DIAGNOSTIC MANUAL

®
MaxxForce 11 and 13 Engine

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 DIAGNOSTIC MANUAL

TABLE OF CONTENTS
Foreword...................................................................................................................1

Service Diagnosis ........................................................................................................2

Safety Information........................................................................................................3

Engine Systems ...........................................................................................................5

Engine and Vehicle Features..........................................................................................55

Diagnostic Software Operation .......................................................................................63

Engine Symptoms Diagnostics.......................................................................................77

Hard Start and No Start Diagnostics................................................................................111

Performance Diagnostics .............................................................................................145

Electronic Control Systems Diagnostics ..........................................................................185

Diagnostic Tools and Accessories..................................................................................909

Abbreviations and Acronyms ........................................................................................931

Terminology .............................................................................................................939

Appendix A: Performance Specifications.........................................................................951

Appendix B: Signal Values...........................................................................................967

Appendix C: Technical Service Information (TSI)................................................................977

3
II DIAGNOSTIC MANUAL

4
 DIAGNOSTIC MANUAL 1

Foreword Technical Service Literature

®
Navistar, Inc. is committed to continuous research 4328086 MaxxForce 11 and 13 and N13
and development to improve products and introduce with SCR Engine Operation and
technological advances. Procedures, specifications, Maintenance Manual
and parts defined in published technical service ®
0000001682 MaxxForce 11 and 13 Engine
literature may be altered.
Service Manual
®
NOTE: Photo illustrations identify specific parts 00000017 41 MaxxForce 11 and 13 Engine
or assemblies that support text and procedures; Diagnostic Manual
other areas in a photo illustration may not be ®
EGED-475 MaxxForce 11 and 13 Hard Start
exact.
and No Start Diagnostics Form
This manual includes necessary information and ®
® EGED-530 MaxxForce 11 and 13
specifications for technicians to maintain Navistar
Performance Diagnostics Form
diesel engines. See vehicle manuals and Technical
®
Service Information (TSI) bulletins for additional 0000002941 MaxxForce 11 and 13 Electronic
information. Control Systems Diagnostics Form

Technical Service Literature is revised periodically. If

a technical publication is ordered, the latest revision
will be supplied.
NOTE: To order technical service literature,
contact your International dealer.

5
2 DIAGNOSTIC MANUAL
Service Diagnosis
Service diagnosis is an investigative procedure that
must be followed to find and correct an engine
application problem or an engine problem.
If the problem is engine application, see specific
vehicle manuals for further diagnostic information.
If the problem is the engine, see specific Engine
Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges and diagnostic test
equipment
Availability of current information for engine
application and engine systems
Knowledge of the principles of operation for
engine application and engine systems
Knowledge to understand and do procedures in
diagnostic and service publications
Technical Service Literature required for Effective
Diagnosis
Engine Service Manual
• Engine Diagnostic Manual
• Diagnostics Forms
• Electronic Control Systems Diagnostics Forms
• Service Bulletins
6
 DIAGNOSTIC MANUAL
Safety Information
This manual provides general and specific
maintenance procedures essential for reliable engine
operation and your safety. Since many variations in
procedures, tools, and service parts are involved,
advice for all possible safety conditions and hazards
cannot be stated.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions,
and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note.
Warning: A warning describes actions necessary to
prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause
damage to the engine or vehicle.
Note: A note describes actions necessary for correct,
efficient engine operation.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
Use safety blocks and stands.
Protective Measures
Wear protective safety glasses and shoes.
Wear correct hearing protection.
3
Wear cotton work clothing.
Wear sleeved heat protective gloves.
Do not wear rings, watches or other jewelry.
Restrain long hair.
Vehicle
Make sure the vehicle is in neutral, the parking
brake is set, and the wheels are blocked before
servicing engine.
Clear the area before starting the engine.
Engine
• The engine should be operated or serviced only
by qualified individuals.
Provide necessary ventilation when operating
engine in a closed area.
• Keep combustible material away from engine
exhaust system and exhaust manifolds.
Install all shields, guards, and access covers
before operating engine.
Do not run engine with unprotected air inlets or
exhaust openings. If unavoidable for service
reasons, put protective screens over all openings
before servicing engine.
• Shut engine off and relieve all pressure in the
system before removing panels, housing covers,
and caps.
• If an engine is not safe to operate, tag the engine
and ignition key.
Fire Prevention
Make sure charged fire extinguishers are in the
work area.
NOTE: Check the classification of each fire
extinguisher to ensure that the following fire
types can be extinguished.
1. Type A - Wood, paper, textiles, and rubbish
2. Type B - Flammable liquids
3. Type C - Electrical equipment
7
4 DIAGNOSTIC MANUAL

Batteries • Make sure all standard electrical tools are

grounded.
Always disconnect the main negative battery
cable first. Check for frayed power cords before using power
• tools.
Always connect the main negative battery cable
last. Fluids Under Pressure
Avoid leaning over batteries. Use extreme caution when working on systems
under pressure.
Protect your eyes.
• Follow approved procedures only.
Do not expose batteries to open flames or sparks.
Fuel
Do not smoke in workplace.
• Do not over fill the fuel tank. Over fill creates a fire
Compressed Air
hazard.
• Use an OSHA approved blow gun rated at 207
Do not smoke in the work area.
kPa (30 psi).
Do not refuel the tank when the engine is running.
Limit shop air pressure to 207 kPa (30 psi).
Removal of Tools, Parts, and Equipment
Wear safety glasses or goggles.
• Reinstall all safety guards, shields, and covers
Wear hearing protection.
after servicing the engine.
Use shielding to protect others in the work area.
Make sure all tools, parts, and service equipment
Do not direct compressed air at body or clothing. are removed from the engine and vehicle after all
work is done.
Tools
• Make sure all tools are in good condition.

