Thanks again to EVERYONE who has helped me with your knowledge and expertise over the last few years, especially lately! I posted a while back about a misfire immediately after my out of frame overhaul on this 5EK, which turned out to be a timing calibration issue since the engine was entirely disassembled. SO....started working this new engine right away, hauling heavy loads of rock in and out of Wyoming, and really the engine has ultimately been fine.....even after 15k miles of hauling. The PROBLEM....is that prior to overhauling this engine it has a slight misfire, like one cylinder isn't quite doing its job. It's what led me to overhaul it in the first place, with 1.2million since last being apart. I noticed even after getting the BIG misfire (timing calibration) corrected, it STILL has this miss.....even after breaking it in. Under load in low range, starting out loaded heavy, it is a cab shaker. Here's the breakdown....Idle is glassy smooth in the mornings, when things are cold, but the misfire is worse when under load. When the engine is hot, the misfire is worst at idle to 1300rpm, listening to the exhaust it sounds terrible...an obvious "lope" like a hotrod with a hot cam. However when the engine is hot, it smoothes out under load in the higher gears. I have replaced all sensors on this engine, replaced the injector wire harness (again), the engine wire harness is brand new when I out of framed.
The only three things I have not replaced: cam sensor, ECM, and camshaft/rockers......although the machine shop looked at these and said they were good, and repolished the cam. The cam did not have any signs of flaking/wear that I could see either.
1. Can the cam be worn enough to cause a partial miss, without any obvious signs of wear?
2. Can an ECM cause a single cylinder to partially misfire?
Cat ET shows it is cylinder 3...it contributes very little but still passes the automated cutout tests. I have replaced the injector in cylinder 3 (3) times. Miss was terrible with two Cat Reman injectors, but finally smoothed out under load when hot with a BRAND NEW cat injector. Like whatever is causing this problem, the NEW injector responded to it under load much better.....I have yet to read or hear about ECM problems causing this...they seem to just cause an engine to die and no start when they do go bad?
THANK YOU again to anyone willing to chime in on this EXPENSIVE and perplexing issue....
3406E misfire that won't go away, even after overhaul
Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by JCMtrans, Jun 2, 2019.
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While without having the truck to properly diagnose I can say that you should watch just throwing parts at it. I don't like seeing guys throwing good money at bad. Now with the three injectors...did you ever have them tested to see if the remans we're actually bad? Was the head checked during the overhaul? Was the cam checked/replaced during the overhaul? Sorry for the 60 questions, just trying to give you ideas of where to look.
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Aaaannnnndddd it says you haven't replaced the cam.....I'm retarded......
Did you have it measured to make sure it doesn't have a smoked lobe? -
Have you ever checked the fuel lines or fuel pressure.?
There was a guy on here having sorta same symptoms and it ended up the return line to the tanks was plugged up. Couldn't return the fuel, causing overheated fuel staying in head and trapped air also.
If you have never replaced the cam timing sensor and still running the old style, I'd replace it anyway. The new style is a better sensor, just throw the old one in your tool box. Always good to carry a spare on an E model anyway. -
I think I would of replaced the cam since you did a complete overhaul. I mean with 1.2 million miles.
JCMtrans Thanks this. -
I don't hardly use the automated cylinder test anymore, but run the engine with five injectors cut out running on only one cylinder @ a time. I think you replaced the fuel pressure regulator when had the rough running after overhaul. I would make sure had no air in fuel before replacing hard parts. Engine coolant temp, amb pressure, intake air temp, fuel temp sensor and boost sensor readings all affect fuel timing and delivery so monitor them when engine is running rough. What kind of fuel are you running? I know a guy with a C-15 that swears he can hear a difference in exhaust with the places he buys fuel(bio amount) and fuel temp. Here is cool tool I keep going back in forth over to help diagnose injector issues.
General Technologies Corp. GTC605 Fuel Injection AnalyzerLast edited: Jun 2, 2019
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Do you not know anyone with a E you can borrow there ecm for a day to test.??
As far as the cam goes, you could just put a dial indicator on each rocker and measure lift . Im guessing with that kind of mileage the cam has been replaced already if not a couple times. If it visually looks nice I'm sure it's fine. Lobes dont go flat and still look good.spsauerland and JCMtrans Thank this. -
No need to recalibrate with just a sensor change out.JCMtrans Thanks this.
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