NHTSA ID Number: 10161137
Manufacturer Communication Number: 0105-19
TSB/Document Date: 2019-06-10
Summary
Service Information Bulletin
01 05-19
1
01 05-19
SUBJECT
DATE
Symptom Diagnostics: Hard Start / No Start - Test A; Test C
February 2019
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0191
Platform
GHG17 DD
Platform
Section Title
Test A - Two-Filter Fuel
System
Test C - Two-Filter Fuel
System
Change
Improve troubleshooting steps.
DiagnosticLink users: Please update the troubleshooting guides in DiagnosticLink with this newest version. To update the
tool troubleshooting guide, open DiagnosticLink and from the Help – Troubleshooting Guides menu, select the appropriate
troubleshooting manual, then click Update.
All information subject to change without notice.
01 05-19
Copyright © 2019 DETROIT DIESEL CORPORATION
3
2 Test-A - Two-Filter Fuel System
2
Test-A - Two-Filter Fuel System
NOTICE: “Hard Start/No Start – Two Filter Fuel System” test MUST be completed before performing this test.
Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be Done First)".
Table 1.
Service Tools Used in the Procedure
Tool Number
Description
J-48704
HP Fuel Rail Test Caps
NOTE: KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
Check as follows:
1. Review Fuel System Integrity Check (FSIC) routine log file using DiagnosticLink ® 8.0 or higher. Is the engine speed
over 150 rpm while cranking?
a. Yes; Go to step 2.
b. No; perform the following checks. If any are the cause of cranking speed under 150 rpm, fix the issue and
attempt to start the engine using FSIC. If cranking speed is now above 150 rpm and engine does not start, Go to
step 2.
• Verify battery voltage; refer to Original Equipment Manufacturer (OEM) specifications.
• Perform a cranking compression test.
• Remove the accessory drive belt and check cranking speed.
• Remove the air compressor and check cranking speed.
2. Is fuel compensation pressure over 241 kPa (35 psi) while cranking?
a. Yes; Go to step 3.
b. No; Go to step 9.
3. Does “Engine State” equal “Start” while cranking?
a. Yes; Go to step 4.
4
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
01 05-19
01 05-19
4.
5.
6.
7.
8.
b. No; correct status of the AUX shutdown switch or starter type.
Does Kw/Nw show or stay “ON / Enabled / True” while cranking the engine?
a. Yes; Go to step 5.
b. No; repair the camshaft or crankshaft sensor failure; refer to appropriate troubleshooting.
Is the actual fuel rail pressure over 150 bar (2176 psi)?
a. Yes; Go to step 6.
b. No; Go to step 7.
Did the vehicle exhibit a no-start condition prior to coming in for service?
a. Yes; replace the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System".
b. No; replace the fuel injectors, fuel rail, and high pressure fuel lines. Refer to section "Removal of the Fuel
Injector - Two-Filter System".
Perform the PLV flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System". Was PLV
flow greater than 25 mL (0.84 oz.) while cranking?
a. Yes; Go to step 8.
b. No; Go to step 15.
Has the PLV previously been replaced?
a. Yes; replace the rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor".
b. No; replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System".
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
9. Install Detroit-approved priming tool. Start priming, and attempt to start the engine with Manual FSIC. Does the
engine start?
a. Yes; go to “Test C." Refer to section "Test-C - Two-Filter Fuel System".
b. No; Go to step 10.
10. During start attempt, does fuel compensation pressure increase to more than 241 kPa (35 psi)?
a. Yes; Go to step 14.
b. No; Go to step 11.
11. Remove and inspect the two-stage valve. Refer to section "Removal of the Two-Stage Valve - Two-Filter System ".
Was damage found?
a. Yes; replace the two-stage valve. Refer to section "Installation of the Two-Stage Valve - Two-Filter System".
b. No; Go to step 12.
12. Remove and inspect the fuel filters and fuel filter stand pipe. Refer to section "Removal of the Coalescer/Final Filter ".
Was any damage found to the fuel filters?
a. Yes; replace the damaged filter. Refer to section "Installation of the Coalescer/Final Filter".
All information subject to change without notice.
01 05-19
Copyright © 2019 DETROIT DIESEL CORPORATION
5
2 Test-A - Two-Filter Fuel System
b. No; reinstall fuel filters, ensuring that the filter is seated correctly. Refer to section "Installation of the
Coalescer/Final Filter". Go to step 13.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
13. Attempt to start the engine. Does the engine start?
a. Yes; release vehicle to customer.
b. No; replace the Low Pressure Relief Valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter
System".