8
 1 ENGINE SYSTEMS 5

Table of Contents

Engine Identification.....................................................................................................7
Engine Serial Number..........................................................................................7
Engine Emission Label ........................................................................................7
Engine Accessory Labels and Identification Plates.......................................................8
Engine Specifications..........................................................................................8
Heavy Duty On Board Diagnostics ( H D-OBD)...................................................10
Engine Description...................................................................................10
Optional Equipment ..................................................................................11
Chassis Mounted Equipment.......................................................................11
Engine Component Locations...............................................................................12

Air Management System...............................................................................................16

Airflow...........................................................................................................17
Turbochargers..................................................................................................18
Air Control Valve (ACV).......................................................................................19
Boost Control...................................................................................................19
Low Pressure Charge Air Cooler ( L PCAC)................................................................20
High Pressure Charge Air Cooler ( H PCAC)...............................................................20
High Pressure Boost Pressure ( H P BP) Sensor ..........................................................20
High Pressure Boost Temperature ( H PBT) Sensor .....................................................20
Low Pressure Boost Pressure ( L P BP) and Low Pressure Boost Temperature ( L P BT) Sensors
................................................................................................................20
Exhaust Gas Recirculation (EGR) System ................................................................21
Aftertreatment (AFT) System ................................................................................24
Diesel Particulate Filter ( D P F)......................................................................25
Diesel Oxidation Catalyst (DOC)...................................................................25
Aftertreatment (AFT) System Conditions and Responses....................................25
Downstream Fuel Injection.........................................................................26
Crankcase Oil Separator......................................................................................28

Fuel Management System.............................................................................................30

Fuel System Components ....................................................................................30
Fuel Flow........................................................................................................31
Low Pressure Fuel System...................................................................................32
High Pressure Fuel System..................................................................................34

Inlet Air Heater System.................................................................................................35

Inlet Air Heater System Components ......................................................................35
Inlet Air Heater System Operation..........................................................................36

Oil Flow and Components.............................................................................................37

Engine Cooling System................................................................................................41

Cooling System Flow..........................................................................................41
Thermostat Operation.........................................................................................42
Coolant Control Valve (CCV) assembly operation.......................................................43

9
6 1 ENGINE SYSTEMS

Engine Brake System ...................................................................................................44

Engine Brake Control System Components ..............................................................44
Engine Brake System Description..........................................................................45
Engine Brake System Operation............................................................................45

Electronic Control System .............................................................................................46

Electronic Control System Components ..................................................................46
Operation and Function .............................................................................46
Reference Voltage (VREF)..........................................................................46
Signal Conditioner...................................................................................46
Microprocessor.......................................................................................46
Diagnostic Trouble Codes..........................................................................46
Microprocessor Memory............................................................................46
Actuator Control......................................................................................47
Actuators........................................................................................................47
Coolant Control Valve (CCV).......................................................................47
Exhaust Back Pressure Valve (EBPV) Control..................................................47
Exhaust Gas Recirculation (EGR) Valve .........................................................47
Air Control Valve (ACV).............................................................................47
Inlet Air Heater Relay (IAHR).......................................................................47
Inlet Air Heater Fuel Solenoid (IA H FS) Valve....................................................48
Engine Throttle Valve (ETV)........................................................................48
Fuel Pressure Control Valve ( F P CV)..............................................................48
Aftertreatment Fuel Doser (AFTFD)...............................................................48
Aftertreatment Fuel Shutoff Valve (AFT FSV)....................................................48
Engine and Vehicle Sensors.................................................................................48
Thermistor Sensors..................................................................................48
Variable Capacitance Sensors .....................................................................50
Magnetic Pickup Sensors...........................................................................51
Potentiometer Sensors ..............................................................................52
Switches ...............................................................................................53
Additional Sensors............................................................................................53
Oxygen Sensor (02S)................................................................................53
Humidity Sensor ( HS)................................................................................53

10
 1 ENGINE SYSTEMS 7

Engine Identification Y - Huntsville, Alabama

7 digit suffix - Engine serial number sequence
Engine Serial Number

Engine Emission Label

Figure 1 Engine serial number

1. Engine Serial Number (ESN) location
2. Engine emission label
3. Cylinder head
4. Flywheel housing
5. Crankcase V35405a

Figure 2 2010 U.S. Environmental Protection

The Engine Serial Number (ESN) is located on the Agency (EPA) exhaust emission label (example)
front of the crankcase (left side), below the cylinder
head.
The U.S. Environmental Protection Agency (EPA)
Engine Serial Number Examples exhaust emission label is on top of the valve cover
® (front left side). The EPA label typically includes the
MaxxForce 11: 106HM2XXXXXXX
following:
®
MaxxForce 13: 125HM2XXXXXXX
Model year
®
MaxxForce 11: 106HM2YXXXXXXX
Engine family, model, and displacement
®
MaxxForce 13: 125HM2YXXXXXXX
Advertised brake horsepower and torque rating
Engine Serial Number Codes Emission family and control systems
106 - Engine displacement (10.5 L) Valve lash specifications
125 - Engine displacement (12.4 L)
ESN
H - Diesel, turbocharged, Charge Air Cooler (CAC),
and electronically controlled EPA, Onboard Diagnostics (OBD), EURO, and
M2 - Motor truck reserved fields for specific applications

