Series 60 EGR – Section 10.4 Tests

Section 10.4
Tests

The following tests support the recommended troubleshooting flow for specific operational concerns.‪

Section 10.4.1
TEST A

Test A steps are as follows.‪

Note: Two regulated air supply lines will be required to perform this test.

1. Remove the turbocharger to charge-air-cooler (CAC) pipe.

   PRESSURIZED CHARGE COOLER SYSTEM ‪
   To avoid eye or face injury from flying debris, wear a face shield or goggles. ‪

2. Pressurize the CAC inlet to 207 kPa (30 psi) using special tool TLZ00100 or equivalent.
3. Using DDDL, monitor the boost pressure (psi).
   1. If the pressure is below 187 kPa (27 psi), visually inspect the CAC, hoses, and the delivery tube for leaks. Repair as necessary.
   2. If the pressure is 187 kPa (27 psi) or higher, continue to step 4 .
4. Disconnect the EGR actuator oil line.

   Note: The oil line fitting is a 37 degree JIC #6 fitting.

5. Connect a regulated air supply line to the EGR actuator regulated to 69 kPa (10 psi).
6. Using DDDL, activate the EGR Valve (PWM #2) to 90%.
7. Monitor the boost pressure for pressure drops when the EGR valve opens.

   Note: The pressure should have dropped significantly to approximately 62 kPa (9 psi).

   1. If the air pressure dropped to 62 kPa (9 psi), no further testing is required. Test A has been completed.
   2. If the pressure dropped slightly, perform step 8 through step 10 .
8. Physically inspect the EGR valve for a mechanical failure. If the EGR valve is not functioning correctly, replace the EGR valve.
9. Visually inspect the EGR cooler for restrictions. If the EGR cooler is restricted, replace the EGR cooler.
10. Visually check the delivery pipe for restrictions. Clean the pipe as necessary to remove restrictions.
11. Verify repairs.

Section 10.4.2
TEST B

Test B steps are as follows and should be performed in order as written.‪

Perform test as follows.‪

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.

1. Run the engine on a dynamometer to get the engine hot. If a dynamometer is not available, run the engine until hot (> 170° F (76° C) coolant temperature).
2. Activate the VPOD outputs to 50% duty cycle using the DDDL. Visually inspect the VNT and EGR valve for proper rod travel.
   1. If the VNT is not functioning properly, please visit the Detroit Diesel Technical Service Letter Web Page at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical Service Letter 04 TS 16 or Detroit Diesel Special Publications Web Page at http://192.135.85.10/public/sp/spnav.asp and browse for Special Publication Number 18SP604.
   2. If the VNT is functioning properly, no further troubleshooting is required.

   Note: Repeat this step three times.

3. Verify repairs.

Section 10.4.3
TEST C

Test C has eight basic tests and are as follows.‪

• Delta P Sensor
• VPOD Output Pressure
• Barometric Sensor (Test D)
• VPOD Input Pressure
• VPOD Part Number and Supply Voltage
• VPOD Wiring
• Active Codes
• Final Test

The following tools are required to perform the six basic tests.‪

• Low wattage 1,000 Ω resistor
• DDDL version 4.2 or higher or DDR suite 8
• Volt Ohm Meter (VOM)
• Pressure gage 1379 kPa (0-200 psi)
• Pressure gage 690 kPa (0-100 psi)

Section 10.4.3.1
Delta P Sensor Test

Check the Delta P Sensor as follows:‪

1. Remove the Delta P Sensor from the mounting plate.

   EYE INJURY ‪
   To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

2. Blow down through the sensor tubes (by way of the holes in the mounting plate) using an airline.
3. Gently shake the sensor to remove any moisture before reinstalling. Moisture in the sensor does not cause permanent damage.
4. Turn ignition On. (key ON, engine OFF).
5. Connect either a Detroit Diesel Diagnostic Link® (DDDL) or a Diagnostic Data Reader (DDR).
6. Read the Delta P counts.
   1. If the recorded Delta P counts read 86-118, verify that the Venturi Tube hoses-to-Delta P Sensor, are correctly installed and are not damaged. See Figure "Location of Venturi Tube Hoses" . Repair as necessary, verify repairs.Visually inspect the delivery pipe for damage and proper assembly. If no problem was found, perform a VPOD Output Pressure Test "10.4.3.2 VPOD Output Pressure Test" found in the next section.

      Note: Reversed and damaged hoses will have an adverse effect on engine performance resulting in black exhaust smoke and engine surging.

