ENGINE UPDATE

V-8 Engine Updates

TRAINING
1
04MY DT-466 & 04MY VT 365

04MY DT-466
• Low fuel pressure diagnostics
• Low ICP no-start diagnostics
• Turbocharger actuator pinpoint diagnostics
• I-6 Repair tips
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

04MY VT 365
• 2004 Changes
• 04MY Low ICP no-start diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Common I-6 and VT 365 Diagnostics

• EGR Valve pinpoint diagnostics
• Injector Disable Test
• Relative compression Test
• Recording snapshots and evaluating Boost, EBP,
and VGT offset for AMS Diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Course Objectives
After completion of this class you should be able to:
• Perform each step of the I6 low fuel pressure diagnostics and evaluate
the results
• Perform each step of the low ICP diagnostics and evaluate the results
• Verify correct inputs to the Turbo actuator
• Identify 04MY VT 365 changes
• Record snapshots with PID and DTC triggers
• Perform EGR Valve pinpoint diagnostics
• Perform Injector Disable Test and evaluate results
• Perform Relative compression Test and evaluate results
• Identify incorrect boost, EBP, and VGT Offset readings in snapshot
recordings.
ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

2004 Model Year I-6

 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

I-6: Low fuel pressure diagnostics

System Changes
• No fuel return to tank
• Slow to bleed air
• Test points have
changed
• Restriction test has
changed
ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

I-6: Low fuel pressure diagnostics

Diagnostic Steps
• Replace filter, service
strainer, then retest
• Check for aeration at
the rail test port
• Measure pump draw in
in Hg.
• Replace regulator
• Measure restriction
under full load
ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

I-6: Low ICP no-start diagnostics

Tools required
• IPR breakout ZTSE4484
• ICP test kit ZTSE4655
• HP hose 1842571C91
• ICP Sensor 1845274C92
• ICP breakout ZTSE4658
 ENGINE UPDATE
V-8 Engine Updates
TRAINING
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04MY DT-466 & 04MY VT 365

I-6: Low ICP no-start diagnostics

Diagnostic steps
• Verify ECM can Control
IPR
• Verify reservoir is full
• Verify IPR is working
• Verify pump will
produce pressure
• Verify there are no
leaks under the valve
cover
 ENGINE UPDATE
V-8 Engine Updates
TRAINING
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04MY DT-466 & 04MY VT 365

I-6: Turbo actuator pinpoint diagnostics

Diagnostic Steps
• Breakout harness verifies
B+, Grd, and PWM signal.
• PWM signal can be
checked W/harness
disconnected using 1/2k
Ohm load (positive)
• Output State test can be
used to verify PWM at two
points
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

I-6: Repair Tips

1.CMP/CKP DTC’s: Check ECM X-1 connector for water intrusion.
2.Poor cold start: Inlet Air Heater / Calibration
3.Erroneous codes
a. code 222 Brake switch circuit fault
b. code 267 Engine crank inhibit OCC
c. code 251 Inlet Air Heater OCC
d. code 335 Unable to build ICP during cranking
4.Fuel system priming procedure
5.Valve cover gasket
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

2004 Model Year VT 365

 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

VT 365: Design Updates

• EGR VALVE
• EGR DRIVE MODULE
• EGR COOLER
• ICP SENSOR and LOCATION
• HIGH PRESSURE PUMP
• HIGH PRESSURE RAIL
• INTAKE MANIFOLD
• BREATHER ASSEMBLY
• UPPER OIL PAN
 ENGINE UPDATE
V-8 Engine Updates
TRAINING
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04MY DT-466 & 04MY VT 365

VT 365: EGR Valve

Drive Module
• The new EGR valve us
a Drive Module mounte
to the ECM/IDM
assembly.

