Inspection
| Action
|
DEFINITION: Black smoke under load, idle or start up hot or cold.
|
Preliminary Inspection
|
| • | Ensure the customer has an actual problem. |
| - | During light to moderate acceleration there should be no black smoke. |
| - | During the 2-3 hard accelerations after normal light load driving there may be some black smoke momentarily but should not last for more than 5 seconds. |
| - | During hard acceleration there may always be a very faint puff of black smoke. |
| - | Black smoke during light to moderate acceleration |
| - | Heavy black smoke during hard acceleration that lasts for more than 5 seconds |
| - | Heavy black smoke during every hard acceleration and/or during transmission shift transitions |
| • | Compare the scan tool data at idle with the scan tool data list. Refer to
Scan Tool Data List
. |
|
Fuel System Inspection
|
| • | Observe the actual vs. desired fuel rail pressure with a scan tool, with the engine running. |
| • | If the engine control module (ECM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to
Fuel Injector Flow Rate Programming
. |
|
Sensor Inspection
| Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature
on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself.
|
Air Intake System Inspection
|
| • | Inspect for an air leak in the charge air cooler or the air ducts between the turbocharger and the intake manifold. Refer to
Charge Air Cooler Diagnosis
. |
| • | Inspect for a restriction in the air cleaner or the air intake ducts. |
| • | Inspect for a restriction in the turbocharger charge air cooler. |
| • | Inspect for a restriction in the intake manifold. |
| • | Inspect that the EGR valve is fully closing. Remove the EGR valve and visually inspect that there is no light seen between the valves and the valve seats. |
| • | Ensure that the EGR valve does not bind when manually moving the valve. |
|
Engine Mechanical Inspection
|
| • | Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, etc. |
|
Inspection
| Action
|
DEFINITION: Gray or blue smoke under load, idle or start up hot or cold.
|
Preliminary Inspections
|
| • | Ensure the customer has an actual problem. |
| • | Check the coolant level in the reservoir. White coolant smoke may be mistaken for blue/gray smoke. If the coolant level is low refer to
Loss of Coolant
. |
| • | Compare the scan tool data at idle with the scan tool data list. Refer to
Scan Tool Data List
. |
|
Fuel System Inspection
|
| • | Observe the actual vs. desired fuel rail pressure with a scan tool, with the engine running. |
| • | If the engine control module (ECM) glow plug control module (GPCM) or a fuel injector has recently been replaced, it may be necessary to confirm the fuel injector flow rate values. Refer to
Fuel Injector Flow Rate Programming
. |
|
Sensor Inspection
| Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature
on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself.
|
Air Intake System Inspection
|
| • | Inspect the air cleaner and the air intake ducts for restriction. |
| • | Inspect for contamination of the mass air flow (MAF) sensor. |
| • | Inspect for a restriction in the turbocharger charged air cooler. |
| • | Inspect for a restriction in the intake manifold. |
|
Engine Mechanical Inspection
|
| • | Perform a cylinder leakage test. |
| • | Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, piston rings, and valves. |
|
Turbocharger Inspection
| Inspect for leaking seals in the turbocharger. A slight film on the intake side is normal.
|
Inspection
| Action
|
DEFINITION: White smoke under load, idle or start up hot or cold.
|
Preliminary Inspection
|
| • | Ensure the customer has an actual condition. |
| • | Check the coolant level in the reservoir. White coolant smoke may be mistaken for blue/gray smoke. If the coolant level is low refer to
Loss of Coolant
. |
| • | Compare the scan tool data at idle with the scan tool data list. Refer to
Scan Tool Data List
. |
|
Fuel System Inspection
| If excessive smoke is present, inspect for a stuck fuel injector. Refer to
Fuel Injector Balance Test with Tech 2
.
|
Sensor Inspection
| Inspect the engine coolant temperature (ECT) sensor. Use the scan tool in order to compare the ECT with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 degrees more or less than the ambient air temperature
on a cold engine, inspect for a high resistance in the coolant sensor circuit or the sensor itself.
|
Air Intake System Inspection
|
| • | Inspect the air cleaner and the air intake ducts for restriction. |
| • | Inspect for a restriction in the turbocharger charge air cooler. |
|
Engine Mechanical Inspection
|
| • | Inspect for incorrect basic engine parts such as the cam, the heads, the pistons, etc. |
| • | Inspect for coolant entering the combustion chamber. |
|
