IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV ENGINES ONLY)

For troubleshooting DDEC I and DDEC II engines, refer to section .

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); for one-piece refer to section , for two-piece refer to section , for three-piece refer to section .

2. Record the injector calibration code of each injector noting the cylinder number; see Figure 21495 .

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

Injector Calibration Code Location

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/IV 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 21495 ; refer to section .

2. If test codes match; refer to section .

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

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Note: Injector calibration and bar codes may be absent from the load plates on first-run production DDEC III/IV injectors 5235575, 5235580, and 5235550. The correct calibration code for these units is "01''. Load plates on current DDEC III/IV injectors include the required calibration or bar code information. See Figure 21495 .

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 , 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.

Note: Turning the ignition to the off position and waiting five seconds before starting the engine is not required.

9. Disconnect the DDR; refer to OEM guidelines.

Verification of Repair for Improper Injector Setting

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

1. Install the valve rocker cover(s); for one-piece refer to section , for two-piece and three-piece refer to section . 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 down the engine. 2. If the engine is misfiring, shut down the engine. Check for improper valve clearance and injector height

and damaged or worn camshaft lobes and rollers; refer to section .

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.

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