Detroit 60 Series Starting Problems – Reasons and Fixes

The Detroit 60 Series Diesel engine is the most successful engine ever made by the Detroit Diesel Corporation. Over 1.2 million units have been sold and it also ranks as one of the most common heavy-duty engines used in trucks in North America during its lifetime. Additionally, it was the first engine to have full electronic controls.

In today's article, we shall look at the Detroit 60 Series starting problems, examine what causes these problems, and explain several remedies to deal with the problem.

Detroit 60 Series Overview

The Detroit 60 series engine is famed for its longevity and durability across several platforms where it is widely used. The engine has extensive applications in trucks, emergency vehicles, fire trucks, power generators, boats, and mining equipment. It is manufactured by the Detroit Diesel Corporation (in Detroit), a subsidiary of Daimler Truck North America (and Daimler Truck AG).

The Detroit Diesel 60 series engine first rolled off the production line in 1987. It is an in-line 6, 4 stroke engine with an overhead camshaft and an electro-mechanical Dbw electronic control technology. The Detroit 60 Series was produced in three different engine configurations,

• The Detroit 60 11.1 L configuration
• The Detroit 60 12.7 L configuration, and,
• The Detroit 60 14 L configurations

The 60 series engine was outstanding due to its fuel efficiency and the electronic control system that gave engine diagnostics and warning lights to the driver through the Detroit Diesel Electronic Control. Though the production of the 60 Series was discontinued in 2011, it is still running in several city buses and trucks. This is because it still has a history of reliability and durability to date, especially the smaller engine trims.

Engine Start Problems

Despite its fame and history, the Detroit 60 Series has its fair share of problems, one of which is related to starting. Here, we highlight these problems, their symptoms, and remedies.

For the diesel engine to start, compression and combustion must take place in the engine to produce energy that turns and starts the engine. The compression system produces heat while combustion occurs after fuel interacts with heat. These two systems have an array of components that work in unison to start and run the engine. Any fault in one of the systems leads to an engine that cannot start.

The most common causes of the Detroit 60 Series engine failing to start include:

• Cold start issues
• Faulty sensors
• Defective fuel pump
• Start system faults
• Fuel contamination
• Compression and combustion issues
• Lack of air or restricted air intake

1. Cold Starts

Cold starts are required when temperatures fall below -8 degrees Celsius. Although diesel engines have mechanisms to cold start when required, the Detroit 60 Series has had difficulties cranking into life on a cold start. 

Cause

Diesel requires a higher ignition temperature than petrol to start. At low temperatures, it is even harder to start. Diesel has gelling properties and at temperatures below -90C, it forms wax crystals that clog the fuel filter. This prevents diesel from reaching the combustion chamber in the right quantity and pressure, causing the engine not to start.

This problem is exacerbated by the aging components of the Detroit 60 series engine which have lost their prime.

Solution

• Use a starting fluid-starting fluid is a volatile and highly flammable liquid put in pressurized containers that assist in starting a stubborn engine. It is made of diethyl ether, volatile hydrocarbons, and carbon dioxide which act as a propellant. The liquid is sprayed into the air intake in small amounts and this assists the engine to start.
• Use block heater-block heaters to heat the engine coolant which then circulates through the block to warm up the combustion chamber. The warm engine block also warms the diesel as it flows into the chamber, making it easier to start the engine.
• Use winter fuel-there are two diesel variants, 1D and 2D. While 2D is the most commonly used, 1D is thinner, volatile, and easily combustible. By blending 1D and 2D, you can create a diesel blend that is easy to ignite during a cold start.
• Winter fuel additives-additives prevent the gelling of diesel when temperatures drop. They also keep all injectors clean. As winter sets in, supplement your diesel with an additive to boost the cold starting of your Detroit 60 engine. However, do not use additives on blended diesel.
• Full tank- A full tank minimizes the chances of the diesel crystallizing and gelling since there is a low volume of air in a full tank. Frequent fill-ups of diesel will go a long way in ensuring your engine does not develop cold start problems.

