Diagnostic Procedure A

DIAGNOSTIC PROCEDURE A: Engine Cranks But Does Not Start.

1. Using the DRBIII(R), perform a "Module Scan". Check for DTC's and record DTC's on the repair order. If DTC's are present, proceed to Step # 2. If DTC's are not present, proceed to Step # 3.

2. In case of a DTC with the status "CURRENT and/or STORED", follow the service information for that DTC and repair accordingly. When the repair is completed, proceed to Step # 17.

3. Using the DRBIII(R), check the synchronization status of the Cam/Crankshaft sensor. Record the fuel pressure displayed while performing the Cam/Crankshaft sensor test on the repair order. If the sensors are synchronized, proceed to Step # 5. If the sensors are not synchronized, proceed to Step # 4.

4. Check the cam/crank sensor (with an oscilloscope if available). Check the flywheel segments for damage (crankshaft sensor signal). When the repair is completed, proceed to Step # 17.

5. Was the fuel rail pressure, recorded in Step # 3, above 24821 kPa (3600 PSI)? If the pressure is less than 24821 kPa (3600 PSI), proceed to Step # 6. If the pressure is greater than 24821 kPa (3600 PSI), the high pressure fuel system is OK. Check for a mechanical problem.

6. Using the DRBIII(R), perform the "Fuel Rail Pressure Sensor Test" with the ignition key "On", engine off. If the voltage is between .47 and .53 volts, proceed to Step # 7. If not, proceed to Step # 15.

7. Check the fuel pressure between the in-tank fuel pump and the fuel filter. If the fuel pressure is between 379 kPa (55 PSI) and 552 kPa (80 PSI), proceed to Step # 8. If the fuel pressure is below 379 kPa (55 PSI), proceed to Step # 13. If the fuel pressure is above 552 kPa (80 PSI), proceed to Step # 14.

8. Perform the "Fuel Leak Quantity" test. Refer to the information available in TechCONNECT. Refer to 14 - Fuel System - Diagnosis And Testing. Each small vial must not exceed 2.5 ml (between 2 & 3 graduation lines of the inner vial). If the vials contain less than 2.5 ml, proceed to Step # 9. If any vial exceeds 2.5 ml, proceed to Step # 12.

9. Check the leak quantity of the fuel rail pressure solenoid as outlined in Diagnostic Procedure D. If there is noticeable leakage (greater than 0 ml), proceed to Step # 10. If there is no noticeable leakage, proceed to Step # 11.

10. Replace the complete fuel rail with the pressure sensor and the solenoid. Refer to the service information available in TechCONNECT. When the repair is complete, proceed to Step # 17.

11. Replace the Fuel Injection Pump. Refer to the service information available in TechCONNECT. When the repair is complete, proceed to Step # 17.

12. Replace the injector with excessive leakage. Refer to the service information available in TechCONNECT. Return to Step # 8 and repeat the test.

13. Check the in-tank fuel pump and the fuel lines between the tank and fuel filter for leakage and/or restriction. Repair as necessary. When repair is complete proceed to Step # 17.

14. Check the fuel filter and fuel lines between the filter and the high pressure pump for restriction. Repair as necessary. When repair is complete, proceed to Step # 17.

15. Check the Engine Control Module (ECM) connector and wiring harness for corrosion, pushed out wire, or connection problems. If a problem was detected, repair as necessary and proceed to Step # 17. If no problem was detected, proceed to Step # 16.

16. Replace the fuel rail pressure sensor. Refer to the service information available in TechCONNECT. Proceed to Step # 17.

17. Perform the "Road Test Verification" - VER-2. Refer to the service information available in TechCONNECT.