Series 50 – Section 16.3 Improper Injector Calibration Setting (DDEC III Engines Only)

Section 16.3
Improper Injector Calibration Setting (DDEC III Engines Only)

For troubleshooting DDEC II engines, refer to "16.4 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers" .‪

To determine if an improper injector calibration setting is causing the cylinder to misfire, perform the following steps:‪

1. Remove the valve rocker cover(s); refer to "1.6.2 Cleaning and Removing of Two-piece Rocker Cover-Diesel Engines Only" .
2. Record the injector calibration code of each injector noting the cylinder number; see Figure "Injector Calibration Code" .

   Note: Injector calibration and bar codes may be absent from the load plates on first-run production DDEC III injectors 5235575, 5235580, and 5235550. The correct calibration code for these units is "01". Load plates on current DDEC III injectors include the required calibration or bar code information.

   

   Figure 1. Injector Calibration Code

3. Turn vehicle ignition to the on position , but do not run engine.
4. Install Display Data Line (DDL) adaptor to the data cable and plug the adaptor into the DDL connector in the vehicle; refer to OEM guidelines.
5. From the Diagnostic Data Reader (DDR) DDEC III Select Menu, scroll to select ENGINE and press the ENTER key.
6. Scroll to select FUEL INJECTOR INFO and press the ENTER key.
7. Scroll to select FUEL INJECTOR CAL and press the ENTER key.
8. Scroll to select FUEL INJECTOR CAL. Select VIEW and press the ENTER key.
9. Compare the calibration code(s) shown on the display with the two digit calibration code(s) on the injector(s).
   1. If the calibration code on the display is different then the calibration code on the suspect injector for that cylinder, the injector setting must be repaired, see Figure "Injector Calibration Code" ; refer to "16.3.1 Improper Injector Setting Repair" .
   2. If test codes match; refer to "16.4 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers" .

Section 16.3.1
Improper Injector Setting Repair

Perform the following steps to recalibrate improper injector setting:‪

NOTICE:
Whenever a DDEC III injector is removed from the engine, it should be reinstalled in its original location to maintain proper cylinder balance. If reinstalled in a different cylinder head location, injector calibration must be rechecked with the DDR and updated. Failure to observe these steps may result in reduced engine performance.‪

Note: Injector calibration and bar codes may be absent from the load plates on first-run production DDEC III injectors 5235575, 5235580, and 5235550. The correct calibration code for these units are "01''. Load plates on current DDEC III injectors include the required calibration or bar code information.

See Figure "Injector Calibration Code" when performing step 1 through step 7 .‪

1. Scroll to select FUNCTION to return to the FUEL INJECTOR CAL menu on the DDR.
2. Scroll to select FUEL INJECTOR CAL. Select UPDATE and press the ENTER key.
3. Type the four-digit "Update Injector Calibration" password for the DDR and press the ENTER key. If this feature is not password protected, type "0000" and press the ENTER key.
4. A message will appear telling you to use the scroll keys to select the cylinder (requiring changes) or select TYPE # enter the numerical keys to change the CAL (calibration value).

   Note: An asterisk (*) will highlight the first cylinder number on the list.

5. Scroll to the cylinder requiring change and type in the required two-digit injector calibration code number. Press the ENTER key.

   Note: The ENTER key must be pressed before the DDR will allow selection of another cylinder number.

6. Repeat step 5 , until all changes have been made.
7. Scroll to select FUNCTION and press the ENTER key.
8. Scroll to select YES and press the ENTER key to reprogram the ECM with the revised injector calibration codes.
9. Turn the ignition to the off position and wait a minimum of five seconds before starting the engine.
10. Disconnect the DDR; refer to OEM guidelines.
11. Verify repaired injector settings, refer to "16.3.1.1 Verification of Repair for Improper Injector Setting" .

Section 16.3.1.1
Verification of Repair for Improper Injector Setting

Perform the following to determine if the proper injector setting adjustment resolved the misfiring cylinder condition:‪

1. Install the valve rocker cover(s); refer to "1.6.6 Pre-installation of Rocker Cover Base" .
2. Start the engine.
3. Run the engine at 1000 r/min.
4. Listen for misfiring cylinder.
   1. If the engine is not misfiring, no further troubleshooting is required. Shut the engine down.
   2. If the engine is misfiring, check for improper valve clearance and injector height and damaged or worn camshaft lobes and rollers; refer to "16.4 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers" . Shut the engine down.