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Diagnosis and Testing|Removal and Installation > < Fuel Charging and Controls

Galaxy 2000.75 (04.2000-02.2006)

Fuel Charging and Controls - 1.9L Diesel - Fuel Charging and Controls Galaxy 2000.75 (04/2000-02/2006)
Diagnosis and Testing

Refer to Wiring Diagrams Section 303-04, for schematic and connector information.

Inspection and Verification

WARNING:
WARNING:Do not smoke or carry lighted tobacco of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. The fuel injection pump is fully electronic and has no linkages or cables. Do not grease any of the fuel injection pump terminals or connectors. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
NOTE:
NOTE:As well as carrying out its normal function the glow plug lamp also acts as an engine check lamp. This will flash continuously when a hard diagnostic trouble code (DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by the PCM but will only be known if the system is checked for DTCs using WDS.
NOTE:
NOTE:If a DTC is detected, all DTCs must be cleared after the cause is repaired. Failure to clear all DTCs may cause driveability concerns.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel level
  • Fuel leak(s)
  • Air leak(s)
  • Fuel filter
  • Air cleaner element
  • Fuel supply lines
  • Hose(s)/hose connections
  • Tube(s)/tube connections
  • Contaminated fuel
  • Fuel pump
  • Unit injector(s)
  • Unit injector rocker shaft(s)
  • Unit injector rocker arm(s)
  • Unit injector rocker shaft cam lobe(s)
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Passive anti-theft system (PATS) indicator
  • Sensor(s)
  • Fuel pump module
  • Unit injector solenoid valve(s)
  • Battery
  • PCM
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine does not crank
*
PATS.
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
DTC detected.
*
REFER to WDS.
*
Starting system.
*
REFER to Section  303-06 Starting System.
Engine cranks but does not start
*
DTC detected.
*
REFER to WDS.
*
Inertia fuel shutoff (IFS) switch.
*
RESET the IFS switch.
*
Glow plug relay.
*
CARRY out the relay component test. REFER to Wiring Diagrams.
*
Fuel filter blocked.
*
Fuel lines damaged or blocked.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Sensor(s).
*
Fuel pump.
*
Glow plugs.
*
PCM.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
Poor starting
*
DTC detected.
*
REFER to WDS.
*
Fuel filter blocked.
*
Fuel system leak.
*
Fuel system restriction.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel filter to fuel pump supply line one-way valve.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Glow plug relay fuse.
*
CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Glow plug relay.
*
CARRY OUT the Relay Component Test. REFER to Wiring Diagrams.
*
Glow plugs.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and engine oil. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Cylinder head temperature (CHT) sensor.
*
Temperature and manifold absolute pressure (T-MAP) sensor.
*
REFER to WDS.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Engine starts but immediately stops
*
DTC detected.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
PCM relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
CKP sensor.
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
Poor idling
*
DTC detected.
*
REFER to WDS.
*
Fuel filter blocked.
*
Contaminated fuel.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Sensor(s).
*
REFER to WDS.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Engine stumbling
*
DTC detected.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Acceleration pedal position (APP) sensor.
*
REFER to WDS.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Engine lacks power
*
DTC detected.
*
REFER to WDS.
*
Brakes binding.
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
Vehicle overloaded, or excessive wind resistance (roof racks, towing etc).
*
ADVISE the customer about the effects of overloading the vehicle and wind resistance on the fuel consumption.
*
Charge air cooler blocked or cracked.
*
Charge air cooler pipes split or cracked.
*
Charge air cooler retaining clips missing or loose.
*
INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
*
Sensor(s).
*
REFER to WDS.
*
Fuel filter blocked.
*
Contaminated fuel.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Turbocharger vacuum control.
*
Vane adjustment solenoid valve.
*
CHECK vacuum line(s).
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Fuel cooler.
*
REFER to Section  310-00 Fuel System - General Information.
*
Turbocharger vacuum diaphragm unit.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
*
Catalytic converter blocked.
*
CHECK if the catalytic converter rattles if gently hit. If noise is present, REMOVE and visually INSPECT the catalytic convertor for damage. INSTALL a new catalytic converter as necessary. REFER to Section  309-00 Exhaust System.