11
8 1 ENGINE SYSTEMS

Engine Accessory Labels and Identification Plates

The following engine accessories may have
manufacturer's labels or identification plates:
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Engine Control Module (ECM)
High pressure (HP) fuel pump
Power steering pump
Starter motor
Turbochargers

Engine Specifications
®
MaxxForce 11 and 13 Diesel Engines
Engine Configuration 4 stroke, inline six cylinder diesel
Advertised brake horsepower @ rpm
®
MaxxForce 11 See EPA exhaust emission label
®
MaxxForce 13 See EPA exhaust emission label
Peak torque @ rpm
®
MaxxForce 11 See EPA exhaust emission label
®
MaxxForce 13 See EPA exhaust emission label
Displacement
®
MaxxForce 11 10.5 L (641 in3)
®
MaxxForce 13 12.4 L (758 in3)
Compression ratio
®
MaxxForce 11 16.5:1
®
MaxxForce 13 17.0:1
Stroke
®
MaxxForce 11 155 mm (6.10 in)
®
MaxxForce 13 166 mm (6.54 in)
Bore (sleeve diameter)
®
MaxxForce 11 120 mm (4.72 in)
®
MaxxForce 13 126 mm (4.96 in)
Total engine weight (dry weight without trim or accessories)

12
 1 ENGINE SYSTEMS 9

®
MaxxForce 11 1087 kgs (2392 lbs)
®
MaxxForce 13 1087 kgs (2392 lbs)
Firing order 1-5-3-6-2-4
Engine rotation direction (facing flywheel) Counterclockwise
Aspiration Dual turbocharged and charge air cooled
Combustion system Direct injection turbocharged
Fuel system High pressure common rail
Lube system capacity (including filter) 40 L (42 qts)
®
• MaxxForce 11
®
• MaxxForce 13
Lube system capacity (overhaul only, with filter) 44 L (46 qts)
®
MaxxForce 11
®
MaxxForce 13
Engine oil pressure at operating temperature with SAE 15W-40 oil
• Low idle 69 kPa (10 psi) min.
• High idle 276 - 483 kPa (40 - 70 psi)
Idle speed (no load) 600 rpm, nominal

Thermostat operating temperature

• Primary 83 °C - 95 °C (181 °F - 203 °F)

• Secondary 87 °C - 102 °C (189 °F - 216 °F)

13
10 1 ENGINE SYSTEMS
Heavy Duty On Board Diagnostics ( H D-OBD)
The EPA has added new regulations for 2010 to
reduce heavy duty vehicle emissions. The HD-OBD
system is designed specifically for electronically
controlled heavy duty engines. The key goal for
HD-OBD regulation is to keep engine emissions in
specification for as long as a given vehicle is in use.
HD-OBD is legislated to be implemented in three
phases:
• 2010: First engine for each Original Equipment
Manufacture (OEM) becomes fully certified.
The lead engine is determined by a legislated
equation based on projected sales volume &
useful life of the engine.
For Navistar®, this is the EPA 2010
®
MaxxForce 13 engine.
• and aft thrust controlled at the sixth bearing. One
2013: One engine in each engine family becomes
fully certified.
This will be the largest step of the three
phases.
2016: All engines must be fully HD-OBD certified.
The HD-OBD system continuously monitors for proper
engine operation, and will alert the vehicle operator to
emission-related faults using the Malfunction Indicator
Lamp (MIL).
The MIL is installed in the Electronic Instrument
Cluster. When a detected emissions fault occurs,
the MIL will be illuminated. Diagnostic information is
also stored in the ECM, and may be accessed by the
technician for diagnosis and repair of the malfunction.
Diagnostic information is accessed by connecting the
Electronic Service Tool (EST) to the in-cab Diagnostic
Connector.
Engine Description
® common-rail system. The common-rail includes a
The MaxxForce 11 and 13 diesel engines are
designed for increased durability, reliability, and ease
of maintenance.
The cylinder head has four valves per cylinder for
increased airflow. The overhead valve train includes
rocker arms and valve bridges to operate the four
valves. The fuel injector is centrally located between
the four valves, directing fuel over the piston for
improved performance and reduced emissions.
The overhead camshaft is supported by seven
bearings in the cylinder head. The camshaft gear
is driven from the rear of the engine. The overhead
valve train includes roller rocker arms and dual
valves that open, using a valve bridge. For 2010,
the camshaft has been redesigned to incorporate
six additional lobes. These new lobes are used
with the en�ine brake housings for operation of the
MaxxForce Engine Brake.
R
®
The MaxxForce 11 engines use aluminum pistons,
®
and the MaxxForce 13 engines use one piece steel
pistons. All pistons use an offset piston axis and
centered combustion bowls. Crown markings show
correct piston orientation in the crankcase.
The one-piece crankcase uses replaceable wet
cylinder liners that are sealed by dual crevice seals.
The crankshaft has seven main bearings with fore
fractured cap connecting rod is attached at each
crankshaft journal. The piston pin moves freely inside
the connecting rod and piston. Piston pin retaining
rings secure the piston pin in the piston. The rear oil
seal carrier is part of the flywheel housing.
A gerotor lube oil pump is mounted behind the front
cover and is driven by the crankshaft. Pressurized
oil is supplied to various engine components. All
®
MaxxForce 11 and 13 engines also use an engine
oil cooler and a cartridge-style engine oil filter, which
are located in the engine lube oil module.
The low pressure fuel pump draws fuel from the
fuel tank(s) through a chassis mounted filter/water
separator. The low pressure fuel pump provides fuel
for the engine mounted fuel module. Conditioned low
pressure fuel is supplied from the engine mounted
fuel module to the high pressure fuel pump, inlet air
heater fuel solenoid, and the Downstream Injection
(OSI) unit.
The high pressure fuel system is a direct fuel injected
high pressure fuel pump, two fuel rail supply lines,
fuel rail, six fuel injectors, and pressure relief valve.
The fuel injectors are installed in the cylinder head
under the valve cover and are electronically actuated
by the ECM.
®
MaxxForce 11 and 13 engines use a dual stage,
fixed geometry turbocharger assembly. Each stage
includes a pneumatically operated wastegate, and
14
 1 ENGINE SYSTEMS 11

