*LACK OF ENGINE POWER

For a complete wiring diagram Refer to Section 8W

Possible Causes

AIR IN FUEL SYSTEM

FUEL INJECTOR CLASSIFICATION

BRAKE SWITCH PROBLEM

EGR SYSTEM PROBLEM

BOOST PRESSURE PROBLEM

LOW ENGINE COMPRESSION

FUEL DELIVERY SYSTEM RESTRICTION

ENGINE DRIVE BELT/CHAIN

FUEL INJECTOR(S)

FUEL INJECTION PUMP

FUEL SYSTEM CONTAMINATION

FUEL SYSTEM LEAK

TURBOCHARGER

Diagnostic Test

1. CHECKING FOR ECM DTCS

WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 23,200 PSI (1600 BAR). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.

WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.

Turn the ignition on.
With the scan tool, read the ECM DTCs.

Are there any DTCs present?

Yes

Refer to symptom list for problems related to this DTC.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Go To 2

2. CHECKING THE BRAKE SWITCH ADJUSTMENT

Refer to the Service Information and check for proper Brake Switch adjustment.

Is the Brake Switch adjusted correctly?

Yes

go to 3

Adjust or replace the Brake Switch as necessary.
Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

3. EGR SYSTEM

Refer to the symptom list and perform the CHECKING THE EGR SYSTEM test.

Were any problems found during the EGR System test?

Yes

Repair or replace as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

4. FUEL SYSTEM LEAK

Turn the ignition off.

Inspect the entire fuel system for leakage.

Is there any evidence of leakage?

Yes

Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Go To 5

5. FUEL SYSTEM CONTAMINATION

NOTE: Mixing any other fuels such as gasoline or kerosine can cause this symptom to occur.

Turn the ignition off.

Inspect the fuel system for contamination.

Is the fuel contaminated?

Yes

Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Go To 6

6. CHECKING BOOST PRESSURE

Turn the ignition on.

NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the scan tool readings.

With the scan tool in Sensors, read and compare the Boost Pressure (PSI) with the Boost Pressure Desired/Setpoint (PSI) while test driving the vehicle under various load conditions such as idle, hard acceleration, and cruise.

NOTE: The Boost Pressure reading should directionally follow (trail) the Boost Pressure Desired/Setpoint reading.

Does the Boost Pressure reading follow the Boost Pressure Desired/Setpoint reading?

Yes

Go To 7

Refer to the symptom CHECKING THE BOOST PRESSURE.

7. FUEL INJECTOR CLASSIFICATION

NOTE: Each Fuel Injector is labeled with a code. This code determines the injector classification. Each Injector classification must be programmed into the ECM using the scan tool.

Turn the ignition off.
Refer to the Service Information to locate each fuel injector label and check for the correct classification for each fuel injector in the ECM.

Are all of the injectors classified correctly?

Yes

Go To 8

Using the scan tool, program the correct Fuel Injector classifications into the ECM.
Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

8. ENGINE COMPRESSION

Start and idle the engine.
With the scan tool, perform the Cylinder Compression Test.

Does the Cylinder Compression Test indicate low compression in any of the cylinders?

Yes

Using the Service Information, repair the engine as necessary to regain proper cylinder compression.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Go To 9

9. FUEL INJECTOR

NOTE: An injector that sticks open can cause this symptom. A sticking injector will cause the engine to misfire and emit excessive black smoke from the exhaust system.

Start and idle the engine.
With the scan tool, perform the Cylinder Fuel Quantity Correction Test.

NOTE: A problem injector will be indicated by a significant change in correction quantity as compared to the rest of the injectors.

Are any of the injectors displaying a significant amount of injection quantity correction?

Yes

Using the Service Information, remove and inspect the Fuel Injectors for signs of damage or debris that may cause the injector to stick. Sticking injectors may cause the combustion chamber to become black and oil soaked. Replace Injector(s) as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Go To 10

10. ENGINE DRIVE BELT/CHAIN

Refer to the Service Information to ensure the Engine Drive Belt/Chain is installed correctly and the camshaft and crankshaft gears are timed correctly.

Were any problems found?

Yes

Repair as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Test Complete.

11. CHECKING THE SUPPLY SIDE FUEL DELIVERY SYSTEM

Refer to the appropriate Service Information and test for proper Fuel pressure and volume from the fuel tank to the high pressure Fuel Injection Pump.

NOTE: The following is a list of problems that can cause fuel pressure to deviate from specification: restricted fuel filter or fuel lines, air in fuel system, failed fuel sending unit, contaminated fuel.

Were there any problems with the Fuel Delivery System?

Yes

Repair as necessary in accordance with the Service Information.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Test Complete