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Caterpiller Cummins Detroit Diesel ECM Programming Repair and Testing

Diesel Control Service homepage. Programming Repair and Testing for Caterpillar, Cummins, and Detroit Diesel ECMs

The (ECM) engine control module is without a doubt the most widely misunderstood component of a modern engine.  The ECM is the only part of the engine that cannot be easily evaluated.

 For example: It's easy to feel if a cylinder liner has been scored. It's easy to see if a camshaft lobe is flaking. It's easy to listen for air leaking out of a charge air cooler but how do you find out if your ECM is why your fuel mileage or horsepower is down? Or your engine is misfiring?  An electronic injector is another example of a component where most of the time you cannot inspect the part and tell if it’s bad or not. With an injector you can switch injector positions and see what happens...Sometimes this method identifies a bad injector and sometimes it doesn't.  So what happens when you apply this logic to ECM diagnostics? You could try to switch the ECM from the poor performing engine to a known good engine and see if the problem follows the ECM. Once in a while it will but does that mean the ECM is bad? The ECM could just be timed for a different camshaft and different sensor group, or the ECM could just have a corrupt program in it and after you core it and pay $2000 for a replacement you find you still have the old problem. If that happens what did you just get for your $2000 dollars? The newest OEM programming that is calibrated to run with the newest OEM injector updates and the newest camshaft variation of which you may or may not have. Now you find your engine runs worse than before and you haven't even identified the real problem yet.  Lots and lots of good ECMs end up in a core pile every day because of this method of diagnostics and that makes OEMs lots and lots of money. 

If you have a Detroit Diesel DDEC III, DDEC IV, or A3 70 pin Caterpillar ECM Diesel Control Service has a solution for this problem. Our ECM Dyno allows us to evaluate an ECMs condition by sending automated signals to the ECM and checking the ECMs response with live injectors. So in short the ECM dyno is the perfect test truck running a real set injectors. Injector output is carefully recorded and horsepower and torque is estimated for each and every performance program tune. The ECM Dyno isn’t something you will see anywhere else and that’s why our level of quality is also something you won’t see anywhere else.

When it comes to DDEC III, DDEC IV and A3 70 pin Caterpillar performance tuning we take before and after ECM Dyno reports on every job. We compare live injector pulse width maps relative to the camshaft gear position signal with hundreds of actual dyno runs to produce horsepower, torque and fuel consumption estimates that are more accurate as than any other bench ECM tuning options offered anywhere.  We also don’t have to deal with all the air temperature and pressure changes and all the other variables associated with a live engine test. So our estimates are going to average out to be more accurate than an actual dynamometer test as long as your engine is healthy and has the correct valve timing, injectors, and camshaft for its engine family.

DCS performance ECM programs are specific to an engine family not just an engine series like most other guys out there. When you consider that a Series 60 has more than twenty camshaft variations you’ll see why knowing the engine family is important. This is why it’s always a crap shoot with how much horsepower, torque, exhaust gas temperature and fuel mileage if any you will gain when you install one of those universal cheater harnesses and other devices that cheat sensors and modify pulse width with no regard to what your engine family is. If it’s a product that fits all for DDEC IVs that leaves six possible camshafts and two different displacements that the device cannot account for. With a device like this you’ll get is a compromise between all 12 versions of DDEC IV at best. Keep that in mind if you install someone’s one magic size fits all DDEC IVs box or cheater harness on your truck and you are getting high exhaust gas temperature and smoke. Those devices and harnesses are undermining your ECMs careful programming and it’s a roll of the dice as to how it will perform.