Charge Air Cooler (CAC). The Low Pressure Charge Chassis Mounted Equipment
Air Cooler (LPCAC) is mounted on the lower right
The chassis mounted fuel filter/water separator
side of the engine, and uses the engine cooling
removes a majority of the water and foreign
system to regulate charge air temperatures. The High
particles that may enter the fuel system from the
Pressure Charge Air Cooler (HPCAC) is mounted in
supply tank(s). This filter works with the engine
front of the engine cooling package. The HPCAC is
mounted fuel module to eliminate foreign matter
an air-to-air type cooler, and requires no connections
and moisture from the fuel before entering the
to the engine's cooling system.
fuel injection system.
The Exhaust Gas Recirculation (EGR) system • The Low Temperature Radiator (LTR) regulates
circulates cooled exhaust into the stream in the air
the temperature of the LPCAC and the low
inlet duct. The dual stage EGR cooler provides
temperature stage of the EGR cooler. The LTR is
regulated cooling of the EGR gases before entering
mounted in front of the radiator cooling package,
the air intake duct. This cools the combustion process,
and requires connections to the engine cooling
and reduces Nitrogen Oxides (NOx) emissions.
system.
The open crankcase breather system uses a • The HPCAC lowers the temperature of the after
Centrifugal Crankcase Oil Separator (CCOS) to
the air is compressed by the turbochargers and
return oil mist to the crankcase, and vent the cleaned
has no connections to the engine cooling system.
crankcase gasses to the atmosphere. The CCOS is
The HPCAC is an air-to-air cooler. The HPCAC is
part of the oil module. The breather system has been
mounted in front of the radiator cooling package.
redesigned, and uses no crankcase breather filter
or external piping. Blowby gases enter the CCOS The Diesel Oxidation Catalyst (DOC) oxidizes
directly through the side of the crankcase. hydrocarbons and carbon monoxide, provides
heat for exhaust system warm-up, aids in
The inlet air heater system warms the incoming air
temperature management for the Diesel
supply prior to and during cranking.
Particulate Filter (DPF), and oxidizes NO into
® ®
The MaxxForce Engine Brake by Jacobs is optional N02 for passive DPF regeneration. The DOC
®
for both MaxxForce 11 and 13 engine displacements. is monitored by the ECM using one Diesel
The engine brake is a compression release system Oxidation Catalyst Inlet Temperature (DOCIT)
that provides additional vehicle braking performance. sensor positioned at the DOC inlet, and one
The operator can control the engine brake for different Diesel Oxidation Catalyst Outlet Temperature
operating conditions. (DOCOT) sensor positioned at the DOC outlet.
The DPF temporarily stores carbon-based
particulates, oxidizes stored particulates, stores
Optional Equipment
non-combustible ash, and provides required
Optional cold climate features available are an oil pan exhaust back pressure for proper engine
heater and a coolant heater. Both heaters use an performance. The DPF is monitored by the
electric element to warm engine fluids in cold weather. ECM using one Diesel Particulate Filter Outlet
Temperature (DPFOT) sensor located at the
The oil pan heater warms engine oil to ensure
outlet of the DPF, and one Diesel Particulate Filter
optimum oil flow to engine components.
Differential Pressure (DPFDP) sensor located on
The coolant heater warms the engine coolant or near the DPF.
surrounding the cylinders. Warmed engine coolant
increases fuel economy and aids start-up in cold
weather.

15
12 1 ENGINE SYSTEMS

Engine Component Locations

V00095

Figure 3 Component location - top view

1. Engine coolant inlet 6. Pre-DOC assembly 13. Engine oil fill
2. Exhaust Gas Recirculation 7. EGR Valve (EGRV) 14. Engine oil level gauge
(EGR) cooler (low temperature 8. Crankshaft Position (CKP) 15. Intake throttle duct assembly
stage) Sensor 16. Engine coolant outlet
3. Air intake duct 9. Air compressor 17. EGR cooler outlet pipe (coolant)
4. Air Control Valve (ACV) 10. Power steering pump 18. EGR cooler outlet tubes (gases)
assembly 11. Engine mounted secondary fuel
5. EGR cooler (high temperature filter access
stage) 12. Emission label (location)

16
 1 ENGINE SYSTEMS 13

11
12

V00096

Figure 4 Component location - front view

1. Mass Air Flow (MAF) sensor 7. Charge Air Cooler Outlet 14. Coolant Control Valve (CCV)
2. Air inlet duct Temperature (CACOT) sensor 15. HP turbocharger compressor
3. EGR cooler 8. Intake throttle duct assembly outlet
4. EGR Temperature (EGRT) 9. Thermostat housing
sensor 10. HP pump pulley
5. Inlet Air Heater Fuel Igniter 11. Vibration damper
6. Intake Manifold Pressure (IMP) 12. Water engine inlet
sensor 13. Water distribution housing.