The Drive Module interprets messages from the ECM then

positions the Valve. The position sensors send a signals
back to the Drive Module which then shares the information
with the ECM.
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

VT 365: New High Pressure Oil Pump

 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

VT 365: New High Pressure Rail

 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

VT 365: New High Pressure Rail

Case to Head Tube
Port Plugs
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V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

VT 365: Injection Control Pressure (ICP)

Sensor Relocated
ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Common Diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Common: Relative Compression Test

 ENGINE UPDATE
V-8 Engine Updates
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23
04MY DT-466 & 04MY VT 365

Common: Injector Disable Test

 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Common: EGR
Valve Pinpoint
Diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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25
04MY DT-466 & 04MY VT 365

Common: EGR
Valve Pinpoint
Diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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26
04MY DT-466 & 04MY VT 365

Common: EGR
Valve Pinpoint
Diagnostics
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Turbocharger Diagnostics
Symptoms
• Customer • Dealer
– Engine warning lamp on – Multiple inactive AMS
– Loss of power DTCs
– Excessive black smoke – Can/Cannot duplicate
– Excessive white smoke – Fails AMS tests
– No acceleration
– Engine Surge
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

What Engine Reliability will ask for:

• Calibration Reference number.
• KOEO signal voltages of:
– MAP sensor
– EBP sensor
• EGR valve% position (output state test high and low)
• External linkage position on I6 (KOEO and Output State test)
• BARO Reading – verify accuracy - compare to another
chassis.
• Check MAP & EBP sensor and port/tube for carbon plugging.
• Run AMS tests.
• Visually inspect exhaust system for restriction/flow.
• Duplicate issue and record a snapshot for review.
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V-8 Engine Updates
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04MY DT-466 & 04MY VT 365
Vanes Sticking Closed
50

Over 38 psi EBP (Sensor Boost Pres (psig)

limit is 38 psi) Exhaust Back Pres (psig)
VGT Duty Offset (%)
40

TCC

Boost is approximately 24 psi.

30
20

DTC 343 Excessive EBP logged,

also will set 355 Turbo overspeed
10
0

109

127

151

163

181
1

13

19

25

31

37

43

49

61

67

73
79

91

103

115

121

133

139

145

157

169
175

187

193

199

205

211

217
55

85

97

ECM trying to pull turbo vanes off

-1
0
-2
0
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V-8 Engine Updates
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04MY DT-466 & 04MY VT 365
Vanes Sticking Open
39
Exhaust Back Pres (psig)
VGT Duty Offset (%) VGT duty offset excessive. Over
30%
Boost Pres (psig)
34 TCC

29

24

19

Very low exhaust back pressure - around 3 psi.

14
Boost is 0 psi.

9
DTC 353 VGT control over
duty logged

-1
1
14
27
40

79
92

118
131

157
170
183

209
222

248
261
274

300
313
326
339
352
365
378
391
404
417

456
469
482

508
53
66

105

144

196

235

287

430
443

495
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V-8 Engine Updates
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04MY DT-466 & 04MY VT 365
Plugged Catalyst/Muffler
30
Exhaust Back Pres (psig)
VGT Duty Offset (%)
Exhaust Backpressure higher than normal Boost Pres (psig)
20

10

Boost is well below specifications

0
1
10
19

37
46
55
64
73
82
91
100
109

136
145
154

172
181
190
199

217
226

253
262
271
280

298
307
316
325

343
352
361
28

118
127

163

208

235
244

289

334
-10

ECM is trying to reduce backpressure with

VGT duty offset %
-20

-30

-40
 ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Recording Snapshots
– Snapshot uses
• Use for documenting Turbocharger issues
• Use to troubleshoot Diagnostic Trouble Codes
• Use for Performance Diagnostics

Note: Additional snapshot information is available in

MasterDiagnostics® Help section and MD Software User’s Manual.

• The following slides demonstrate two of the most

requested snapshot setups.
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V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Snapshot Setup Using a DTC

ENGINE UPDATE
V-8 Engine Updates
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04MY DT-466 & 04MY VT 365

Snapshot Setup Using a PID