Series 60 Improper Injector Setting Repair

Perform the following steps to recalibrate improper injector setting: ‪

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.

  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)
  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;

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