17
14 1 ENGINE SYSTEMS

18
17 16
V00097

Figure 5 Component location - left view

1. EGRT sensor 7. EGR cooler coolant manifold 14. Engine Oil Level (EOL) sensor
2. Engine Throttle Valve (ETV) 8. Oxygen Sensor harness 15. Fuel Delivery Pressure (FOP)
3. ECM 9. Camshaft Position (CMP) sensor sensor
4. Low Pressure (LP) fuel pressure 10. Flywheel Housing 16. Fuel primer pump assembly
test port 11. Air Compressor 17. LP fuel pump
5. Intake Manifold Temperature 12. OSI unit 18. HP fuel pump
(IMT) 13. Engine mounted secondary fuel 19. Fuel Rail Pressure (FRP) sensor
6. EGRV filter access 20. Intake throttle duct assembly

18
 1 ENGINE SYSTEMS 15

15

12 11
__j V00098

Figure 6 Component location - right view

1. EGR cooler coolant manifold 7. Oil filter cap 13. LP Turbocharger
2. HP turbocharger 8. EGR Cooler 14. Exhaust Back Pressure Valve
3. Humidity Sensor (HS) / Inlet Air 9. CCV (EBPV)
Temperature (IAT) sensor 10. Engine Oil Pressure (EOP) 15. Aftertreatment Fuel Injector
4. ACV sensor (AFI)
5. MAF sensor 11. Crankcase Oil Separator 16. Engine Coolant Temperature 1
6. Engine Coolant Temperature 2 (CCOS) (ECT 1) sensor
(ECT2) 12. LPCAC

19
16 1 E N G I N E SYSTEMS

A i r Management System

--Exhaust Gas Flow

--
->I ntake Air Flow --c::J--

E G R Valve
-.\
7

LP Tu rbocharger
Wastegate
�

EBPV Air Filter

Tu rbocharger Housing

V00078A

F i g u re 7 Air Management System

1. Charge Air Cooler Outlet 4. MAF Sensor 8. I ntake Man ifold Pressure ( I M P)
Temperatu re (CACOT) Sensor 5. H u m i d ity Sensor (HS) / I n l et Air Sensor
2. I ntake Man ifold Temperatu re Temperatu re (IAT) Sensor
(I MT) Sensor 6. Oxygen Sensor (0 2 S)
3. LP Boost/LP Tem peratu re 7. Exhaust Gas Reci rcu lation
Sensor Temperatu re (EG RT) Sensor

20
 1 ENGINE SYSTEMS
Airflow
Air flows through the air filter assembly and enters
the low pressure turbocharger. The LP turbocharger
increases the pressure and temperature of the before
entering the LPCAC. Cooled and compressed air
then flows from the LPCAC into the HP turbocharger
(compressor inlet). Hot and highly compressed air
flows from the HP turbocharger (compressor outlet)
into the HPCAC where it is cooled, and into the
intake throttle duct, and continues through the Engine
Throttle Valve (ETV). The HP and LP turbochargers
increase pressures up to 345 kPa (50 psi).
If the EGRV is open, exhaust gases pass through the
EGR cooler and into the intake throttle duct where
it is mixed with filtered air. This mixture flows into
the intake manifold, and then the cylinder head. The
intake manifold is an integral part of the cylinder head
casting.
During cold weather, the inlet air heater system rapidly
activates the heater element, vaporizing and igniting
small quantities of fuel into the air inlet duct.
17
After combustion, exhaust gases exit through the
cylinder head exhaust valves and ports. The exhaust
gas is forced through the exhaust manifold where,
depending on EGRV position, it is split between
the EGR system and the exit path through the HP
turbocharger, LP turbocharger, and EBPV.
The EBPV is operated by a pneumatic actuator.
When the ACV is applied, the EBPV restricts flow and
increases exhaust back pressure. Operation of the
EBPV is controlled by the ECM using the ACV and the
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
sensor. When the EBPV is opened, exhaust back
pressure is released.
Exhaust gases exiting the engine systems flow
through the EBPV, then through the vehicle
Aftertreatment (AFT) system, and out the exhaust tail
pipe.
21
18 1 E N G I N E SYSTEMS

Tu rbochargers

6
V00079

Fig u re 8 High and low pressu re tu rbocharger components - i n ner and outer views
1. H P tu rbocharger compressor 5. HP turbocharger wastegate 1 0 . LP tu rbocharger com pressor
i n let actuator outlet
2. H P tu rbocharger turbine i n let 6. LP tu rbocharger 1 1 . LP tu rbocharger com pressor
3. LP turbocharger wastegate 7. LP turbocharger turbine outlet in let
actuator 8. Oil supply line 1 2 . H P tu rbocharger compressor
4. H P tu rbocharger 9. Oil retu rn line outlet

®
MaxxForce 11 and 1 3 engi nes are eq u i pped with Exhaust gas flow: The HP tu rbocharger is
a pneu matically reg u lated two-stage tu rbocharg i n g con nected d i rectly to the exhaust man ifold th rough
system . T h e H P and LP tu rbochargers are i n stal led the H P tu rbine i n let. Exhaust gases exit the HP
parallel on the rig ht side of the engine. tu rbine outlet and are d i rected to the LP turbine i n let.
The HP and LP tu rbochargers are eq u i pped with
I ntake a i r flow: Fi ltered a i r enters the LP compressor,
wastegates, which are control led by two pneu matic
where it is compressed and d i rected to the LPCAC .
actuators. I nd ividual wastegates are used to reg u l ate
Cooled LP air then enters the H P compressor, where
boost by contro l l i n g the amount of exhaust gases that
it is fu rther compressed and d i rected into the H PCAC .
bypass the tu rbine of each tu rbocharger. When boost
Compressed air then goes th rough the ETV and the
demand is low, both wastegates are opened , al lowi ng
intake th rottle d u ct. Th is system provides h i g h charge
part of the exhaust gas flow to bypass the H P and LP
a i r pressu re to improve engine performance and to
turbines.
help red u ce em issions.

