the turbocharger Repair or replace the turbocharger if necessary Refer to Procedures 010 038 and 010 047 Check the turbocharger pa
36. ction Check the hydraulic pump and air compressor Isolate gear driven accessories and check for vibration Jl Power Take Off PTO is damaged eee Check the PTO for garage and Correct installation Refer to the manufacturer s instructions Jl Vibrationdamgerisdaniaded hoiei Check the vibration damper Refer to Procedure 001 P g 051 or 001 052 Gear driven accessories are malfunctioning 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 69 Engine Will Not Crank or Cranks Slowly Electric Starter This is symptom tree T078 Cause Correction Check the battery heater Refer to the manufacturer s Batteries are cold i instructions Battery cables or connections are loose broken or Check the battery cables and connections corroded excessive resistance fated he Refer to Electrical System Specifications Check the starter interlock devices Refer to the vehicle service manual Check the batteries and the unswitched battery supply circuit Refer to Procedure 019 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines LI Engine driven units are engaged ttt Disengage engine driven units Battery voltage is low Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 70 Troubleshooting Symptoms Engine Will Not Crank or Cranks Slowly Electric Starter Continued Cause C
37. ctor for nicks or damage that may cause fuel leaks Refer to Procedure 006 005 006 026 or 014 008 Check the fuel supply line from the fuel pump to the cylinder head for sharp bends which can cause restrictions ORANY Check the engine mounts Refer to the service manual and Procedure 016 003 or 016 010 ear a Dry the connectors with an electronic contact cleaner Fuel supply line restriction between the fuel pump and the injectors Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 47 Engine Runs Rough at Idle Continued Cause Correction Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Use the PTO feature for loaded conditions at low Idling with excessive load engine speeds Refer to the vehicle operation and maintenance manual Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Measure and adjust the overhead settings Refer to Procedure 003 004 Fuel grade is not correct for the application or the fuel quality is poor Remove the injectors and verify the injector shim thickness Refer to Procedure 006 026
38. d J terres 010 023 Locate the fuel source and repair as necessary inieimakenaine damages renan Analyze the oil and inspect the filters to locate an area g g of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 103 Turbocharger Leaks Engine Oil or Fuel This is symptom tree T122 Cause Correction Engine is operating for extended periods under light orno Review the engine operating instructions in the vehicle load conditions slobbering operation and maintenance manual OK LI Lubricating oil or fuel is entering the turbocharger J eee Pamoa Me intake ands pxhaust piping sand sce ek ar oil or fuel LI CIEN f Remove the turbocharger drain line and check for Turbocharger drain line is restricted 8 p eee ee ae restriction Clean or replace the drain line Check for excessive blowby Refer to the Crankcase Gases Blowby Excessive symptom tree Crankcase pressure is excessive Check the turbocharger part number and compare it to Turbocharger is not correct the Control Parts List CPL Replace the turbocharger if necessary Refer to Procedure 010 033 Jl Tarbocharaer ollisaaiisleakings reii Check the turbocharger compressor and turbine seals 9 S Aang Refer to Procedure 010 040 or 010 049 Jl Valve stem clearance is excessive or the valve stem seals Check the valve stems and seals Refer to Procedure are damaged 002 0
39. e service manual Fan shroud is damaged or missing or the air recirculation baffles are damaged or missing Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 7 Coolant Temperature Above Normal Gradual Overheat Cause Correction Check the fan drive belt Replace the belt if necessary Fan drive belt is broken Replace the belt if necessary Refer to Procedure 008 002 LI Radiator hose is collapsed restricted or leaking oee Ae otalne ve diatoy ese Bete ta Prca dures 08 LI Electronic fault codes m counts of inactive fault Refer to Section TF for fault code troubleshooting LI foes Wl Test the temperature gauge Repair or replace the Coolant temperature gauge Is malfunctioning gauge if necessary Refer to Procedure 008 004 J f ROR Refer to the Intake Manifold Air Temperature Above Intake manifold air temperature is above specification eds Specification symptom tree LI f hs Check the fan drive and controls Refer to Procedure Fan drive or fan controls are malfunctioning eee 008 027 Check the oil level Add or drain oil if necessary Refer Lubricating oil level is above or below specification to Procedure 007 025 Check the dipstick calibration Refer to Procedure 007 009 Jl Vent lines or fill line are restricted obstructed or not routed Check the vent lines and the fill line for correct routing correctly and for restrict
40. e the cause of the complaint has been corrected Troubleshooting Symptoms Charts Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms Read each row of blocks from top to bottom Fol low through the chart to identify the corrective action A WARNING A Troubleshooting presents the risk of equipment damage personal injury or death Troubleshooting must be performed by trained experi enced technicians 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 2 Troubleshooting Symptoms Communication Error Electronic Service Tool or Control Device This is symptom tree T016 Cause Correction Key switch is in the OFF position pocece Turn on the key switch OK U Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Data bus cable is not connected correctly be Seen eM REP i fe velectonic Key switch circuit is malfunctioning Check the power lighton the inline adapter If the light Inline adapter data bus adapter is not connected to the is not illuminated connect the battery voltage to the battery voltage supply inline adapter Refer to the appropriate electronic service tool user s manual Select System Menu User Options and change the communication port seting Refer to Communication Messages in the electronic service tool Help menu and the appropriate
41. ead gasket is leaking 002 004 or 002 021 LI Cylinder head is cracked or porous eee Pressure test the cylinder head Refer to Procedure 002 004 LI Torque converter cooler or hydraulic oil cooleris Remove and inspect the cooler cores and o rings malfunctioning Refer to the vehicle service manual 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 95 Smoke White Excessive This is symptom tree T118 Cause Electronic fault codes active or high counts of inactive fault codes Electronic Control Module ECM is not calibrated or has incorrect calibration Engine is cold Engine is operating atlow ambient temperature Starting aid is necessary for cold weather or starting aid is malfunctioning Engine block heater is malfunctioning if equipped Coolant temperature sensor is malfunctioning Continued 7 89351NH Section 10 Chapter 7 Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Compare the calibraton stored in the ECM with the engine rating and the Vehicle Parts List Ifnecessary calibrate the ECM Allow the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal symptom tree Check the winterfront shutters and under hood air Refer to the v
42. ehicle operation and maintenance manual Check for correct operation of the starting aid Refer to the manufacturer s instructions Refer to Cold Weather Starting Aids in the vehicle operation and maintenance manual Check the electrical sources and wiring to the cylinder block heater Replace the block heater if necessary Refer to the vehicle service manual Check the coolant temperature sensor Refer to Procedure 019 019 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Issued 8 2001 24 Valve 8 3 Liter Engine Page 96 Troubleshooting Symptoms Smoke White Excessive Continued Cause Correction Check the intake manifold temperature sensor Refer t Procedure 019 059 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Intake manifold temperature sensor is malfunctioning Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedure 006 026 J seg Remove the injectors and verify the injector shim NEEDE Shin Hic ices nol paraa thickness Refer to Procedure 006 026 Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Measure the fuel pressure before and after the fuel filter Refer to Procedure 005 011 Fuel grade is not correct for application or the fuel quality is poor