   2. If the Delta P counts are out of the 86-118 range, replace the sensor, and go to the Verification section.

Section 10.4.3.2
VPOD Output Pressure Test

Test steps are as follows:‪

1. Disconnect the air hose from the VNT actuator. See Figure "Location of Venturi Tube Hoses" .
   

   Figure 1. Location of Venturi Tube Hoses

2. Install gage at the outlet of the VNT air line. See Figure "Gage Setup" .

   Note: The gage should be accurate to within 1.4 kPa (0.2 psi).

   

   Figure 2. Gage Setup

3. Using either DDDL or DDR, activate PWM #2 and PWM #4 duty cycles and monitor the output pressure from the VPOD. Activate the duty cycle to 50%. Pressure should equal 305-315 kPa (42-47 psi @ VPOD).

   Note: Both activations must have full linkage travel.

4. Repeat step 3 a total of 3 times.

   NOTICE: ‪

   Ensure that the VPOD air supply line fitting is not crossed-thread when connecting the VPOD air supply to the EGR actuator. If the air supply line fitting is not properly seated, the EGR actuator will not function properly.‪

5. Connect VPOD air supply line to the EGR actuator. Perform a VPOD Input Pressure Test "10.4.3.3 VPOD Input Pressure Test" .

Section 10.4.3.3
VPOD Input Pressure Test

Perform the following steps to test the VPOD input pressure.‪

1. Measure the VPOD input pressure to Port 1.
   1. If the supply pressure is not between 703-1296 kPa (90-120 psi), troubleshoot the vehicle air system until that result is obtained. Repair as necessary.
   2. If the supply pressure is between 703-1296 kPa (90-120 psi), perform a VPOD Part Number and Supply Voltage Test "10.4.3.4 VPOD Part Number and Supply Voltage Test and Part Number Check" .
2. Verify repairs.

Section 10.4.3.4
VPOD Part Number and Supply Voltage Test and Part Number Check

Perform the follow steps to verify the VPOD part number and supply voltage.‪

1. Check VPOD label to determine if it is + 12 V or + 24 V system.

   Note: A 1,000 Ω resistor or a volt Ohm meter is required to perform step 2 .

2. Unplug the VPOD wire connectors and insert the 1,000 Ω resistor between cavities 1 and 3.
   1. Turn ignition switch ON.
   2. Measure voltage from pin 3 to pin 1.
   3. Plug in DDDL or DDR to measure the ECU voltage.
3. Is the VPOD part number and voltage and the ECU voltage correct?
   1. If the VPOD part number and voltage and the ECU voltage are correct, perform a VPOD Wiring Test "10.4.3.5 VPOD Wiring Test" .
   2. If the VPOD part number and voltage and the ECU voltage were not correct, match the VPOD component to the ECU voltage and perform a VPOD Wiring Test "10.4.3.5 VPOD Wiring Test" .

Section 10.4.3.5
VPOD Wiring Test

Perform the following steps to test the VPOD wiring.‪

Note: VPOD power should have been verified during the VPOD and Supply Voltage Test and Part Number Check. If not, perform a VPOD Part Number and Supply Voltage Test.

1. Turn ignition switch ON.
2. Disconnect the VPOD sensor connectors.
3. Insert a 1,000 Ω resistor between cavities Number 2 and Number 1 for a 12 V version, or cavities Number 2 and Number 3 for a 24 V version.
4. Connect a VOM to the VPOD connector between pin Number 2 and pin Number 3 for a 12 V VPOD or pin Number 2 and pin Number 1 for a 24 V VPOD.
5. Using either a DDDL or DDR, activate the PWM #4 (VNT) and ensure that activating 50 % duty cycle: VDC = 50% of the VPOD supply voltage ± 1 volt. (e.g. voltage to VPOD = 13.8 V * 0.5 = 6.8 V, therefore 5.8 V to 7.8 V at VPOD is okay).
6. Listen for air leaks from the VPOD when PWM are activated to 50%.
   1. If the PWM voltage measurement is correct, go to step 7 .
   2. If the PWM voltage measurement is incorrect and the wiring checks were correct, try a test ECU programmed for EGR or contact the Detroit Diesel Customer Support Center at 313-592-5800.
7. Verify repairs. Perform an Active Codes Test "10.4.3.6 Active Codes Test" .

Section 10.4.3.6
Active Codes Test

Perform the following steps to test for active codes.‪

1. Turn ignition ON.
2. Connect either a DDDL or a DDR reader.
3. Read active codes.
4. Record or print codes. Ensure that PID, SID, and FMI are recorded. Refer to the proper code section of the DDEC V Single ECU Troubleshooting Guide , (6SE565) to troubleshoot that code.