22
 1 ENG I N E SYSTEMS 19

Control system signals associated with the H P and LP control port, the E B PV control port, and the TC 1 TO P
tu rbochargers have been renamed for 20 1 0 . port. Although these components are integral to
the ACV, each ci rcu it is control led by the ECM. The
All signals related to the LP tu rbocharger are
ACV controls compressed air for each control valve.
designated as Tu rbocharger 1 (TC 1 ) signals, and are
The a i r su pply port is con nected to the veh icle's a i r
identified below:
system .
• Tu rbocharger 1 Wastegate Control (TC 1 WC)
T h e ECM provides a Pu lse Width Mod u late ( PWM)
• Tu rbocharger 1 Tu rbine Outlet P ress u re signal for operation of both wastegate control valves.
(TC 1 TOP) With no PWM sig nal, the control valves are ope n , and
veh icle a i r is suppl ied to the wastegate actuators. The
All signals associated with the H P tu rbocharger
air suppl ied wi l l mai nta i n both wastegates i n the open
are designated as Tu rbocharger 2 (TC2) , and are
position .
identified below:
• When an i ncrease i n the charge air pressu re is
Tu rbocharger 2 Wastegate Control (TC2WC)
req u i red , the ECM suppl ies PWM voltage to close
• Tu rbocharger 2 Compressor I n let P ress u re both control valves. Red uced air pressu re is routed
(TC2CI P) from the closed a i r control valves to the wastegate
actuators causing the wastegate to close and vent
air pressu re . This resu lts i n i ncreased charge a i r
Air Control Va lve (ACV)
pressu res. T h e l i mit val u es o f t h e PWM s i g n a l s are
between approxi mately 9%, correspon d i n g to a fu lly
opened a i r control valve, and 1 00% correspon d i n g to
a closed air control valve.
The TC 1 TO P sensor and E B PV control valve are i n
t h e ACV. T h e E B PV control valve is also operated
by the ECM using PWM , and the TC 1 TOP sensor
is mon itored by the ECM. The E B PV control valve
operates the E B PV actuator.

Boost Control
Wastegate control valves, in the ACV, provide for
operation of a pneu matic wastegate actuator for
each tu rbocharger. Boost is control led for each
tu rbocharger independently, by signals sent from the
ECM to the ACV. In normal operation the wastegates
are actuated by the ACV using veh icle compressed
a i r, reg ulated to 296 kPa ( 4 3 psi) . Position i n g of the
wastegates by the ACV is based on boost pressu re
and temperatu re signals monitored by the ECM.
Fig u re 9 Air Control Valve (ACV) con nections
Because of the abil ity to generate very h i g h charge
1. Electrical connector a i r pressu re levels and to avoid Charge Air Cooler
2. LP tu rbocharger wastegate control port (CAC) overload i n g , the wastegate actuator for each
3. Vehicle air su pply port tu rbocharger is also spri n g loaded . When boost levels
4. E B PV control port i ncrease above specificatio n , boost pressu re alone
5. TC 1 TO P sensor port wi l l open the wastegates, and the exhaust gases wi l l
6. H P turbocharger wastegate control port bypass t h e tu rbochargers. Exhaust back pressu re is
constantly mon itored by the ECM using TC 1 TO P. The
The ACV assembly contains the LP tu rbocharger TC 1 TO P sensor is part of the ACV, and is con nected
wastegate control port, H P tu rbocharger wastegate to the exhaust system by a steel l i n e .