43. ehicle speed sensor VSS or circuit is malfunctioning Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Paar Dry the connectors with an electronic contact cleaner Check for air in the fuel system Refer to Procedure 006 003 Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Check for fuel inlet restriction Refer to Procedure 006 020 Remove the injectors and compare the part numbers fo the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 57 Engine Speed Surges at Low or High Idle Continued Cause Correction ee Remove the injectors and verify the injector shim Meco srimibeMiess RMOL OMAGA thickness Refer to Procedure 006 026 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedures 006 026 Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedure 006 026 Use the PTO feature for loaded conditions at low Idling with excessive load engine speeds Refer to t
44. el grade is not correct for the application or the fuel quality is poor 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 59 Engine Speed Surges Under Load or in Operating Range This is symptom tree T067 Cause Correction Fuel level low in the tank Jt Fill the supply tank OK Refer to Section TF in the Fuel Systems Electronic fault codes active or high counts of inactive fault Troubleshooting and Repair Manual for CDC 24 codes Valve 8 3 Liter Engines for fault code troubleshooting for fault code troubleshooting LI Fuel filter is plugged Measure the fuel pressure before and afer the fuel yee fiter Refer to Procedure 005 011 Compare the calibraton stored in the ECM with the Electronic Control Module ECM calibration is outdated most recent calibration version available If necessary calibrate the ECM Compare the calibration stored in the ECM with the engine rating and the Vehicle Parts List Ifnecessary Calibrate the ECM Alternately disconnect all other J1939 control devices J1939 control devices are interfering with the engine from the data bus circuit until communications or controls functionality is restored Refer to the vehicle service manual to locate and repair J1939 control devices Check the percent throte reading on an electronic service tool Verify that it reads 100 percent with the Accelerator pedal is restricted or malfunctioning accelerator ped
45. electronic service tool user s manual Electronic service tool is addressing the wrong communication port Verify that the electronic service tool is working and that the Refer to the appropriate electronic service tool and correct sofware or cartridge is being used sofware or cartridge manuals OK Fuse s malfunctioning tte Replace the fuse s in the interface harness OK U Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 3 Communication Error Electronic Service Tool or Control Device Continued Cause Correction Check the battery connections Refer to Procedure 019 087 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Battery voltage supply to the electronic control ECM is low interrupted or open Check the data bus circuit Refer to Procedure 019 Data bus circuit is malfunctioning 028 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Refer to Section TF for fault code troubleshooting Calibrate the ECM Alternately disconnect all other J1939 control devices J1939 control devices are interfering with the engine from the data bus circuit until communications or controls functionality is restored Refer to the vehicle service manual to locate and repair J1939 control devices Electronic service tool COM PORT has been interrupted or Refer to the appropriate electro
46. ews Refer to Procedure 016 005 LI Check the torque converter Refer to the vehicle Torque converter is loose ppoe service manual J Refer to the Engine Noise Excessive Main Bearing Main bearing or connecting rod bearing noise ss f symptom tree Check for air intake system leaks Refer to Procedure 010 024 Check the pistons and piston rings for wear or damage Refer to Procedures 001 043 and 001 047 II Refer to the Engine Noise Excessive Turbocharger Turbocharger noise sd ttt symptom tree LI Refer to Engine Noise Excessive combustion knock Combustion noise excessive ttt symptom tree Piston or piston rings are worn or damaged 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 33 Engine Noise Excessive Combustion Knocks This is symptom tree T048 NOTE Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Finer starting aid ismatfuncioning9 iess Repair or replace the ether starting aids Refer to the manufacturer s instructions OK Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the Fuel grade is not correct for the application or the fuel quality is poor i vehicle service manual LI Ait inthetuelsysem 0 eeeit Check for air in the fuel system Bleed air from the y system Refer to Proced
47. for fault code troubleshooting Coolant temperature is above specification Refer to the Coolant Temperature Above Normal symptom tree Check the oil level Add or drain oil if necessary Lubricating oil level is above or below specification Refer to Procedure 007 025 Check the dipstick calibration Refer to Procedure 007 009 p Lubricating oil temperature switch gauge or sensor Check the oil temperature switch gauge or sensor for malfunctioning or not in the correct location correct operation and location Check the oil cooler Refer to Procedure 007 003 Electronic fault codes active or high counts of inactive fault codes Vehicle components cooled with engine lubricating oil are Check the components Refer to the vehicle service malfunctioning manual 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 94 Troubleshooting Symptoms Lubricating or Transmission Oil in the Coolant This is symptom tree T108 Cause Correction Check the bulk oil supply Drain the oil and replace Bulk oil supply is contaminated with non contaminated oil Replace the oil filters Refer to Procedure 007 025 LI Lubricating oil cooler is malfunctioning p verre Check the oil cooler Refer to Procedure 007 003 II PEE Check the cylinder liners for corrosion or cracks Refer Cylinder liner is corroded or cracked to Procedure 001 028 LI fee ee ie Check the cyliunder head gasket Refer to Procedure Cylinder h
48. fuel system Refer to Procedure Air in the fuel system 006 003 Check the fuel lit pump for correct operation Check Fuel lit pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Battery voltage supply to the electronic control ECM is low interrupted or open p Fueiinedion ouro is malindan Replace the fuel injection pump Refer to Procedure E g 005 012 or 005 014 or 005 016 Replace the ECM Refer to Procedure 019 031 in Electronic Control Module ECM is malfunctioning the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Ll ernaiendine danade Analyze the oil and inspect the filters to locate an area 9 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 55 Engine Speed Surges at Low or High Idle This is symptom tree T066 Cause Correction Fuel level low in the tank ttt Fill the supply tank OK Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Compare the calibration stored in the ECM with the Electronic Control Module ECM calibration is outdated most recent calibration version available If necessary calibrate the ECM Compare the calibration stored in
49. h the engine rating and the Vehicle Parts List Ifnecessary calibrate the ECM Electronic Control Module ECM is not calibrated or has incorrect calibration Verify the correct idle speed setting Increase the idle speed with the idle increment switch or an electronic service tool Engine idle speed is set too low electronic controlled fuel systems Check for air in the fuel system Refer to Procedure 006 003 Check for fuel inlet restriction Refer to Procedure 006 020 Check the fuel lit pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 46 Troubleshooting Symptoms Engine Runs Rough at Idle Continued Cause Correction Fuel filter is plugged d eean Measure the fuel pressure before and after the fuel pugg filter Refer to Procedure 005 011 OK Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Perform the automated cylinder performance test Replace injectors as necessary Refer to Procedures 006 026 or 014 008 Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and inje