14. Perform the PLV flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System". Was PLV
flow greater than 25 mL (0.84 oz.) while cranking?
a. Yes; replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System".
b. No; Go to step 15.
15. Check for aerated fuel. Is the fuel aerated?
a. Yes; determine cause of aerated fuel and repair as necessary. Refer to section "Aerated Fuel Test – Two-Filter
Fuel System".
b. No; Go to step 16.
16. Cap the fuel rail at all six fuel injector feed connections using J-48704 tool (HP Fuel Rail Test Caps) and attempt to
start the engine. Does the fuel rail pressure reach the desired rail pressure?
a. Yes; Go to step 17.
b. No; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - TwoFilter System".
17. Does the fuel rail pressure bleed down under 100 bar (1450 psi) in less than two minutes?
a. Yes; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - TwoFilter System".
b. No; replace the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System".
6
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
01 05-19
01 05-19
3
Test-C - Two-Filter Fuel System
NOTICE: Hard Start/No Start - Two-Filter Fuel System test MUST be complete before performing this test. Refer
to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be Done First)".
Check as follows:
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
1. Allow engine to run for one minute and then remove the Detroit-approved priming tool; does the engine quit running?
a. Yes; Go to step 2.
b. No; allow engine to reach 65°C (149°F), then shut down engine. Go to step 2.
2. Once the rail pressure drops below 10 bar (145 psi), attempt to restart the engine without using a priming source. Does
the engine restart?
a. Yes; Go to step 6.
b. No; Go to step 3.
3. Remove and inspect the pressure relief valve for damage. Refer to section "Removal of the Pressure Relief Valve Two-Filter System". Is the valve damaged?
a. Yes; replace the pressure relief valve.
b. No; Go to step 4.
4. Install the Detroit-approved priming tool, start priming, restart the engine, turn the primer off, and then monitor LPPO
fuel pressure. Is LPPO below specified range at idle? Refer to section "Normal Fuel System Pressures".
a. Yes; Go to step 5.
b. No; Go to step 6.
5. Remove and inspect the two-stage valve. Refer to section "Removal of the Two-Stage Valve - Two-Filter System ". Is
the two-stage valve stuck in stage 1?
a. Yes; replace the two-stage valve.
b. No; Go to step 6.
All information subject to change without notice.
01 05-19
Copyright © 2019 DETROIT DIESEL CORPORATION
7
3 Test-C - Two-Filter Fuel System
6. Perform a Fuel Injection System (FIS) Low Pressure Leak Test routine. Refer to section "FIS Low Pressure Leak
Test". Did the fuel system pass the FIS Low Pressure Leak Test routine?
a. Yes; Go to step 7.
b. No; inspect fuel system for leaks. Refer to section "FIS Low Pressure Leak Test".
7. Check for aerated fuel. Refer to section "Aerated Fuel Test – Two-Filter Fuel System". Is the fuel aerated?
a. Yes; determine cause of aerated fuel and repair as necessary. Refer to section "Aerated Fuel Test – Two-Filter
Fuel System".
b. No; Go to step 8.
8. Perform the Chassis Fuel System Isolation test. Refer to section "Chassis Fuel System Isolation Test". Did the test
pass?
a. Yes; Go to step 9.
b. No; repair as necesssary.
9. With Chassis Fuel System Isolation Test lines still connected, start the engine and monitor LPPO. Is LPPO below
specified range at idle? Refer to section "Normal Fuel System Pressures".
a. Yes; Go to step 10.
b. No; repair the cause of inlet restriction.
10. Remove and inspect the pressure relief valve for damage. Refer to section "Removal of the Pressure Relief Valve Two-Filter System". Is the valve damaged?
a. Yes; replace the pressure relief valve.
b. No; Go to step 11.
11. Inspect the pre-filter for any debris or plugging. Is the pre-filter plugged?
a. Yes; Go to step 12.
b. No; replace the low pressure fuel pump. Refer to section "Removal of the Low Pressure Fuel Pump - TwoFilter System".
12. Is the pre-filter debris caused by contaminated fuel?
a. Yes; refer to the appropriate contaminated fluid troubleshooting.
Refer to section "Metal in the Fuel System – Two-Filter Fuel System".
Refer to section "Diesel Exhaust Fluid in Fuel".
b. No; replace the pre-filter.
8
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
01 05-19
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