‘To prevent personal injury or death, do not refuel the tank when the engine is running.

To prevent property damage, clean glow plug bores and
surrounding areas prior to removing glow plugs. Cover engine
lopening to prevent inducing dirt and debris into the engine.

To prevent property damage, do not allow glow plugs to touch
leach other or metal engine components.

threa'

To prevent property damage, never use power tools to install

ded components

[Action

Decision

DIAGNOSTIC:

‘Complete the symptom-based diagnostics for low engine oil pressure light, low
power, smoking, or running rough.

Yes. Please complete the 6.6 engine
|replacement checklist. Please then start!
a case file with the powertrain team and
attach the completed checklist, pictures
of your findings, and the oil change
records to the case.

Drain the engine oil and capture it in a clean and clear container for inspection.

4 |YES/NO QUESTION?
Yes, no resolution. Proceed to step 2.
Hi h i - i ics be iL in the 6.
lave the appropriate symptom-based diagnostics been completed in the 6.6 No. Complete the appropriate
manual? . ine
symptom-based diagnostics in the 6.6
manual.
Step Action Decision
DIAGNOSTIC: Yes. End diagnostics.
Repair any concerns found in the symptom-based diagnostics.
2 YES/NO QUESTION?
No. Proceed to step 3.
Did the repairs resolve the concern?
Step|Action Decision
3. +|DIAGNOSTIC: Metal glitter or debris. Please

icomplete the 6.6 engine replacement
checklist. Please then start a case file
with the Powertrain team and attach the
Icompleted checklist, pictures of your
findings, and the oil change records to
ithe case.

YES/NO QUESTION? No. Proceed to step 4.

\Was the oil thick or contaminated with metal, fuel, or coolant?

Fuel or coolant. Please complete the
lappropriate symptom-based diagnostics
lin the 6.6 manual. If there is no
resolution, please start a case file with
jthe Powertrain team.

Step |Action Decision

IDIAGNOSTIC: Yes. Please complete the 6.6 engine

|replacement checklist. Please then start
la case file with the Powertrain team and
lattach the completed checklist, pictures

4 \VES/NO QUESTION? lof your findings, and the oil change
. records to the case.

Remove the glow plugs and inspect for damage.

Do the glow plugs have any contamination, damage, or missing tips?
INo. Proceed to step 5.

Step |Action Decision

DIAGNOSTIC: Yes. Please proceed to step 6.

‘Compression tests the cylinders using the compression testing instructions in
ithe 6.6 manual.

5 |YES/NO QUESTION?

No. please proceed to step 7.

Do any cylinders have lower than 2,069 KPA (300 PSI) or a difference of
greater than 345 KPA (50 PSI) between the suspect cylinder and the average
compression of all 8 cylinders?

Step Action Decision

6 DIAGNOSTIC: Yes, air leak at the intake

. oe . , ‘manifold. Proceed to step 7.
Perform a cylinder leakdown test using the directions in the 6.6 diagnostics :

manual and regulating shop air to 80 PSI.

YES/NO QUESTION? :

Yes, air leaks into the

ls there an audible leak and do any cylinders have a leakage of more than exhaust. Proceed to step 7.
25%? i

Air leaks into the crankcase. Proceed
‘to step 9.

‘Air bubbles in the cooling
‘system. Proceed to step 9.

Step|Action Decision
IDIAGNOSTIC: Yes. Proceed to step 8.
Remove the valve cover and inspect the rockers and valve stems.
7
[YES/NO QUESTION? No. Proceed to step 9.
[Are any rockers loose, valve bridges missing, or valve stems damaged?
Step|Action Decision
IDIAGNOSTIC: Yes. Please complete the 6.6 engine
. . \replacement checklist. Please then start
Remove the lifters and inspect the camshaft. la case file with the Powertrain team and
lattach the completed checklist, pictures
9 ,
)YESINO QUESTION? lof your findings, and the oil change
8 Does the camshaft or lifter have abnormal wear or damage? records to the case.
No. Please start a case with the
powertrain team for further directions.
Step|Action Decision
IDIAGNOSTIC: Nalve damage. Replace the head and
. Inecessary components. Retest for the
Remove the head and inspect the valve faces and cylinders for damage concern after the repairs.
[YES/NO QUESTION?
(Cylinder or piston damage. Please
Are the valve faces or cylinders damaged? complete the 6.6 engine replacement
checklist. Please then start a case file
9 ith the Powertrain team and attach the

completed checklist, pictures of your
findings, and the oil change records to
he case.

No. Please start a case with the
powertrain team for further assistance.

REPAIR STEP(s)

REMOVAL PROCEDURE:

Glow plug removal bank 1
Glow plug removal bank 2
Valve lifter removal

Cylinder head removal Passenger's side

Cylinder head removal Driver's side
Valve cover removal Passenger's side

Valve cover removal Driver's side

INSTALLATION PROCEDURE:
Glow plug installation bank 1

Glow plug installation bank 2

Valve lifter installation

Cylinder head installation Passenger's side

Cylinder head installation Driver's side

Valve cover installation Passengers side

Valve cover installation Driver's side

ION

TY INFORM.

Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

OTHER RESOURCES
Master Service Information Site
Compression testing steps

6.6 Engine checklist

Cylinder leakage test

a
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