50. he vehicle operation and maintenance manual Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual Check the vibration damper Refer to Procedure 001 052 Compare the drive train specifications to CDC recommendations Check the clutch for correct operation Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 58 Troubleshooting Symptoms Engine Speed Surges at Low or High Idle Continued Cause Correction Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual LI ee er Remove and inspect the rate shape snubber valve Fuel injection pump is malfunctioning 8 foteeeee Refer to Procedure 006 056 LI Fudlinjedtion pamp ieman Maea of pump to engine timing Refer to Procedure 005 ese Remove and inspect the distributor snubber valve Refer to Procedure 005 020 oo Replace the fuel injection pump Refer to Procedure 005 012 or 005 014 or 005 016 internialenaiiedamaas Mensas Analyze the oil and inspect the filters to locate an area g g of probable damage Refer to Procedure 007 002 Fu
51. iate electronic service tool user s manual Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Check the fuel lines fuel connections and fuel filters for leaks Refer to Procedure 006 024 Check the fuel lines to the supply tanks Refer to the vehicle service manual Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 66 Troubleshooting Symptoms Engine Starts But Will Not Keep Running Cause Correction i dass f Replace the fuel filter Refer to Procedure 005 015 Fuel filter or fuel suction line is restricted ss J oerte SAna o Check the fuel suction line for restriction OK Check the fuel lift pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 LI Anthenea iade Check for air in the fuel system Refer to Procedure y 006 003 LI Bk PN Check the CAPS coupling for wear or failure Refer to Fuel injection pump is malfunctioning J treet Procedure 005 072 LI Fuel injection pump is malfunctioning eee na pump to engine timing Refer to Procedure 005 Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual Vehicle parasitics are excessive 7 89351NH Section 10 Chapter 7 Is
52. ion Refer to the vehicle specifications Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 8 Troubleshooting Symptoms Coolant Temperature Above Normal Gradual Overheat Cause Correction Lubricating oil is contaminated with coolant orfuel eetet as nie Feb ricetn ge Olle Comeininalzd eympiom OK Check the water pump using the diagnostic test in Water pump is malfunctioning p pee Procedure 008 020 Replace the water pump if necessary Refer to Procedure 008 062 LI Radiator core is internally obstructed or damaged or the f S A Wl eisai Inspect the radiator and clean if necessary check valve or J tube is malfunctioning Ree Check the torque converter Refer to the vehicle service manual Verify that the engine and vehicle cooling systems are using the correct components Refer to the vehicle specifications oo Check the engine fuel rate Refer to Engine Testing General Information in Section 14 ae Check the oil thermostat Refer to Procedure 007 039 LI f Soe E Check the cylinder head gasket Refer to Procedure Cylinder head gasket is leaking 002 004 or 002 021 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 9 Coolant Temperature is Above Normal Sudden Overheat This is symptom tree T023 Cause Correction Inspect the engine and radiator for external coolant Coolant level is below specific
53. ircuit is malfunctioning appropriate electronic service tool user s manual If the monitor shows speed check the sensor and circuit Refer to Procedures 019 090 019 091 a Compare the vehicle tachometer and speedometer readings with an electronic service tool reading Check the calibration values for the flywheel teeth rear axle ratio and fire revolutions Adjust the values if necessary Refer to the appropriate elec Check for air in the fuel system Refer to Procedure 006 003 Tachometer or speedometer is not calibrated or is malfunctioning Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 41 Engine Power Output Low Continued Cause Correction Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedures 006 005 006 026 or 014 008 Remove the injectors and compare the part numbers Injectors are not correct to the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Fuel connector is leaking fuel Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedure 006 026 or 014 008 Check the fuel drain lines for restriction Clear or Fuel drain line restriction replace the fuel lines check valves or tank ven
54. ive Continued Cause Correction Vibration damper is damaged N eee Check the vibration damper Refer to Procedure 001 3 9 051 or 001 052 OK Check the accessory drive axial end play Visually Accessory drive is worn axial end play is out of specification inspect the shaft for wear Refer to Procedure 009 016 Refer to the Coolant Temperature is Above Normal Coolant temperature is above specification Sudden Overheat or the Coolant Temperature is Above Normal Gradual Overheat symptom tree LI pania Disconnect the drive train Check for engine noise Drive train noise is excessive trees i Refer to the vehicle service manual J Enana OUTS SRS WOW damaoed ornotcorest ieee Check the engine mounts Refer to the vehicle service g gsc manual and Procedure 016 003 oo Measure and adjust the overhead settings Refer to Procedure 003 004 Inspect the rocker levers rocker shafts and valves for Overhead components are damaged damage or excessive wear Refer to Procedure 003 008 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 32 Troubleshooting Symptoms Engine Noise Excessive Continued Cause Correction Perform the single cylinder cut out test Replace the Injector is malfunctioning injectors as necessary Refer to Procedure 006 026 or 014 008 LI Flywheel or flexplate capscrews are loose orbroken eetet epee tec ywhas or Topas andi Me mourn y P p capscr
55. llowing information as a guide to diagnosing engine noise Main Bearing Noise Refer to Engine Noise Excessive Main Bearing symptom tree The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load If all main bearings are loose a loud clatter will be heard The knock is heard regularly every other revolution The noise is the loudest when the engine is lugging or under heavy load The knock is duller than a connecting rod noise Low oil pressure can also accompany this condition If the bearing is not loose enough to produce a knock by itself the bearing can knock if the oil is too thin or if there is no oil at the bearing An irregular noise can indicate worn crankshaft thrust bearings An intermittent sharp knock indicates excessive crankshaft end clearance Repeated clutch disengagements can cause a change in the noise Connecting Rod Bearing Noise Refer to Engine Noise Excessive Connecting Rod symptom tree Connecting rods with excessive clearance knock at all engine speeds and under both idle and load conditions When the bearings begin to become loose the noise can be confused with piston slap or loose piston pins The noise increases in volume with engine speed Low oil pressure can also accompany this condition Piston Noise Refer to Engine Noise Excessive Piston symptom tree It is difficult to tell the difference between piston pin connecting rod and piston noise A loose piston pin
56. ment Procedure 001 014 J Connecting rod capscrews are loose or not tightened Check the torque on the connecting rod capscrews correctly Refer to Procedure 001 014 oo Inspect the connecting rod bearings Refer to assembled correctly or are the wrong bearings Procedure 001 005 Connecting rod bearings are damaged or worn are not 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 35 Engine Noise Excessive Main Bearing This is symptom tree T050 NOTE Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Check the oil pressure Refer to Procedure 007 052 If Lubricating oil pressure is below specification the pressure is low refer to the Lubricating Oil Pressure Low symptom tree Check the oil level Verify the dipstick calibration and Lubricating oil level is below specification the oil pan capacity Fill the system to the specified level Refer to Procedures 007 009 and 007 025 Refer to Lubricating Oil System General Information in Section 7 Refer to the Lubricating Oil Contaminated symptom tree Check the torque on the main bearing capscrews Inspect the capscrews for wear Refer to Procedure 001 006 Main bearing capscrews are loose worn or not tightened correctly Inspect the main bearings for damage excessive wear and the correct part number Refer to Procedure 001 006
