Series 60 DDEC V Troubleshooting – Section 20.2 Engine Cranks But Will Not Start

Section 20.2
Engine Cranks But Will Not Start

The following procedures will diagnose engine cranks but will not start. ‪

Section 20.2.1
Amber Warning Lamp

Check the CEL/AWL as follows:‪

1. Turn on the ignition while observing the CEL/AWL.
   1. If the light comes on and stays on, refer to "18.3.1 Amber Warning Lamp" .
   2. If the light comes on for up to five seconds, and then goes off, refer to "20.4.2 Display ECM/ECU Light Status"
   3. If the lights are off, go to step 2 .
2. Check both ECM/ECU power fuses or circuit breakers.
   1. If both fuses are okay, refer to "20.2.12 Battery Volts Check" .
   2. If either fuse is not okay, refer to "20.2.20 Check for Blown Fuses" .

Section 20.2.2
Fuel Check

Perform the following steps to check the fuel supply:‪

1. Disconnect the fuel return line.
2. Check for fuel flow while cranking the engine.
   1. If fuel flow is okay, refer to "20.2.3 White Smoke Check" .
   2. If fuel supply is not okay, refuel the vehicle. The system may need to be re-primed. Refer to the appropriate engine service manual.

Section 20.2.3
White Smoke Check

Perform the following steps to check for white smoke:‪

1. Reconnect fuel return line.
2. Look for white smoke coming out of the exhaust stack while cranking the engine.
   1. If white smoke is present, refer to "20.2.4 Check Crankshaft Position Sensor Status" .
   2. If white smoke is not present, refer to "20.2.22 Check Fuel Filters" .

Section 20.2.4
Check Crankshaft Position Sensor Status

Perform the following steps to check the TRS/CKP Sensor status via a rpm readout:‪

1. Select engine speed and active codes on the DDR.
2. Crank the engine for ten seconds while observing DDR display. A battery voltage surge while cranking with electric starters may blank or reset the DDR.
   1. If the display reads greater than or equal to 60 rpm, refer to "20.2.7 Check for Good Camshaft Position Sensor Signal" .
   2. If the display reads less than 60 rpm or constantly reads 60 rpm, refer to "20.2.5 Check Crankshaft Position Sensor" .
   3. If code 41 is displayed, refer to "44.2.1 Check for Signal Open" .
   4. If code 42 is displayed, refer to "45.2.1 Resistance Check" .

Section 20.2.5
Check Crankshaft Position Sensor

Perform the following steps to check the TRS/CKP Sensor:‪

1. Turn vehicle ignition OFF.
2. Disconnect engine harness connector at the ECM/ECU.
3. Measure resistance between sockets E-17 and E-18 at the engine harness connector.
   1. If the resistance measurement is greater than 200 Ω, refer to "44.2.3 Open Crankshaft Position Sensor Line Check" .
   2. If the resistance measurement is less than 100 Ω, refer to "44.2.2 Check for Short" .
   3. If the resistance measurement is between 100 and 200 Ω, go to step 4 .
4. Inspect TRS/CKP mounting.
   1. If the sensor and mount are secure, go to step 5 .
   2. If the sensor and mount are not secure, tighten the bolt or replace if necessary. Refer to "20.2.22.1 Verify Repairs" .
5. Inspect DDEC pulse wheel for loose wheel or chipped or missing teeth.
   1. If the pulse wheel is damaged, repair or replace as necessary. Refer to "20.2.22.1 Verify Repairs" .
   2. If the pulse wheel is not damaged, refer to "20.2.6 Check ECM/ECU Connectors" .

Section 20.2.6
Check ECM/ECU Connectors

Perform the following steps to check the ECM/ECU connectors:‪

1. Turn vehicle ignition OFF.
2. Disconnect both connectors at the ECM/ECU.
3. Check terminals at all ECM/ECU connectors (both the ECM/ECU and harness side) for damaged, bent, corroded or unseated pins or sockets.
   1. If the terminals and connectors are damaged, repair them. Refer to "20.2.22.1 Verify Repairs" .
   2. If the terminals and connectors are not damaged, replace the ECM/ECU. Refer to "20.2.22.1 Verify Repairs" . (Try a test ECM/ECU first.)

