Series 40E Troubleshooting – Section 10.3 Visual Inspection

Section 10.3
Visual Inspection

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Figure 1. Diagnostic Form

Visually inspect the general condition of the engine and look for obvious causes of hard or no start conditions. For a reproduction of the applicable portion of the diagnostic form, see Figure
“Diagnostic Form”

, above.‪

Section 10.3.1
Test Procedure

Follow this procedure to visually check the general condition of the engine: ‪

  1. Inspect entire fuel system for leaks including the tank and lines. Inspect fuel lines for damage (kinks and bends).
  2. Check high pressure oil line from high pressure pump to high pressure oil supply manifold for major oil leaks.
  3. Inspect entire cooling system, (coolant level in reservoir, hoses, water pump and radiator) for coolant leaks. Check for residue that may have been caused from prior leakage.
  4. Check air induction system for leaks. Refer to “10.4.2 Air Induction System Pressure Test”


  5. Inspect engine wiring harness for correct routing and ensure that no rubbing or chaffing has occurred Check connections to sensors, relays and control modules. Inspect battery cable connections for corrosion. Check the fuses at the battery. All connections should be seated and in good condition, free from damage and corrosion.

Note: Harness connections fastened to the ECM must be torqued to 35 lb·in.

Section 10.3.2
Possible Causes

The following are possible causes of the hard start/no start condition:‪

  • Loose or leaking fuel supply lines could cause the fuel system to lose prime.
  • Kinked or blocked fuel supply lines will create restriction to fuel flow.
  • Massive fuel or oil leaks may contribute to no start conditions.
  • Coolant leaks could indicate serious engine problems.
  • Electronic connectors may be damaged or not installed properly, causing a no start condition.

Note: The Camshaft Position sensor (CMP) and the Injection Pressure Regulator valve (IPR) are the two most critical electronic components to inspect when the engine fails to start.

Section 10.3.3
Tools Required

Inspection light.‪

Series 40E Troubleshooting Manual – 6SE241
Generated on 10-13-2008