57. n 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 44 Troubleshooting Symptoms Engine Power Output Low Continued Cause Correction Fuel injection pump is malfunctioning Remove and inspect the distributor snubber valve Refer to Procedure 005 020 ae A SN Check for seized distributor rotor Refer to Procedure Fuel injection pump is malfunctioning 005 072 Replace the CAPS sensor Refer to Procedure 019 164 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 valve 8 3 Liter Engines Check the CAPS coupling for wear or failure Refer to Procedure 005 072 Replace the fuel injection pump Refer to Procedure 005 012 or 005 014 or 005 016 internal amine damage Analyze the oil and inspect the filters to locate an area 9 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 45 Engine Runs Rough at Idle This is symptom tree T061 Cause Correction Allow the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal symptom tree Engine is cold ttt ees OK Refr to Secion TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Compare the calibration stored in the ECM wit
58. nic service tool and is malfunctioning personal computer user s manuals Dry the connectors with an electronic connector Cleaner Repair the electrical ground for the data bus shield Refer to the vehicle wiring diagram and service manual Replace the ECM Refer to Procedure 019 031 in the Electronic Control Module ECM is malfunctioning Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 4 Troubleshooting Symptoms Coolant Loss External This is symptom tree T020 Cause Correction spate Check the coolant level Refer to the vehicle service Coolant level is above specification ira ial Visually inspect the engine for coolant leaking from hoses drain cocks water manifold jumper tubes External coolant leak expansion and pipe plugs fitings radiator core air compressor and cylinder head gaskets lubricating oil cooler water pump seal and vehicle mou Radiator cap is not correct is malfunctioning or has low Check the radiator pressure cap Refer to Procedure pressure rating 008 047 Check the aftercooler and connections for leaks Inspect the radiator hoses Refer to Procedure 008 045 Check the coolant fll line for restrictions or obstructions Check the vent lines and the fill line for correct routing and for restricion Refer to the vehicle service manual be de Refer to the Coolant Temperatu
59. nnnnnnnnnnnnnnnnnnnnnnnnnnnnn 104 Main Bearing Noise ine Connecting Rod Bearingi NOSO agunia teaiin a T N aia brain dais 104 Piston NoiSe mya ne aiaa a a a a A Nia A Matis 104 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 1 Troubleshooting Procedures and Techniques A thorough analysis of the customer s complaint is the key to successful troubleshooting The more information known about a complaint the faster and easier the problem can be solved The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first Complete all steps in the sequence shown from top to bottom It is not possible to include all the solutions to problems that can occur however these charts are designed to stimulate a thought process that will lead to the cause and correction of the problem Follow these basic troubleshooting steps e Get all the facts concerning the complaint e Analyze the problem thoroughly e Relate the symptoms to the basic engine systems and components e Consider any recent maintenance or repair action that can relate to the complaint e Double check before beginning any disassembly e Solve the problem by using the symptom charts and doing the easiest things first e Determine the cause of the problem and make a thorough repair e After repairs have been made operate the engine to make sur
60. nsor and circuit Refer to Intake manifold pressure boost sensor or circuitis Procedures 019 061 in the Fuel Systems malfunctioning Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the idle or PTO time with an electronic service Engine idle or PTO time is excessive tool Low oil and coolant temperatures can be caused by long idle tme greater than 10 minutes Check the vehicle speed sensor and circuit Refer to Procedures 019 090 and 019 091 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the vehicle speed sensor and circuit for tampering Check for Fault Code 242 Repair the circuit as necessary Refer to Procedures 019 090 and 019 091 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Vehicle speed sensor VSS has been tampered with Check the fuel lines fuel connections and fuel filters for leaks Refer to Procedure 006 024 Check the fuel lines to the supply tanks Refer to vehicle service manual Visually inspect the air intake and exhaust systems for air leaks Refer to Procedure 010 024 Check the air intake system for restriction Clean or replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 78 Troubleshooting Symptoms Fuel Consumption Excessive Continued Cause Correction
61. om a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Fuel grade is not correct for the application or the fuel quality is poor Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 24 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 Check the vehicle key switch circuit Refer to Procedure 019 064 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the static injection timing Refer to Procedure 006 025 or 005 037 Check CAPS accumulator pressure Refer to Procedure 005 077 Check CAPS gear pump output pressure Refer to Procedure 005 025 Perform ICV solenoid click test Refer to Procedure 005 078 Perform CAPS plunger cut out test Refer to Procedure 005 079 Check for seized distributor rotor Refer to Procedure 005 072 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 25 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Si SHnischon puioismiatinetionina Aiesa Replace the fuel injection pump Refer to Procedure a 9 005 012 or 005 014 OK LI rs Procedure 001 008 LI of pro
62. ompare it to Turbocharger is not correct the Vehicle Parts List Replace the turbocharger if necessary Refer to Procedure 010 033 rere Check the wastegate for correct operation Refer to Procedure 010 050 Check the radial bearing clearance and axial clearance Inspect the turbocharger Repair or replace the turbocharger if necessary Refer to Procedures 010 038 and 010 047 Monitor the turbocharger boost pressure with an electronic service tool Refer to the appropriate Turbocharger is malfunctioning electronic service tool user s manual Replace the turbocharger if necessary Refer to Procedure 010 033 or 010 037 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 19 Engine Acceleration or Response Poor Continued Cause Correction Fill the fuel tank turn off or bypass the fuel heaters Fuel inlet temperature to pump is above specification and check the fuel cooler Refer to the vehicle service manual Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual LI mean a aaee Aa Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 Remove the injectors and compare the part numbers Injectors are not correct to the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 J Fuel injection p
63. ons and fuel filters for leaks Refer to Procedure 006 024 Check the fuel lines to the supply tanks Refer to vehicle service manual Fuelleak tt ttt OK ig ZA Check for fuel inlet restriction Refer to Procedure 006 Fuel inletrestricton 020 Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual Vehicle parasitics are excessive Charge air cooler CAC is restricted or leaking Soe air resticion or leaks Refer to Compare the drive train specifications to CDC recommendations Check the clutch for correct operation Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 16 Troubleshooting Symptoms Engine Acceleration or Response Poor Continued Cause Correction f ne Check for correct gearing and drive train components Drive tr t cty matched to th A i a BRUA Refer to the vehicle specifications Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Check the programmable parameters and the Programmable parameters or selected features are not selected features with an electronic service tool Set correct the parameters and features again if necessary Refer fo the appropria
