04.5 flash update problems

this should help ill do more looking into when i get into school tomorrow morning


NUMBER: 18-006-12
GROUP: Vehicle Performance
DATE: February 04, 2012




THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-011-11 REV. B., DATED JULY
1, 2011, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL OVERVIEW AND
DIAGNOSTIC INFORMATION.
HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS
AVAILABLE BY SELECTING “HELP” THEN “HELP CONTENTS” AT THE TOP OF
THE wiTECH DIAGNOSTIC APPLICATION WINDOW.
THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 12.02 OR HIGHER TO
PERFORM THIS PROCEDURE.
THE DRBIII® FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON
DealerCONNECT.
SUBJECT:
Flash: Diagnostic Enhancements For Fuel System
OVERVIEW:
This bulletin provides Engine Control Module (ECM) software enhancements to improve
robustness to fuel system issue detection and two new Diagnostic Trouble Codes (DTC's).
This bulletin involves selectively erasing and reprogramming the Engine Control Module
(ECM) with new software.
Diagnostic procedures for these new DTC's are included in this Service Bulletin on the last
2 pages which may be printed.
The two new injector Diagnostic Trouble Codes (DTC's) for excessive injector return flow
are:
· P1222 - LEAK DETECTION DURING MOTORING
· P1223 - LEAK DETECTION BASED ON QUANTITY BALANCE
**When the fault(s) occur, a solid Wait to Start lamp will illuminate in the cluster along with
chiming 10 times. When the fault goes inactive, it will clear the wait to start lamp with no
chimes**.

and for the p0148

P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM

For the Engine circuit diagram (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -SCHEMATIC -ELECTRICAL)

For a complete wiring diagram Refer to Section 8W.

When Monitored:

• While the engine is running.
Set Condition:

• A deviation between the fuel pressure set point and the actual fuel pressure.
Possible Causes

OTHERS DTC’S PRESENT
FUEL LEAKS
FUEL CONTROL ACTUATOR
FUEL PRESSURE SENSOR
CASCADE OVERFLOW VALVE
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
LIFT PUMP FLOW
AIR IN FUEL SYSTEM
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
HIGH PRESSURE FUEL PUMP
INTERMITTENT CONDITION

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 -ENGINE
DIAGNOSIS AND TESTING)

Diagnostic Test

1. OTHERS DTC’S PRESENT
With the scan tool, read DTCs.

Are any other DTC’s present?

Yes >> Repair other DTC’s first.

Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL).
No >> GoTo2

2. FUEL LEAKS
Ensure that the fuel level is above 15% using the scan tool.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components.


Do you have any fuel leaks or damaged components?

Yes >> Repair the fuel leak.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

No >> GoTo3


DR/DH ENGINE -ELECTRICAL DIAGNOSTICS -DIESEL 9 -1117


P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)

3. FUEL CONTROL ACTUATOR
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.

NOTE: The fuel control actuator will only click when cycled off..

Do you hear a click from the actuator when you cycle the actuator off with the scan tool?

Yes >> GoTo4
No >> Replace the fuel Injector pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

4. FUEL PRESSURE SENSOR
Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM

Is the fuel rail pressure reading higher at 2000 RPM than at idle?

Yes >> GoTo5
No >> Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

5. HIGH FUEL PRESSURE
Using the scan tool compare the fuel rail pressure set point with the actual fuel rail pressure.

Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Yes >> GoTo6
No >> GoTo9

6. CASCADE OVERFLOW VALVE
Perform the no trouble code test 9*fuel pump return flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Did the fuel injection pump pass the test?

Yes >> GoTo7
No >> Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

7. CHECK VALVE DAMAGED OR BLOCKED
Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.

Is the check valve damaged or blocked?

Yes >> Repair the cause of the damaged or blocked check valve or replace the valve.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo8


9 -1118 ENGINE -ELECTRICAL DIAGNOSTICS -DIESEL DR/DH


P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)

8. FUEL RETURN LINE OBSTRUCTION, DAMAGED OR DEBRIS
Check the fuel return lines for signs of obstruction, damage, or debris.

Are the fuel drain lines damaged or blocked?

Yes >> Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo9

9. LIFT PUMP FLOW
Perform the no trouble code 9Lift Pump flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Did the Lift pump pass the test?

Yes >> GoTo10
No >> Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

10. PRESSURE LIMITING VALVE
Perform the no trouble code test . Pressure Limiting Valve on the Fuel Rail for internal leaks9.

Did the pressure limiting valve pass the test procedure?

Yes >> GoTo11
No >> Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

11. LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
Perform the no trouble test 9*Injector return flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Are any Injectors leaking or high pressure connectors leaking?

Yes >> Replace or repair the leaking fuel injectors or high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo12

12. HIGH PRESSURE FUEL PUMP
Perform the no trouble code test 9HIGH PRESSURE FUEL PUMP PERFORMANCE TEST9. (Refer to 9 -ENGINE
-DIAGNOSIS AND TESTING)

Did the fuel pump pass the high pressure fuel pump performance test?

Yes Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 -ENGINE
DIAGNOSIS AND TESTING)

No Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

@schliebe - Yes after you replace your Airdog pump I would suggest looking into the injectors you could have a leaking injector or a connecting tube coming loose or something in there.

@S415bmxer - There are high pressure connectors that your fuel lines connect into on the side of the head that connect to your fuel injectors.

Yeah if you have some knowhow working on diesels you should be able to do them and valve adjustments are simple also.

This should help:

VALVE LASH ADJUSTMENT AND VERIFICATION

NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F) .

The 24-valve overhead system is a low-maintenance design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors.


Disconnect battery negative cables.
Remove cylinder head cover.
Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 O'clock position.
If both number one cylinder rocker levers are loose, continue to next step.
If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees.








With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required.
VALVE LASH LIMIT CHART








If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained:
INTAKE 0.254 mm (0.010 inch)
EXHAUST 0.660 mm (0.026 inch) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash.
Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 O'clock position.








With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits.
Install the cylinder head cover.
Connect the battery negative cables.