• Crankshaft
Troubleshooting and Repair Test Procedure
1. Current and Recorded Codes
A. Establish communication between the Electronic Service Tool and the Electronic Control Module (ECM). Refer to Troubleshooting and Repair, “Electronic Service Tool,” if necessary. Result: Current codes exist. Repair: Proceed to test step 2.
B. Before performing any troubleshooting or clearing diagnostic fault codes, download the “Warranty Report” from the engine ECM. Before this step, diagnose and clear all current codes. Result: No current codes. Proceed to test step 2.
2. Electrical Connections
A. Check that the ECM J1/P1 and J2/P2 connectors are installed correctly. Check that the injector connectors are installed correctly. Result: Suspected connectors exist. Repair: Repair or replace the suspected connector. Perform a “shake test” on the electronic service tool. Result: No suspicious connectors. Proceed to test step 3.
Result: Test unsuccessful.
Repair: Diagnose and repair the fault.
Reset all current codes and clear all recorded codes.
Confirm the fault is resolved after repair.
4. Fuel Quality
A. Refer to the operating and maintenance manual for information on the correct fuel characteristics for the engine. If necessary, obtain fuel analysis to confirm that the fuel being used on the engine is correct. Refer to System Operation, Testing and Adjustment, “Fuel Quality – Test” for the correct procedures.
Result: Fuel quality is normal.
Proceed to test step 5.
Result: Fuel quality is poor.
B. Before performing any troubleshooting or clearing diagnostic fault codes, download the “Warranty Report” from the engine ECM.
Before this step, diagnose and clear all current codes.
Result: No current codes.
Proceed to test step 2.
5. Lubrication
A. Check that the valve components are adequately lubricated.
B. Check for oil passage blockages. Oil passages must be clean. Clean all suspected oil passages. For more information, refer to Disassembly and Assembly.
C. Check the engine oil filter for ferrous materials.
D. Obtain an oil analysis.
Note: Analysis helps to better understand oil contamination and its sources.
Result: Oil passages are not blocked, and the engine is adequately lubricated.
Proceed to test step 6.
Result: Oil passages are blocked, or the engine is not adequately lubricated.
Repair: Perform necessary repairs to confirm that the fault has been resolved.
6. Isolate the Noise Source
A. If the noise source is an engine accessory, remove and inspect the suspected item.
Result: Engine accessory is the noise source.
Repair: Repair and/or replace the engine accessory, if necessary.
Result: Engine accessory is not the noise source.
Proceed to test step 7.
7. Valve Train Components
A. Check valve clearance. See Troubleshooting, “Excessive Valve Clearance”.
B. Check valve train components for damage. Remove the valve cover from the suspected cylinder. Check the following components for damage:
· Camshaft
· Valve spring
· Camshaft follower
· Rocker arm shaft
· Valve bridge
Result: Valve train components are not damaged.
Proceed to test step 8.
Result: Valve train components are damaged.
Repair: Perform necessary repairs to confirm that the fault has
been resolved.
8. Piston and Connecting Rod
A. Inspect the piston for damage and wear.
B. Inspect the connecting rod bearings for damage and wear.
Result: One or more components are worn or damaged.
Replace all worn or damaged parts.
Confirm noise is eliminated after repair.
Result: All components are normal.
Proceed to test step 9.
9. Crankshaft
A. Inspect the crankshaft and related components. Look for wear on the thrust washers and crankshaft.
B. Inspect the connecting rod bearings and bearing surfaces on the crankshaft. Ensure the bearings are in the correct position.
Result: Crankshaft or related components are damaged or worn.
Repair: Repair or replace any damaged parts. Confirm the fault is eliminated after repair.
Result: All components are normal.
Please contact your dealer’s Solution Network (DSN).