64. ons and Specifications in the vehicle operation and maintenance manual Fuel grade is not correct for the application or the fuel quality is poor Check the turbocharger part number and compare it to Turbocharger is not correct the Vehicle Parts List Replace the turbocharger if necessary Refer to Procedure 010 033 or 010 037 LI Turbocharger wastegate is malfunctioning if equipped Sas Reta Tr eorteel Operation REIGNA Check the radial bearing clearance and axial clearance Inspect the turbocharger Repair or replace the turbocharger if necessary Refer to Procedures 010 038 and 010 047 Fuel injection pump is malfunctioning ee Remove and inspect the rate shape snubber valve Refer to Procedure 006 056 J Fuel injection pump is matfunctioning wee eee ie pump to engine timing Refer to Procedure 005 LI nate ee Remove and inspect the distributor snubber valve Fuel injection pump is malfunctioning treet Refer to Procedure 005 020 Turbocharger wheel clearance is out of specification Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 63 Engine Speed Surges Under Load or in Operating Range Continued Cause Correction F elinecionnino is matunton Teenaa Replace the fuel injection pump Refer to Procedure ak ai 9 005 012 or 005 014 or 005 016 OK LI itemnaenane damacan eere Analyze the oil and inspect the filters to locate an area
65. ooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Low idle adjust switch and circuit is malfunctioning Check the low idle adjust switch feature with an Low idle adjust switch feature is not enabled electronic service tool Refer to the appropriate electronic service tool user s manual 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 85 Intake Manifold Pressure Boost is Below Normal This is symptom tree T097 Cause Correction Ree ene eT rr eee Inspect the air intake and exhaust systems for air nipiotaleronex faust leaks leaks Refer to Procedure 010 024 OK Check the air intake system for restriction Clean or Air intake system restriction is above specification tetee replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Ll Inspect the CAC for air restriction or leaks Refer to Charge air cooler CAC is restricted or leaking Procedure 010 027 Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for fault code troubleshooting J ae Check the connection between the manifold and the air Air compressor connection is loose or damaged f f compressor Repair or replace if necessary ey ee Check the exhaust system for restrictions Refer to Procedure 011 009 Check the turbocharger part number and compare it to the Vehicle Parts List Replace the turbocharger if necessary Refer to Proced
66. ormal Sudden Overheat Coolant Temperature is Below Normal Coolant in the Lubricating Oil oc Crankcase Gases Blowby Excessive Cranking Fuel Pressure iS LOW seee Engine Acceleration or Response Poor Engine Decelerates Slowly 0 sesesssssessessessesseceessssessesesseesessesseesessseseesseeases Engine Difficult to Start or Will Not Start Exhaust Smoke sceeeeeeeee Engine Difficult to Start or Will Not Start No Exhaust Smoke Engine Noise EXCeSS V Eanan aaar saaa Aaa oaa reaa iaaa anna A A Engine Noise Excessive Combustion Knocks Engine Noise Excessive Connecting Rod cssssssecsscsssessssssssesseseessssessessesscsessessesssssscnsensseessseeessnsesseseseessssessessecesarsaeeneesesecaesees Engine Noise Excessive Main Bearing sccessvitssscecvscietsesicvesiccunsavesserssssavntsucveedesiesstsatavtan ssdgevvesheseskiiiessaivessevencenedarvditeberscseeatys Engine Noise Excessive Piston E ngine Noise Ex ssive Turbochatqet ission annaa aaa naai aaa aaa Engine Power Output Low Engine Runs Rough at Idle Engine Runs Rough or Misfires Engine Shuts Off Unexpectedly or Dies During Deceleration sssesisssssriessssrriressrriirsssrtrtssnuninennnnrrnnnnntrtennnnrnnnnnnnrrnnnnnnrnnnnnrennnnt 53 Engine Speed Surges at Low or High Idle Engine Speed Surges Under Load or in Operating Range sssssssssssssissserrisssssritressnrriennnnrinnnntitnnnnrtntnnnuntttenntrinnantrntnnnntrnenanneeaana 59 Engine SPSOd
67. orrection path ta mae Check the starting circuit components Refer to the Starting circuit component is malfunctioning J cctcc ces f f vehicle service manual OK LI Starting motor pinion or ring gear is damaged f tt Remove the starting motor and inspect the gear Change the oil and filters Refer to Procedure 007 013 Use the oil type recommended in the vehicle operation and maintenance manual LI wee are uss Install an oil pan heater or drain the oil and fill the Lubricating oil temperature is below specification system with warm oil Remove the injectors and rotate the crankshaft Look Hydraulic lock in a cylinder for the source of fluid in the cylinder Refer to Procedures 006 026 and 001 016 Lubricating oil does not meet specifications for operating conditions Check the oil level Verify the dipstick calibration and Lubricating oil level is above specification oil pan capacity Fill the system to the specified level Refer to Procedure 007 009 or 007 025 Check the oil pressure switch gauge or sensor for correct operation and location Refer to Procedure 007 052 Lubricating oil temperature switch gauge or sensor 0 Check the oil temperature switch gauge or sensor for malfunctioning or not in the correct location correct operation and location hiemaleran edamaot Sicani Analyze the oil and inspect the filter to locate an area g 9 of probable damage Refer to Procedure 007
68. oting Symptoms Page 61 Engine Speed Surges Under Load or in Operating Range Continued Cause Correction Remove the injectors and compare the part numbers Injectors are not correct fo the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 Ll mee Remove the injectors and verify the injector shim Injector shim thickness is not correct thickness Refer to Procedure 006 026 Perform the Automated Cylinder Performance Test to isolate the cylinder with the leaking fuel connector Inspect the fuel connector and injector for nicks or damage that may cause fuel leaks Refer to Procedure 006 026 or 014 008 Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle tme and engine driven units Refer to the vehicle service manual Vehicle parasitics are excessive Compare the drive train specifications to CDC Clutch is malfunctioning or is not correct recommendations Check the clutch for correct operation Refer to the vehicle service manual Check the fuel drain lines for restriction Clear or replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 62 Troubleshooting Symptoms Engine Speed Surges Under Load or in Operating Range Continued Cause Correction Operate the engine from a tank of good fuel Refer to Fuel Recommendati
69. ove specification oil pan capacity Fill the system to the specified level Refer to Procedures 007 009 or 007 025 LI Lubricating oil is contaminated with coolant or fuel fJ s s Sra O an Pubricaling Ob ontaminatad eympiom Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 87 Lubricating Oil Consumption Excessive Continued Cause Correction Check blowby Refer to Section 14 If blowby is excessive check the piston rings for correct seating Refer to Procedures 001 043 and 001 047 Piston rings are not seated correctly after an engine rebuild or piston installation Check for air intake system leaks Refer to Procedure 010 024 Check the pistons and piston rings for wear or damage Refer to Procedures 001 043 and 001 047 eee Check the turbocharger compressor and turbine seals Refer to Procedure 010 040 or 010 049 Intemalenanedamaass Moeras Analyze the oil and inspect the filters to locate an area g 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 88 Troubleshooting Symptoms Lubricating Oil Contaminated This is symptom tree T103 Cause Correction Check the bulk oil supply Drain the oil and replace Bulk oil supply is contaminated with non contaminated oil Replace the oil filters Refer to Procedure 007 025 or 007 013 LI Fuel in the lubrica
