Diagnostic Procedure B

DIAGNOSTIC PROCEDURE B: Engine Has A Long Crank Time (More Than 3 Seconds After The Glow Plug Lamp In The Instrument Cluster Is Off And The Ambient Temperature Is Above 10° C (50° F).

1. Using the DRBIII(R), perform a "Module Scan". Check for DTC's and record DTC's on the repair order. Where any DTC's present? 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. Turn the ignition key to "START" and using the DRBIII(R) check the engine RPM while cranking. If the engine cranking speed is greater than 200 RPM, proceed to Step # 5. If the engine cranking speed is less than 200 RPM, proceed to Step # 4.

4. Check the battery and/or starting system. Also check the crankshaft sensor for wear and/or dirt deposits. Repair as necessary and proceed to Step # 17.

5. Start the engine. Check the fuel rail pressure and time during the starting process. If the fuel rail pressure is less than 24821 kPa (3600 PSI) after 2 seconds, proceed to Step # 7. If the fuel rail pressure is greater than 24821 kPa (3600 PSI) after 2 seconds, proceed to Step # 6.

6. Check the Glow Plug System and/or engine compression. Repair as necessary and proceed to Step # 17.

7. Using the DRBIII(R), perform the "Fuel Rail Pressure Sensor Test". If the voltage is between .47 and .53 volts, proceed to Step # 10. If not, proceed to Step # 8.

8. 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 # 9.

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

10. 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 # 11. If the fuel pressure is below 379 kPa (55 PSI), proceed to Step # 12. If the fuel pressure is above 552 kPa (80 PSI), proceed to Step # 13.

11. Perform the "Fuel Leak Quantity" test. Refer to the information available in TechCONNECT. Refer to 14 - Fuel System - Diagnosis And Testing. Each value must not exceed 5 graduation lines of the large vial (40 ml). If the values do not exceed 5 graduation lines of the large vial (40 ml), proceed to Step # 14. If the values exceed 5 graduation lines of the large vial (40 ml), proceed to Step # 15.

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

13. 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.

14. Using the DRBIII(R), perform the "Pump Pressure Generation" test. The pressure should increase from approximately 39990 kPa (5800 PSI) to approximately 139998 kPa (20305 PSI) within 2 seconds. If the pressure increases within 2 seconds, proceed to Step # 17. If the pressure does not increase to 139998 kPa (20305 PSI) within 2 seconds, proceed to Step # 16.

15. Replace the injector with the excessive leakage. Refer to the service information available in TechCONNECT. Return to Step # 11 and repeat the test.

16. Replace the Fuel Injection Pump. 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.