Black smoke at idle
*
DTC detected.
*
REFER to WDS.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
CHT sensor.
*
T-MAP sensor.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Excessive black smoke during acceleration
*
DTC detected.
*
REFER to WDS.
*
APP sensor.
*
CKP sensor.
*
REFER to WDS.
*
Fuel contamination.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Black smoke at cruising speeds
*
DTC detected.
*
REFER to WDS.
*
Air cleaner element restricted.
*
INSTALL a new air cleaner element.
*
T-MAP sensor.
*
REFER to WDS.
*
Vacuum lines.
*
CHECK all vacuum lines are correctly installed and no signs of air leaks are present. REPAIR or INSTALL new vacuum line(s) as necessary.
*
Turbocharger vacuum diaphragm unit.
*
Vane adjustment solenoid valve.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
Black smoke at high altitude
*
Barometric pressure (BARO) sensor.
*
REFER to WDS.
Blue smoke
*
DTC detected.
*
REFER to WDS.
*
Engine burning oil.
*
CARRY OUT a controlled oil consumption test over 600 miles (1000 km). CONFIRM that the oil consumption is less than one liter per 600 miles (1000 km). REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Worn or damaged valve guide(s), piston ring(s), cylinder bore(s), cylinder head or gasket.
*
REMOVE and INSPECT the cylinder head, pistons and cylinder bores for signs of wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Engine breather system.
*
CHECK engine breather pipes for signs of restriction or blockage.
*
Turbocharger oil return pipe blocked or damaged.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
White smoke
*
DTC detected.
*
REFER to WDS.
*
Water in fuel.
*
DRAIN the fuel tank and FILL with clean fuel. REFER to Section  310-00 Fuel System - General Information.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Coolant in the combustion chamber.
*
CARRY OUT a cooling system pressure test. REFER to Section  303-03A Engine Cooling / 303-03B Engine Cooling. REMOVE and INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
Engine misfire
*
DTC detected.
*
REFER to WDS.
*
Contaminated fuel.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
CHT sensor.
*
REFER to WDS.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Unit injector seal(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Worn or damaged valve(s), tappet(s) or camshaft(s).
*
REMOVE and INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Damaged cylinder head gasket.
*
REMOVE and INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Engine operating temperature too high.
*
REFER to Section  303-03A Engine Cooling / 303-03B Engine Cooling.
Engine knock at idle
*
DTC detected.
*
REFER to WDS.
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
CKP sensor.
*
REFER to WDS.
*
Excessive carbon build up.
*
REMOVE and INSPECT the cylinder head for signs of carbon build up. INSPECT the pistons for signs of carbon build up. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Unit injector rocker arm(s) out of adjustment.
*
CHECK the adjustment of the unit injector rocker arm(s).
REFER to Unit Injectors in this section.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
*
Worn or damaged oil pump.
*
Worn or damaged timing chain or sprocket.
*
Major mechanical engine failure.
*
REFER to Section  301-01D .
Engine knock during acceleration
*
DTC detected.
*
REFER to WDS.
*
Unit injector rocker arm(s) out of adjustment.
*
CHECK the adjustment of the unit injector rocker arm(s).
REFER to Unit Injectors in this section.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.
*
Major mechanical engine failure.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
Excessive fuel consumption
*
DTC detected.
*
REFER to WDS.
*
Brakes binding.
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
Vehicle overloaded, or excessive wind resistance (roof racks, towing etc).
*
ADVISE the customer about the effects of overloading the vehicle and wind resistance on the fuel consumption.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Fuel leak(s).
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
CHT sensor.
*
T-MAP sensor.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and engine oil. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Clutch slipping.
*
REFER to Section  308-01 Clutch.
*
Generator.
*
REFER to Section  414-00 Charging System - General Information.
*
Turbocharger vacuum diaphragm unit.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Turbocharger.
*
Turbocharger actuator.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Unit injector solenoid valve(s).
*
REFER to WDS.
*
Unit injector(s).
*
Have the Unit injectors checked by an appropriate fuel injection specialist agent. CLEAN the unit injectors or INSTALL a new set as required only after the specialist agent checks have been carried out.

Diagnosis and Testing|Removal and Installation > < Fuel Charging and Controls