70. ptoms Coolant in the Lubricating Oil This is symptom tree T025 Cause Correction Lubricating oil cooler is malfunctioning 8 f eee Check the oil cooler Refer to Procedure 007 003 OK LI Air compressor cylinder head is cracked or porous or hasa Inspect the air compressor cylinder head and gasket leaking gasket Refer to Procedure 007 003 J Remove and pressure test the aftercooler Refer to Aftercooler is leaking aftercooled engines only Procedure 010 027 LI wilinger head core ang expansion pugslaakng Ol ll 4 sa ste Check cylinder head Refer to Procedure 002 004 misassembled EEEE Inspect the cylinder block Refer to Procedure 001 026 et Check the cylinder liners for corrosion or cracks Refer Cylinder liner is corroded or cracked to Procedure 001 028 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 13 Crankcase Gases Blowby Excessive This is symptom tree T027 Cause Correction Check the valve guides for wear Replace the cylinder head if necessary Refer to Procedure 002 004 Cylinder head valve guides are excessively worn Check the pistons for correct part numbers Check the Pistons or piston rings are worn damaged or not correct pistons and rings for wear and damage Refer to Procedures 001 043 and 001 047 J Tirbocharoeroikseaiisteakna e anie Check the turbocharger compressor and turbine seals 9 9 Refer to Procedure 010 040 or 010
71. pump temattundioning Tiea i pump to engine timing Refer to Procedure 005 OK LI EERI re Remove and inspect the distributor snubber valve Fuel injection pump is malfunctioning treet Refer to Procedure 005 020 LI F eliniection bimo is imalfinetionina eksas Check the CAPS coupling for wear or failure Refer to l pump 9 Procedure 005 072 LI Engine power output is low sd tts Refer to the Engine Power Output Low symptom tree 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 74 Troubleshooting Symptoms Engine Will Not Shut Off This is symptom tree T081 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Electronic fault codes active or high counts of inactive fault codes Check the vehicle key switch circuit Refer to 019 064 Key switch circuit is malfunctioning in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the air intake ducts Locate and isolate the Engine is running on fumes drawn into the air intake source of the fumes Repair as necessary Refer to the vehicle service manual Ll Turbocharoer oil seal is leakin Check the turbocharger compressor and turbine 9 9 seals Refer to Procedure 010 040 or 010 049 Ll EEE Por Replace the fuel injection pump Refer to Procedure Fuel injection pump is malfunctioning eae bi cette ee Beat
72. re 006 026 Check the fuel supply line from the fuel pump to the cylinder head for sharp bends which can cause restrictions Engine mounts are worn damaged or not correct ete Check the engine mounts es Dry the connectors with an electronic contact cleaner Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctoning Procedure 019 042 and 019 106 in the Fuel Systems Fuel supply line restriction between the fuel pump and the injectors Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 51 Engine Runs Rough or Misfires Continued Cause Correction Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Fuel grade is not correct for the application or the fuel quality is poor Remove the injectors and compare the part numbers Injectors are not correct to the Vehicle Parts List Replace the injectors if necessary Refer to Procedure 006 026 J iGGoPehinthickneeenekGaneae arera Remove the injectors and verify the injector shim J thickness Refer to Procedure 006 026 Ll Static injection timing is not correte Check the static injection timing Refer to Procedure l 9 006 025 or 005 037 J F eiiniectionn
73. re Above Normal Engine is overheating PENE A Ventlines or fil line are restricted obstructed or not routed correctly 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 5 Coolant Loss Internal This is symptom tree T021 Cause Correction 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 6 Troubleshooting Symptoms Coolant Temperature Above Normal Gradual Overheat This is symptom tree T022 Cause Correction Inspect the CAC air conditioner condenser and radiator fins Clean if necessary Refer to Procedures 008 042 and 010 027 and the vehicle service manual Charge air cooler CAC fins radiator fins or air conditioner condenser fins are damaged or obstructed with debris Inspect the engine and radiator for external coolant Coolant level is below specification leaks Repair if necessary Add coolant Refer to Procedure 008 018 Verify the concentration of antifreeze in the coolant Add antifreeze or water to correct the concentration Refer to Section 8 eae Check the thermostat for the correct part number and for correct operation Refer to Procedure 008 013 Radiator cap is not correct is malfunctioning or has low Check the radiator pressure cap Refer to Procedure pressure rating 008 047 Inspect the shroud and the recirculation baffles Repair replace or install if necessary Refer to Procedure 008 038 and the vehicl
74. rea 9 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 30 Troubleshooting Symptoms Engine Noise Excessive This is symptom tree T047 NOTE When troubleshooting engine noise complaints make sure the engine accessories air compressor fan clutch freon compressor or hydraulic pump are not the cause of the noise Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Fan drive belt is loose ttt Check the belt tension and tighten if necessary OK Fan is loose damaged or not balanced ss ttt Check the fan Refer to Procedure 008 040 SETIEN Inspect the air intake and exhaust systems for air leaks Refer to Procedure 010 024 AANT Inspect the air piping chassis and cab for contact points Check the oil level Add or drain oil if necessary Refer to Procedure 007 025 Check the dipstick calibration Refer to Procedure 007 009 Refer to Lubricating Oil System General Information in Section 7 Refer to the Lubricating Oil Contaminated symptom tree Check the oil pressure Refer to Procedure 007 052 If Lubricating oil pressure is below specification the pressure is low refer to the Lubricating Oil Pressure Low symptom tree Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 31 Engine Noise Excess
75. rt number and compare it to Turbocharger is not correct the Vehicle Parts List Replace the turbocharger if necessary Refer to Procedure 010 033 or 010 037 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 101 Smoke Black Excessive Continued Cause Correction ed a ey a RRO re a Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 OK Check and clean the crankcase breather and vent Crankcase ventilation system is plugged tube Refer to Procedure 003 001 003 002 or 003 018 Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual Jl s thickness Refer to Procedure 006 026 Jl i 006 025 or 005 037 Check pump to engine timing Refer to Procedure 005 037 ETT Check the CAPS coupling for wear or failure Refer to Procedure 005 072 Fuel grade is not correct for the application or the fuel quality is poor Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 102 Troubleshooting Symptoms Smoke Black Excessive Continued Cause Correction Fuel injection numo is malfunctioning a aeei Replace the fuel injection pump Refer to Procedure S RAE 9 005 012 or 005 014 or 005 016 OK LI Check the intake manifold for fuel Refer to Procedure Raw fuel in the intake manifol
76. sued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 67 Engine Vibration Excessive This is symptom tree T075 Cause Correction ine ig mistiri Refer to the Engine Runs Rough or Misfires symptom If engine is misfiring 24 ppoe an OK Check the fan hub alternator freon compressor and Belt driven accessories are malfunctioning hydraulic pump for interference Isolate belt driven accessories and check for vibration Verify the correct idle speed setting Increase the idle speed with the idle increment switch or an electronic service tool Jl Endine icici ea SIIB GEOR CRHORE hirse Check the engine mounts Refer to the vehicle service g gee manual and Procedure 016 003 Jl Fan is loose damaged or not balanced ss ttre Check the fan Refer to Procedure 008 040 Compare the drive train components to the engine and equipment specifications Isolate the drive train components and check for vibrations Refer to the vehicle specifications Rees th Check the flywheel housing alignment Flywheel or flexplate capscrews are loose or broken eetet See Me hice Or TeMpictesandie ie mount capscrews Engine idle speed is set too low electronic controlled fuel systems Drive train components are malfunctioning or are not correct Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 68 Troubleshooting Symptoms Engine Vibration Excessive Continued Cause Corre