Section 20.2.7
Check for Good Camshaft Position Sensor Signal

Perform the following steps to check for a good SRS/CMP signal:‪

1. Select engine data list on DDR.
2. Crank engine while observing DDR display of SRS/CMP received. Battery voltage surges while cranking with electric starters may blank or reset the DDR.
   1. If the SRS/CMP RECEIVED signal is YES, refer to "20.2.9 Check for Open" .
   2. If the SRS/CMP RECEIVED signal is NO, refer to "20.2.8 Check Camshaft Position Sensor" .

Section 20.2.8
Check Camshaft Position Sensor

Perform the following steps to check the SRS/CMP:‪

1. Turn vehicle ignition OFF.
2. Disconnect engine harness connector at the ECM/ECU.
3. Measure resistance between sockets E-19 and E-20 at the engine harness connector.
   1. If the resistance measurement is greater than 200 Ω, refer to "44.2.3 Open Crankshaft Position Sensor Line Check" .
   2. If the resistance measurement is less than 100 Ω, refer to "44.2.2 Check for Short" .
   3. If the resistance measurement is between 100 and 200 Ω, go to step 4 .
4. Inspect SRS/CMP mounting.
   1. If the sensor and mount are secure, go to step 5 .
   2. If the sensor and mount are not secure, tighten the bolt or replace if necessary. Refer to "20.2.22.1 Verify Repairs" .
5. Inspect DDEC pulse wheel for loose wheel or chipped or missing teeth.
   1. If the pulse wheel is damaged, repair or replace as necessary. Refer to "20.2.22.1 Verify Repairs" .
   2. If the pulse wheel is not damaged, refer to "20.2.6 Check ECM/ECU Connectors" .

Section 20.2.9
Check for Open

Perform the following steps to check if the injector return wires are open: ‪

1. Turn ignition OFF.
2. Disconnect the engine harness connector at the ECM/ECU.
3. Measure resistance between the injector return pin and all the power driver pins on both harness connectors.
   1. If the resistance measurement is greater than 5 Ω on any reading, an open exists in one of the injector power driver or return wires. Repair the open. Refer to "20.2.22.1 Verify Repairs" .
   2. If the resistance measurement is less than or equal to 5 Ω on any reading, refer to "20.2.10 Short to Ground" .

Section 20.2.10
Short to Ground

Perform the following steps to check if the injector lines are shorted to the ground:‪

1. Disconnect the engine harness connector at the ECM/ECU.
2. Measure resistance between a battery ground to the injector harness Pins E-61 through E-68.
   1. If the resistance measurement is greater than or equal to 10,000 Ω or open on all readings, refer to "20.2.11 Injector Drive Pulses" .
   2. If the resistance measurement is less than 10,000 Ω on any reading, there is a short to ground on the wire where resistance was less than 10,000 Ω. Repair the short and refer to "20.2.22.1 Verify Repairs" .

Section 20.2.11
Injector Drive Pulses

Perform the following steps to check the injector drive pulses:‪

1. Turn ignition OFF.
2. Reconnect all ECM/ECU connectors.
3. Remove rocker covers.
4. Disconnect injector common wire E-61 or E-62 from one injector.
5. Place a 6-volt test light across the previously disconnected injector return side and a good ground.
6. Crank engine and note the test light to see if it lights (flashes).
7. Reconnect the return wire.
8. Repeat the above procedure with all other injectors until all have been tested or until one test fails.
   1. If all tests pass, the problem does not appear to be in the DDEC system.
   2. If all tests do not pass and the test light is flashing for one or more tests, check for proper parts (e.g. bull gear) then try a test ECM/ECU. Refer to "20.2.22.1 Verify Repairs" .
   3. If all tests do not pass and the test light is not flashing for one or more tests, refer to "20.2.6 Check ECM/ECU Connectors" .

Section 20.2.12
Battery Volts Check

Perform the following steps to check for battery volts at the 5-way connector:‪

Note: A high resistance in these wires may prevent engine starting but measure correct voltage. Proper resistance based on wire length and size.