23
20 1 ENGINE SYSTEMS
Low Pressure Charge Air Cooler ( L PCAC)
The LPCAC is installed between the HP and LP
turbochargers, and is mounted to the lower right side
of the engine. The LPCAC air inlet is connected to
the low pressure turbocharger compressor outlet,
and uses engine coolant to regulate the LP charge
air temperature. The LPCAC air outlet is connected
to the compressor inlet of the HP turbocharger.
High Pressure Charge Air Cooler ( H PCAC)
The HPCAC is installed between the HP turbocharger
and the intake throttle duct. The HPCAC air inlet
is connected to the HP compressor outlet, and uses
ambient airflow entering the front of the vehicle to
reduce the charge air temperature. The HPCAC air
outlet is connected directly to the intake throttle duct.
High Pressure Boost Pressure ( H P B P) Sensor
This sensor monitors the pressure of the charge air
entering the duct. The primary function of the sensor
is to provide information used to ensure proper boost
control. It is also used as part of EGR control.
Pressure sensor works by providing an analog voltage
output to the ECM which is proportional to pressure
being applied to an internal diaphragm in the sensor.
The sensor is connected to the control module
through the Reference Voltage (VREF), signal, and
signal ground wires. A transfer function contained
in the ECM software converts the analog voltage
to a pressure value which is then used by software
strategies requiring the pressure information.
The ECM continuously monitors the pressure sensor
output voltage for determination of charge air
pressure. High and low diagnostic voltage thresholds
are evaluated to ensure that output voltage is within
a valid range.
High Pressure Boost Temperature ( H P BT) Sensor
This sensor monitors the temperature of the charge
air entering the duct. The temperature measured is an
input to the engine coolant control strategy. It also is
used for evaluation of on-board diagnostics to ensure
proper functionality of the charge air cooling system.
This temperature sensor is a thermistor and has
two connections to the ECM. A thermistor varies
resistance as temperature changes. When interfaced
to the ECM circuitry, a change in sensor resistance
results in a voltage change internal to the ECM.
A transfer function contained in the ECM software
translates the measured voltage to a temperature
value.
The ECM continuously monitors the voltage resulting
from the thermistor 's changing resistance. High and
low diagnostic voltage thresholds are evaluated to
ensure that the output voltage is within a valid range.
Low Pressure Boost Pressure ( L P B P) and Low
Pressure Boost Temperature ( L P BT) Sensors
This is a combination pressure and temperature
sensor.
This sensor is a dual function sensor that detects
pressure and temperature of the charge air entering
the HP compressor. It is installed in the piping
between the LP compressor outlet and the HP
compressor inlet. This sensor is used for evaluation
by on-board diagnostics to ensure proper functionality
of the charge air cooling system.
This sensor consists of a thermistor which varies
resistance as temperature changes. When interfaced
to the ECM circuitry, a change in sensor resistance
results in a voltage change internal to the ECM. An
internal diaphragm which deflects due to pressure
changes results in an analog voltage output to the
ECM which is proportional to the pressure. Transfer
functions contained in the ECM software translate the
measured voltages into a temperature and a pressure
value.
The ECM continuously monitors the voltages resulting
from changes in both the temperature and pressure.
High and low diagnostic voltage thresholds are
evaluated to ensure that the output voltage is within
a valid range.
24
 1 ENG I N E SYSTEMS 21

Exhaust Gas Reci rculation (EGR) System

V00081

Fig u re 1 0 EGR system components

1. EGRT sensor 6. I ntake Man ifold Temperatu re 1 0 . Low temperatu re EGR cooler
2. EGR cooler air bleed (to (I MT) outlet (coolant)
deaeration tank) 7. EGR cooler outlet tube (2) 1 1 . EGRV coolant supply line
3. EGR cooler (low temperature (gases) 1 2 . E G R cooler inlet tubes (gases)
stage) 8. Low temperature EGR cooler 1 3 . EGRV
4. EGRV coolant return line (to i n let (coolant) 1 4 . E G R cooler i n let (coolant)
deaeration tank) 9. E n g i n e Coolant Temperature 2
5. High temperature EGR cooler (ECT2) sensor

25
22 1 ENGINE SYSTEMS

EGR System Overview monitors and provides an EGRV position signal to the
ECM.
The EGR system reduces NOx engine emissions by
introducing inert cooled exhaust gas into the air inlet The 02S is installed in the exhaust, in front of the
duct. NOx forms during a reaction between nitrogen aftertreatment fuel injector. The 02S has a heater
and oxygen at h igh temperatures during combustion. element that heats the sensor to its normal operating
temperature of 780 °C (1 436 °F) . During initial engine
The ECM monitors signals from the CACOT sensor,
warm-up, the 02S heater element is activated only
Oxygen sensor (02S) , Engine Coolant Temperature
after the engine coolant reaches 40 °C (1 04 °F) and
1 (ECT1 ) sensor, EGRT sensor to control the EGR
the exhaust gas temperatu re DOCIT sensor exceeds
system.
1 00 °C (21 2 °F) for more than 30 seconds.
EGR is switched off (EGRV closed) if any of the
following conditions are present: EGRV Control
Engine coolant temperature less than 1 0 °C (50
°F) will close the EGR valve

. II
2
I ntake manifold temperatures less than 7 °C (45
°F) will close the EGR valve I 1
I I 3

During engine brake operation

------- 8
5

I
EGR Flow
Exhaust gas from the exhaust manifold flows through
the EGR inlet tubes to the EGRV. When EGR function
7
1-: I
6 :_
I
1 _ _ _ _ _ _ _, 4

is activated , the EGRV opens and allows exhaust gas V00082

to enter the EGR cooler. Cooled exhaust gas flows

from the front of the EGR cooler, th rough the EGR Figure 11 EGRV position control
outlet tubes, and into the intake throttle duct where it 1. EGR position monitored by ECM
is mixed with filtered air. 2. ECM
3. ECM commands EGR to desired position
EGR System Control 4. EGRV to desired position
The EGR system consists of the EGRV, ETV, and 5. EGRV
02 S. The EGRV contains a PWM controlled valve and 6. EGRV position matches ECM command
Exhaust Gas Recirculation Position (EGRP) sensor. 7. EGR position sent to ECM

The EGRV is installed at the rear of the EGR cooler,

on the right side of engine valve cover. The EGRV The EGRV has an integrated position sensor, and
limits exhaust gas flow into the EGR cooler. provides feedback to the ECM indicating EGRV
The ECM commands the EGRV to move and hold position.
position. The EGRP sensor, located inside the EGRV,