77. te electronic service tool Manual i Electronic Control Module ECM calibration is notcorrect Compare he calbraton spies nee eeu te engine rating Ifnecessary calibrate the ECM Check the percent throttle reading on an electronic service tool Verify that it reads 100 percent with the Accelerator pedal is restricted or malfunctioning accelerator pedal depressed Calibrate the accelerator if possible Replace the accelerator pedal ifnecessary Refer to the vehicle service manual Check the boost sensor and circuit Refer to Intake manifold pressure boost sensor or circuitis Procedures 019 061 and 019 062 in the Fuel malfunctioning Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 17 Engine Acceleration or Response Poor Continued Cause Correction Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the ambient air pressure sensor Refer to Procedure 019 004 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check for air in the fuel system Refer to Procedure 006 003 Check the fuel supply line from
78. tems Troubleshooting and Repair Manual for CDC 24 valve 8 3 Liter Engine Fill the supply tank Check for fuel inlet restriction Refer to Procedure 006 020 Check the fuel lines fuel connections and fuel filters for leaks Refer to Procedure 006 024 Check the fuel lines fo the supply tanks Refer to vehicle service manual Fuelleak ttt Check the fuel lift pump for correct operation Check Fuel lift pump is malfunctioning the pump output pressure Replace the fuel lift pump if necessary Refer to Procedure 005 045 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 39 Engine Power Output Low Continued Cause Correction Fuel filter is plugged O lt lt t d Measure the fuel pressure before and after the fuel plugs filter Refer to Procedure 005 011 OK Engine power decreases above recommended Engine is operating above recommended altitude altitude Refer to the Engine Data Sheet for specifications Verify the engine duty cycle with an electronic service tool Refer to the appropriate electronic service tool user s manual Check the programmable parameters and the selected Programmable parameters or selected features are not features with an electronic service tool Set the correct parameters and features again if necessary Refer to the appropriate electronic service tool user s manual Compare the calibration stored in the ECM
79. the ECM with the engine rating and the Vehicle Parts List Ifnecessary calibrate the ECM Alternately disconnect all other J1939 control devices J1939 control devices are interfering with the engine from the data bus circuit until communications or controls functionality is restored Refer to the service manual to locate and repair J1939 control devices Verify the correct idle speed seting Increase the idle speed with the idle increment switch or an electronic service tool Engine idle speed is set too low electronic controlled fuel systems Check the percent throttle reading on an electronic service tool Verify that it reads 100 percent with the Accelerator pedal is restricted or malfunctioning accelerator pedal depressed Calibrate the accelerator if possible Replace the accelerator pedal ifnecessary Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 56 Troubleshooting Symptoms Engine Speed Surges at Low or High Idle Continued Cause Correction Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Engine speed sensor ESS or circuit is malfunctioning Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Check the vehicle speed sensor and circuit Refer to Procedures 019 090 and 019 091in the Fuel V
80. ting oil ett Refer to the Fuel in the Lubricating Oil symptom tree II Internal coolant leaks ttt Refer to the Coolant Loss Internal symptom tree PETRS Refer to the Lubricating Oil Sludge in the Crankcase is Excessive symptom tree Identify lubricating oil contamination tres Perform an oil analysis to determine the contaminants 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 89 Lubricating Oil Pressure High This is symptom tree T104 Cause Correction Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting Refer to the Coolant Temperature Below Normal symptom tree Change the oil and filters Refer to Procedure 007 025 Use the oil type recommended in the vehicle operation and maintenance manual Electronic fault codes active or high counts of inactive fault codes Lubricating oil does not meet specifications for operating conditions Check the oil pressure switch gauge or sensor for correct operation and location Refer to Procedure 007 052 Lubricating oil pressure switch gauge or sensor is malfunctioning or is not in the correct location Check the lubricating oil pressure sensor and circuit Lubricating oil pressure sensor or circuit is malfunctioning Refer to Procedure 019 066 in the Fuel Systems electronic controlled fuel system Troubleshooting and Repair Manu
81. ts as necessary Refer to Procedure 006 012 Check the vehicle brakes for dragging transmission malfunction cooling fan operation cycle time and engine driven units Refer to the vehicle service manual LI Turbocharger wastegate is malfunctioning if equipped oe o a Vehicle parasitics are excessive Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 42 Troubleshooting Symptoms Engine Power Output Low Continued Cause Correction Check the radial bearing clearance and axial clearance Inspect the turbocharger Repair or replace the turbocharger if necessary Refer to Procedures 010 038 and 010 047 Turbocharger wheel clearance is out of specification Check the turbocharger part number and compare it to Turbocharger is not correct the Vehicle Parts List Replace the turbocharger if necessary Refer to Procedure 010 033 or 010 037 ae Refer to the Intake Manifold Air Temperature Above Specification symptom tree Fill the fuel tank turn off or bypass the fuel heaters Fuel inlet temperature to pump is above specification and check the fuel cooler Refer to the vehicle service manual Operate the engine from a tank of good fuel Refer to Fuel Recommendations and Specifications in the vehicle operation and maintenance manual J Inspect the CAC for air restriction or leaks Refer to Charge air cooler CAC is restricted or leaking Procedure 010 027 J
82. umois malfunctioning esses Check CAPS accumulator pressure Refer to l pornp 9 Procedure 005 077 ee Perform ICV solenoid click test Refer to Procedure 005 078 Paean Remove and inspect the rate shape snubber valve Refer to Procedure 006 056 Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 52 Troubleshooting Symptoms Engine Runs Rough or Misfires Continued Cause Correction Fuel injection pump is malfunctioning 8 potee Check pump to engine timing OK LI Panes i SI Replace the fuel injection pump Refer to Procedure Fuel injection pump is malfunctioning J treet 005 012 or 005 014 or 005 016 LI Check the camshaft tonewheel for tightness Refer to Camshaft geartonewheelloose sf tres Procedure 001 008 LI ntendiendne darnaass iaae Analyze the oil and inspect the filters to locate an area g g of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 53 Engine Shuts Off Unexpectedly or Dies During Deceleration This is symptom tree T064 Cause Condition Eee Refer to the Engine Difficult to Start or Will Not Start Ifengine will not restart symptom tree LI Fuel level low in the tank o ppe Fill the supply tank Refer to Section TF in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines for fault code troubleshooting
83. ump is malfunctioning J ttt EAA ed PUN OulpUt presure Reet Sete ee Check CAPS accumulator pressure Refer to Fuel injection pump is malfunctioning J ttt Procedure 005 077 LI Fuel injection pump is malfunctioning Remove and inspect the rate shape snubber valve Refer to Procedure 006 056 Fuel injection pump is malfunctioning wwe eee Remove and inspect the distributor snubber valve Refer to Procedure 005 020 J baited Replace the fuel injection pump Refer to Procedure Fuel injection pump is malfunctioning J tree 005 012 or 005 014 LI tentar eninedamasa esre Analyze the oil and inspect the filters to locate an area g 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 Fuel grade is not correct for the application or the fuel quality is poor 24 Valve 8 3 Liter Engine Page 20 Troubleshooting Symptoms Engine Decelerates Slowly This is symptom tree T041 Cause Correction Check the fuel drain lines for restricion Clear or Fuel drain line restriction replace the fuel lines check valves or tank vents as necessary Refer to Procedure 006 012 Check the percent throttle reading on an electronic service tool Verify that it reads 100 percent with the Accelerator pedal is restricted or malfunctioning accelerator pedal depressed Calibrate the accelerator if possible Replace the accelerator pedal ifnecessary Refer to the vehicle service manual Perform the automated cylinder