1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM/ECU. .
3. Measure voltage from socket V-61, V-62, V-65, and V-66 of the vehicle harness connector to a good ground.
   1. If all the voltage measurements are greater than 11.5 volts on all readings, refer to "20.2.15 Check Volts at Ignition Wire" .
   2. If the voltage measurement is less than 11.5 volts on any readings, refer to "20.2.13 ECM/ECU Power Line Check" .

Section 20.2.13
ECM/ECU Power Line Check

Perform the following steps to check if the ECM/ECU power lines are open:‪

1. Measure voltage between battery side of one ECM/ECU fuse or circuit breaker (red lead) and a good ground (black lead).
2. Measure voltage at other ECM/ECU fuse or circuit breaker. Note that battery side does not contain Pins V-61, V-62, V-65, or V-66. See Figure "Pins V-61 through V-68 to Battery Leads" .
   1. If the voltage measurement is less than 11.5 volts on any reading, refer to "20.2.14 Check Battery" .
   2. If the voltage measurement is greater than 11.5 volts on all readings, an open exists in either power wire (Pins V-61, V-62, V-65, or V-66). Repair the open; refer to "20.2.22.1 Verify Repairs" .
   

   Figure 1. Pins V-61 through V-68 to Battery Leads

Section 20.2.14
Check Battery

Perform the following steps to check the battery:‪

1. Connect all connectors.
2. Turn ignition ON.
3. Measure voltage at battery (+) terminal (red lead) to the battery (-) terminal (black lead).
   1. If the voltage reading is less than 11.5 volts, service the discharged battery. Refer to "20.2.22.1 Verify Repairs" .
   2. If the voltage reading is greater than or equal to 11.5 volts, an open or short to ground exists in the battery (+) line. Repair the open. Refer to "20.2.22.1 Verify Repairs" .

Section 20.2.15
Check Volts at Ignition Wire

Perform the following steps to check for +12 or +24 volts at the ignition wire:‪

1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM/ECU. For vehicle harness schematic, see Figure "ECM/ECU Vehicle Harness Connector" .
   

   Figure 2. ECM/ECU Vehicle Harness Connector

3. Turn ignition ON.
4. Measure voltage between socket V-15 on the vehicle harness connector (red lead) and a good ground (black lead).
   1. If the voltage measurement is greater than or equal to 11.5 volts, go to step 5 .
   2. If the voltage measurement is less than 11.5 volts, refer to "20.2.16 Check Ignition Fuse" .
5. To check for a good ground wire, measure voltage between socket V-15 on the vehicle harness connector (red lead) and Pins V-63, V-64, V-67, or V-66 of the vehicle harness connector. For 5-way ECM/ECU power harness schematic, see Figure "Pins V-61 through V-68 to Battery Leads" .
   1. If the voltage measurement is greater than or equal to 11.5 volts, refer to "20.2.6 Check ECM/ECU Connectors" .
   2. If the voltage measurement is less than 11.5 volts, the ECM/ECU ground wire is open or has a poor connection. Repair open; refer to "20.2.22.1 Verify Repairs" .
   

   Figure 3. Pins V-61 through V-68 to Battery Leads

Section 20.2.16
Check Ignition Fuse

Perform the following steps to check the ignition fuse:‪

1. Turn ignition OFF.
2. Check ignition fuse or circuit breaker.
   1. If both the fuse and circuit breaker are okay, go to step 3 .
   2. If the fuse or circuit breaker are not okay, refer to "20.2.17 Check for Ground" .
3. Measure voltage between battery side (hot side) of the ignition fuse (red lead) and a good ground (black lead).
   1. If the voltage measurement is less than 11.5 volts, refer to "20.2.19 Check Battery" .
   2. If the voltage measurement is greater than or equal to 11.5 volts, the ignition line (circuit V-15) is open. Repair the open; refer to "20.2.22.1 Verify Repairs" .