2. Faulty Sensors

A faulty or worn SRS or TRS sensor will prevent your Detroit 60 series engine from starting. The camshaft Synchronous Reference Sensor (SRS) and Timing Reference Sensor (TRS) control the timings of the engine for precise positioning and optimum injection of diesel for combustion. The two sensors relay the speed and positioning of the camshaft to the ECM concerning which cylinder is at the TDC to initiate firing.

If the sensors are faulty, the timing of fuel injection and firing will not be precise; hence, the engine will not start since the cylinders will not produce enough power to crank the engine.

Solution

Change sensors- The Timing Reference Sensor and the Synchronous Reference Sensor should be changed to eliminate this problem. The two sensors should be changed at the same time if the problem is to be solved.

3. Defective Fuel Pump

The fuel pump delivers diesel to the cylinders for firing up to kick the engine into life. The fuel pump controls diesel pressure and injection flows which provide the right amount of diesel for the engine to start. If the fuel pressure is too low, the engine will not start. Sometimes, the fuel injector may 'lock' in the closed position, blocking the flow of diesel into the cylinder.

Solution

Troubleshoot your fuel pump to determine if it is working properly by doing the following:

• Turn the ignition key to the "ON" position and listen to the clicking or buzzing sound of the fuel pump. If there is no sound, the pump is not working.
• To check fuel pressure, use a fuel pressure gauge by connecting it to the fuel pressure valve near the engine and obtain the pressure reading. If it is lower than the recommended, then, the fuel pressure is too low to start the engine.
• If you find that the problem is the fuel pump, then repair or replace it as the case may be.

4. Faulty starter system

The starter system involves several devices including the battery, starter/motor, solenoids/switches, and electrical wiring. The starter system is a process that provides the initial spark to ignite the fuel to produce the power to turn the engine.

The diesel engine starter system makes the crankshaft move, producing mechanical compression to burn the diesel for the engine to start. If any of these components is faulty, the engine will not start.

• Battery drained/discharged battery- This will not produce enough current to move the starter motor.
• Faulty starter- a faulted starter motor will not move the crankshaft when the ignition key is turned on. The engine will thus not start.
• Loose battery connections-the connections at the battery terminal are loose or rusty, the electric current from the battery will not be transmitted to the starter motor.
• Faulty wiring- If any wiring is loose or broken; it will prevent the battery's electric charge from reaching the required components for the engine to start.

Solution

Check all the starting system components to ensure they are in proper working conditions. Repair or replace any faulty or worn component to make the Detroit 60 engine start normally.

5. Faulty Glow plug

A glow plug is used to warm the diesel when temperatures are low to enable it to ignite quickly when starting the engine. If the glow plug is faulty, the Detroit 60 engine will have difficulties starting.

Solution

Replace the faulty glow plug.

6. Combustion/Compression Issues

Engine pressure and air compression are critical in starting the engine. The combustion chamber must sustain the critical pressure and air-to-fuel ratio for the engine to start. Leakages in the chamber lead to loss of compression which prevents combustion from taking place. Thus the engine fails to start. Check all other areas related to engine starts and if they are fine, then your engine could be suffering from a compression/combustion leakage.

Solution

Check for any leakages that may be leading to loss of pressure and have them repaired by a qualified technician.

6. Fuel Contamination

The presence of contaminants in the diesel will prevent the engine from starting. Contaminants present in diesel may include:

• Oil
• Micro-organisms
• Water
• Wax
• Air in the fuel system
• Sediments and solid particles.

 These contaminants will prevent the fuel from firing up upon ignition in the cylinder. They also cause damage to the internal components of the injectors which affects the combustion process

Solution

• Clean fuel lines and the diesel tank
• Clean or change fuel filters
• Clean or repair all fuel system components
• Avoid using contaminated or adulterated diesel. Do not use diesel that has been stored for more than 12 months.