84. ure a oa 9 005 012 or 005 014 or 005 016 LI iRtemarendnedamada eima Analyze the oil and inspect the filters to locate an area g g of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 80 Troubleshooting Symptoms Fuel in Coolant This is symptom tree T091 Cause Correction Cylinder heads tacked orporolg Si we Pressure test the cylinder head Refer to Procedure 002 004 OK Check the bulk coolant supply Drain the coolant and Bulk coolant supply is contaminated replace with non contaminated coolant Replace the coolant filters Refer to Procedure 008 018 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Troubleshooting Symptoms Page 81 Fuel in the Lubricating Oil This is symptom tree T092 Cause Correction Low oil and coolant temperatures can be caused by Engine idle time is excessive long idle time greater than 10 minutes Shut off the engine rather than idle for long periods If idle time is necessary raise the idle speed J iniectoroinasare damaoedormishg e arnis Remove and check the injectors Replace the injector l 9 g g o rings Refer to Procedure 006 026 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedure 006 005 or 006 026 ee tog Pressure test the cylinder head Refer to Procedure 002 004 Check the bulk oil suppl
85. ure 006 003 g Coolant temperature is above specification et Check the coolant level Refer to Procedure 008 018 Perform the automated cylinder performance test Injector is malfunctioning Replace injectors as necessary Refer to Procedure 006 026 or 014 008 LI EE E nt eet EEN Measure and adjust the overhead settings Refer to Overhead adjustments are not correct Procedure 003 004 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 34 Troubleshooting Symptoms Engine Noise Excessive Connecting Rod This is symptom tree T049 NOTE Refer to Engine Noise Diagnostic Procedures General Information on page 104 before using this symptom tree Cause Correction Check the oil level Verify the dipstick calibration and Lubricating oil level is below specification the oil pan capacity Fill the system to the specified level Refer to Procedures 007 009 and 007 025 Check the oil pressure Refer to Procedure 007 052 If Lubricating oil pressure is below specification the pressure is low refer to the Lubricating Oil Pressure Low symptom tree Refer to Lubricating Oil System General Information in Section 7 Refer to the Lubricating Oil Contaminated symptom tree Crankshaft joumals are damaged or outofround Inspect the crankshaft journals Refer to Procedure 001 016 g betaine IN ierat Remove and inspect the connecting rods Refer to Connecting rod is bent or out of align
86. ure 010 033 Electronic fault codes active or high counts of inactive fault codes Check the turbocharger for damage Measure the turbine and compressor wheel clearances Refer to Procedure 010 038 Engine power outputislow sds tts Refer to the Engine Power Output Low symptom tree 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 86 Troubleshooting Symptoms Lubricating Oil Consumption Excessive This is symptom tree T102 Cause Correction Change the oil and filters Refer to Procedure 007 025 Use the oil type recommended in the vehicle Lubricating oil does not meet specifications for operating conditions operation and maintenance manual LI Ab Sa te ddiaa Verify the correct lubricating oil drain interval Refer to Lubricating oil drain interval is excessive J otee f the vehicle operation and maintenance manual Inspect the engine for external oil leaks Tighten the capscrews pipe plugs and fittings Replace gaskets if necessary Refer to the vehicle operation and maintenance manual PRIRA Check the amount of oil added versus the mileage Check the air lines for carbon buildup and lubricating oil Refer to the Air Compressor is Pumping Excessive Lubricating Oil into the Air System symptom tree POSER Check the lubricating oil cooler for coolant leaks Refer to Procedure 007 003 Check the oil level Verify the dipstick calibration and Lubricating oil level is ab
87. with the Electronic Control Module ECM calibration is not correct engine rating and the Vehicle Parts List If necessary calibrate the ECM Alternately disconnect all other J1939 control devices from the data bus circuit until communications or functionality is restored Refer to the vehicle service manual to locate and repair J1939 control devices Check the percent throttle reading on an electronic service tool Verify that it reads 100 percent with the accelerator pedal depressed Calibrate the accelerator if possible Replace the accelerator pedal if necessary Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 40 Troubleshooting Symptoms Engine Power Output Low Continued Cause Correction Check the air intake system for restriction Clean or Air intake system restriction is above specification replace the air filter and inlet piping as necessary Refer to Procedure 010 031 g e Visually inspectthe air intake and exhaust systems for PERAE D SANES air leaks Refer to Procedure 010 024 Check the boost sensor and circuit Refer to Intake manifold pressure boost sensor or circuit is Procedures 019 061 in the Fuel Systems malfunctioning Troubleshooting and Repair Manual for CDC 24 valve 8 3 Liter Engines Use an electronic service tool to monitor the vehicle speed while the vehicle is not moving Refer to the Vehicle speed sensor VSS or c
88. y Drain the oil and replace with non contaminated oil Replace the oil filters Refer to the vehicle specifications Inspect the cam housing for cracks and damage Fuel injection pump is malfunctioning J tet Replace cam module if necessary refer to Procedure 005 088 ig iIMemeaeaeedameess iasan Analyze the oil and inspect the filters to locate an area g 9 of probable damage Refer to Procedure 007 002 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 82 Troubleshooting Symptoms Intake Manifold Air Temperature Above Specification This is symptom tree T096 Cause Correction Inspect the CAC air conditioner condenser and radiator fins Clean if necessary Refer to Procedures 010 027 and 008 042 and the vehicle service manual DOLEN Check the belt tension and tighten if necessary Refer to Procedure 008 002 ths Check the fan drive belt Replace the belt if necessary Refer to Procedure 008 002 Inspect the shroud and the recirculation baffles Repair replace or install if necessary Refer to Procedure 008 038 and the vehicle service manual ie ies Check the exhaust plumbing for leaks or broken components Charge air cooler CAC fins radiator fins or air conditioner condenser fins are damaged or obstructed with debris Fan shroud is damaged or missing or the air recirculation baffles are damaged or missing Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001
89. ystem for restricion Clean or Air intake system restriction is above specification replace the air filter and inlet piping as necessary Refer to Procedure 010 031 Check for correct operation of the starting aid Refer to Starting aid is necessary for cold weather or starting aid is the manufacturer s instructions Refer to Cold Weather malfunctioning Starting Aids in the vehicle operation and maintenance manual Measure the fuel pressure before and after the fuel filter Refer to Procedure 005 011 Check the electrical sources and wiring to the cylinder block heater Replace the block heater if necessary Refer to the vehicle service manual Continued 7 89351NH Section 10 Chapter 7 Issued 8 2001 24 Valve 8 3 Liter Engine Page 22 Troubleshooting Symptoms Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Check the fuel heater and replace if necessary Refer fo the manufacturer s instructions Fuel heater is malfunctioning if equipped Check the engine cranking speed with a hand held tachometer or electronic service tool If the cranking speed is lower than 150 rpm refer to the Engine Will Not Crank or Cranks Slowly symptom tree Check the ESS for correct adjustment and for debris on the sensor Check the ESS circuit Refer to Procedure 019 042 and 019 106 in the Fuel Systems Troubleshooting and Repair Manual for CDC 24 Valve 8 3 Liter Engines Check the fuel lines fuel

24 Valve, 8.3 Liter Engine

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