Section 20.2.17
Check for Ground

Perform the following steps to check if the ignition wire is shorted to ground:‪

1. Replace blown fuse or reset open circuit breaker.
2. Turn ignition ON for ten seconds.
3. Run engine for one minute.
4. Turn ignition OFF.
5. Check ignition fuse or circuit breaker again.
   1. If both the fuse and circuit breaker are okay, refer to "20.2.18 Check Fuse or Circuit Breaker" .
   2. If the fuse and circuit breaker are not okay, the ignition line (circuit V-15) is shorted to ground. Repair the short; refer to "20.2.22.1 Verify Repairs" .

Section 20.2.18
Check Fuse or Circuit Breaker

Perform the following steps to check if the ignition fuse or breaker is okay:‪

1. Reconnect all harness connectors at the ECM/ECU.
2. Start the engine.
3. Run engine for one minute.
4. Turn ignition OFF.
5. Check ignition fuse or circuit breaker again. See Figure "Pins V-61 through V-68 to Battery Leads" .
   1. If both the fuse and circuit breaker are okay, no short is currently present. Be warned of an intermittent short that could shut down the engine or blow a fuse due to reverse voltage at the battery. Refer to "20.2.22.1 Verify Repairs" .
   2. If the fuse or circuit breaker are not okay, refer to "20.2.6 Check ECM/ECU Connectors" .
   

   Figure 4. Pins V-61 through V-68 to Battery Leads

Section 20.2.19
Check Battery

Perform the following steps to check the battery:‪

1. Disconnect the battery cables at the battery.
2. Measure voltage at the battery (+) terminal (red lead) to the battery (-) terminal (black lead).
   1. If the voltage measurement is less than 11.5 volts, service the discharged battery. Refer to "20.2.22.1 Verify Repairs" .
   2. If the voltage measurement is greater than or equal to 11.5 volts, an open or short to ground exists in unfused ignition line. Repair the open. Refer to "20.2.22.1 Verify Repairs" .

Section 20.2.20
Check for Blown Fuses

Perform the following steps to check for blown fuses:‪

1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM/ECU.
3. Replace blown fuse(s) or reset the circuit breaker(s).
4. Wait ten seconds.
5. Check whether fuse(s) or circuit breaker(s) have blown or opened up again.
   1. If the fuse and circuit breaker are okay, refer to "20.2.18 Check Fuse or Circuit Breaker" .
   2. If the fuse or circuit breaker are not okay, refer to "20.2.21 Check for Short to Ground" .

Section 20.2.21
Check for Short to Ground

Perform the following steps to check for a short to ground:‪

1. Disconnect the batteries.
2. Measure resistance between V-61 and V-62 and a good ground (black lead).
3. Measure resistance between V-65 and V-66 and a good ground (black lead).
   1. If the resistance measurement is greater than or equal to 10,000 Ω on all readings, refer to "20.2.6 Check ECM/ECU Connectors" .
   2. If the resistance measurement is less than 10,000 Ω on any readings, a short to ground exists. Repair the short. Refer to "20.2.22.1 Verify Repairs" .

Section 20.2.22
Check Fuel Filters

Perform the following steps to check fuel filters:‪

1. Turn ignition OFF.
2. Check primary and secondary fuel filters to be sure they are not clogged and they are filled with clean fuel.
   1. If the fuel filters are clean, refer to "20.2.4 Check Crankshaft Position Sensor Status" .
   2. If the fuel filters are not clean, replace the filters. Prime the system if required. Refer to "20.2.22.1 Verify Repairs" .

Note: For information concerning Fuel Filters, refer to section 29.4.11 in the appropriate service manual. For information concerning Fuel Filter Replacement, refer to section 18 in the appropriate service manual.

Section 20.2.22.1
Verify Repairs

Perform the following steps to verify repairs:‪

1. Turn ignition OFF.
2. Reconnect all connectors.
3. Turn ignition ON.
4. Clear codes.
5. Start and run the engine for one minute.
6. Stop the engine.
7. Read inactive codes.
   1. If the engine starts and no codes are displayed, troubleshooting is complete.
   2. If the engine does not start, refer to "20.2.1 Amber Warning Lamp" .
   3. If the engine starts and codes display, refer to "18.3 First Step for Diagnosing a Fault Within the DDEC System" .

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