   Note: FMIs listed as 14 are diagnostic information codes and no troubleshooting is required. For example, an engine derates due to high TCO temperature; a 404/14 code will be stored. This would indicate that conditions warranted having the ECU derate the fueling to the engine. If the customer complaint was a power loss, it could be explained that loss of power was done by the ECU to protect other engine components.

5. If the issue is not related to the EGR system components, or if technical support is required, contact the Detroit Diesel Customer Support Center at 313-592-5800.
6. Perform a Final Test "10.4.3.7 Final Test" .

Section 10.4.3.7
Final Test

Follow these steps for a final test:‪

1. Reconnect all disconnected sensors and wiring harnesses and assemble all disassembled components.
2. Start and run the engine.
3. Perform a road test to try and duplicate the original complaint.
   1. If original symptoms and codes are not detected, repairs are complete.
   2. If any original codes are detected, review this section again and contact the Detroit Diesel Customer Support Center at 313-592-5800.

Section 10.4.4
TEST D

Test D steps are as follows.‪

Note: Engines built from February 2004 (Serial Number: 06R0761470) through the end of July 2004 (Serial Number: 06R0788688) may be affected.

1. Turn the ignition ON but leave the engine OFF.
2. Connect either a Detroit Diesel Diagnostic Link® (DDDL) or a Diagnostic Data Reader (DDR) to measure the barometric pressure and the air inlet pressure. Compare the results of the measured values.
   1. If the difference is greater than 4.1 kPa (0.6 psi), replace the Barometric Pressure Sensor.
   2. If the difference is less than 4.1 kPa (0.6 psi), contact the Detroit Diesel Customer Support Center at 313-592-5800.
3. Verify repair.
   1. If Flash Code 39 (SID 147/FMI 2) is not logged, repair is complete.
   2. If Flash Code 39 (SID 147/FMI 2) is logged, contact the Detroit Diesel Customer Support Center at 313-592-5800.

Section 10.4.5
TEST E

Test E steps are as follows.‪

1. Verify ECU program software version.
   1. If the ECU software version is not Level 2.0, perform step 2 and 3 .
   2. If the ECU software is Level 2.0 or higher, "10.4.5 TEST E" is complete.
2. Download the mainframe file for particular engine serial number (no mainframe changes required).
3. Program the ECU.

Section 10.4.6
TEST F

Engines equipped with a tube and shell bolted flanged cooler that have a coolant-lost complaint need to be inspected for leaks from other sources. The spring wire hose clamps are a possible coolant leak path, and should be inspected. If the spring wire clamps are damaged, service kits are available to replace the damaged components.‪

A standard test to pressurize the coolant system and investigation of overall coolant system should have been performed prior to inspecting the cooler. There may be other components of the engine that are responsible for the loss of engine coolant.‪

Note: Coolers with internal leaks usually show signs of a white coolant drop-out at the exhaust side of the cooler, the Delta P Sensor lines, or at the delivery pipe to intake manifold connector.

If the entire system has been tested, perform the following steps to inspect the cooler:‪

1. Use hoses, clamps, plugs, and a regulator to seal the cooler water inlet and water outlet ports. See Figure "EGR Cooler Ports Setup" .
   

   Figure 3. EGR Cooler Ports Setup

2. Fill the exhaust side of the cooler with hot tap water. Allow the water to overflow until the loose carbon has floated away allowing for a clear viewing of any bubbles. See Figure "Filling the EGR Cooler with Tap Water" .
   

   Figure 4. Filling the EGR Cooler with Tap Water

3. Apply 207 kPa (30 psi) of regulated air to the regulator for three minutes. See Figure "EGR Cooler Ports Setup"
4. Disconnect the regulated air supply from the regulator and watch for bubbles on the exhaust side of the cooler. See Figure "Observing the EGR Cooler for Bubbles" .
   1. If bubbles were observed, replace the cooler.
   2. If no bubbles were observed, contact the Detroit Diesel Customer Support Center for further information (313-592-5800).
   

   Figure 5. Observing the EGR Cooler for Bubbles

Section 10.4.7
TEST G

The air supply line which connects to the VPOD must be a dedicated air supply line. To ensure that the air supply line is a dedicated air supply line, please read Freightliner Service Information Bulletin 01–81 (see Figure "Freightliner Service Bulletin 01–81 (Page One of Three)" , see Figure "Freightliner Service Bulletin 01–81 (Page Two of Three)" , and see Figure "Freightliner Service Bulletin 01–81 (Page Three of Three)" ).‪

Figure 6. Freightliner Service Bulletin 01–81 (Page One of Three)

Figure 7. Freightliner Service Bulletin 01–81 (Page Two of Three)

Figure 8. Freightliner Service Bulletin 01–81 (Page Three of Three)