This 10-page PDF is a Cummins 3616 VGT troubleshooting document that provides the complete diagnostic procedure for Fault Code 3616 — Engine VGT Nozzle Position, Mechanical System Not Responding or Out of Adjustment. It covers circuit description, conditions for setting and clearing the fault code, guided troubleshooting steps, and associated repair procedures for Cummins CM2250 engines.
Official Cummins 3616 VGT troubleshooting document details
| Brand | Cummins |
| Model coverage | ISB6.7 CM2250, ISC8.3 CM2250, ISL9 CM2250, ISX11.9 CM2250, ISX15 CM2250 |
| System/Group | Variable Geometry Turbocharger (VGT) — Diagnostic Trouble Codes |
| Fault Code | 3616 (PID: S27, SPN: 2633, FMI: 7) |
| Year/Revision | Last Modified 18-Nov-2010 |
| Pages | 10 |
| File size | 0.2 MB |
| Format | |
| Language | English |
Document table of contents
- Overview — Circuit Description and Component Location
- Fault Code 3616 — Code, Reason, and Effect Summary
- Conditions for Running the Diagnostics
- Conditions for Setting and Clearing the Fault Code
- Shop Talk — ECM Calibration Verification
- Associated Procedures Table (Cooling System 008-018, Air Intake Manifold 010-023 and 010-033, VGT Actuator Electric 010-134, ECM Calibration Code 019-032)
- Step 1 — Check for Other Active Turbocharger Fault Codes (including Fault Code 2387)
- Step 1B — Review Claims History for Recent Turbocharger Failures
- Step 2 — Verify the Complaint (Fault Code Status, Test Drive, Customer Complaint Review)
- Step 2D — Inspect the VGT Actuator Using Sector Gear Travel Gauge (Part Number 4919281)
- Step 3 — Check ECM Calibration and Clear Fault Codes
- Step 3B — Disable and Clear the Fault Code
Applicable truck models
This document applies to all Cummins CM2250-controlled engines: ISB6.7, ISC8.3, ISL9, ISX11.9, and ISX15. These engines are found in medium- and heavy-duty trucks from manufacturers such as RAM, Freightliner, Kenworth, Peterbilt, and International, model years 2010–2012. The procedure requires the INSITE™ electronic service tool for fault code reading, ECM calibration checks, and code clearing. For official service information and the latest ECM calibration revision history, visit Cummins QuickServe Online.
Who needs this Cummins 3616 VGT troubleshooting manual
Diesel mechanics and workshop owners diagnosing cold-start drivability complaints — low power, poor throttle response, or reduced engine braking — on CM2250-equipped trucks will use this guide. It is also essential when Fault Code 2387 or Fault Code 2346 appears alongside FC 3616, indicating an escalated VGT mechanical malfunction or fueling derate condition.
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