26
 1 ENGINE SYSTEMS
EG R - Open Loop
During the engine warm-up period and before the 02S
reaches its normal operating temperature, the EGR
system operates in open loop. In open loop, the EGR
system is controlled by the ECM based on the charge
air temperature, engine coolant temperature, engine
speed, and load conditions.
EGR - Closed Loop
After the 02S reaches its operating temperature, the
EGR system switches to closed loop operation. In
closed loop, the EGR system is controlled by the ECM
based on coolant temperature and 02S readings.
23
EGR Flow Cooling
The EGR system includes a two-stage EGR
cooler, allowing the ECM to regulate EGR Cooler
temperatures. The ECM monitors intake manifold
temperature through the Exhaust Gas Recirculation
Temperature 1 (EGRT1) sensor and to regulate EGR
flow temperatures, the CCV regulates coolant flow
through the LTR. Refer to Cooling System in this
section for more information.
27
24 1 E N G I N E SYSTEMS

Aftertreatment (AFT) System

8 9 -2

i
i

4
V00083

Fig u re 1 2 AFT system overview

1. Pre-DOC exhaust flow 4. DPF 8. DOCOT sensor
2. Aftertreatment Fuel I njector 5. Exhaust out to tai l pipe 9. DOCIT sensor
(AFI) 6. D P FOT sensor
3. DOC 7. DPFDP sensor

The AFT system, part of the larger exhaust system ,
processes e n g i n e exhaust to meet emission
req u i rements. The AFT system traps particulate
matter (soot) and prevents it from leaving the tai l pi pe.
The AFT system performs the followi ng fu nctions:
• Monitors exhaust gas temperatu res DOC i n ,
DOC out, a n d D P F o u t temperatu re a n d delta
pressu re across the D P F. It controls engine
operati ng parameters for emission control and
fai l u re recog n ition
• May cancel regeneration i n the event of catalyst
or sensor fai l u re
• Monitors the level of soot accu mu lation i n the D P F
A F T control system i n itiates regeneration
automatica l ly when D P F is fu l l with soot and
control engine operati ng parameters to increase
temperatu re to have successfu l regeneration
• Mai ntains veh icle and engine performance d u ri n g
regeneration

28
 1 ENGINE SYSTEMS 25

Diesel Particulate Filter ( D P F) Provides heat for exhaust system warm-up

The DPF does the following: Aids in system temperature management for the
DPF
Captures and temporarily stores carbon-based
particulates in a filter
• Allows for oxidation (regeneration) of stored Aftertreatment (AFT) System Conditions and
particulates once loading gets to a particular level Responses
(restriction)
The operator is alerted of system status either audibly
• Provides the required exhaust back pressure drop or with instrument panel indicators. Automatic or
for engine performance manual regeneration is required when levels of soot
exceed acceptable limits. For additional information,
Stores non-combustible ash
see the applicable vehicle Operator's Manual and the
vehicle visor placard.
Diesel Oxidation Catalyst ( DOC)
The DOC does the following:
Oxidizes hydrocarbons and carbon monoxide
(CO) in exhaust stream

29
26 1 E N G I N E SYSTEMS

Downstream Fuel I njection

V00084

F i g u re 1 3 Downstream fuel i njection compone nts

1. OSI u n it 2. F u e l line reta iners (rear of 3. AFI
engine block) 4. AFI fuel pressu re line

The OSI system injects fuel i nto the exhaust system
to in crease temperatu re of the exhaust gases, and
is necessary for D P F regeneration. O S I is co ntrolled
by the E C M . The ECM receives signals from the
Aftertreatment Fuel Doser (AFTF D) sensor (located in
the OSI u n it) , and control operation when downstream
injection (regeneration) is req u i red . The E C M
a l s o controls t h e Aftertreatment Fuel Sh utoff Va lve
(AFTFSV) (located in the O S I u n it) which controls
the volume of fu el sent to the AFI in case of AFTFD
malfu n ction .

30
 1 ENG I N E SYSTEMS 27

Downstream I njection (DSI) U n it
2 amount of fuel to the AF I . The DSI u n it provides
The DSI u n it is con nected to the clean side of the
low pressu re fuel system , and wi l l provide a metered
pressu rized fuel i njection pu lses to the AF I . The AFI
is a mechan ical poppet type i njector, and wi l l o n ly
i nject fuel when fuel l i n e pressu re is i ncreased above
a specific pressu re . The DSI u n it is instal led on the
left side of the engine, to the rear of the fuel mod u le.
The AFTF I S and AFTFP2 sensors mon itor fuel
pressu re and temperatu re i n the DSI system , and
provide constant feed back to the ECM.

Aftertreatment Fuel I njector (AFI)

The AFI is located on the right side of the engine, and
is i n stal led i n the tu rbocharger exhaust pipe after the
exhaust 0 2 S .
P ressu rized fuel is suppl ied to t h e i njector b y the DSI
u n it using the AFTFD valve. When the cond itions
5 req u i red for regeneration are met, the ECM sends a
V00085 PWM voltage to the AFTF D . D u ring operatio n , the
AFTFD i ncreases fuel pressu re to the AF I , causing
Fig u re 1 4 Downstream I njection (DSI) u n it i njection of fuel i nto the exhaust pipe.
1. Fuel su pply from fuel filter assembly To protect the AFI i nternal components, conti nuous
2. Aftertreatment Fuel Shutoff Valve (AFTFSV) engine coolant flow th rough the AFI is mai ntai ned by
3. Aftertreatment F u e l I n let Sensor (AFTF I S) external coolant su pply and retu rn l i nes.
4. Aftertreatment F u e l Doser (AFTF D)
5. Aftertreatment F u e l Pressu re 2 (AFTFP2) sensor
6. Fuel outlet port to AFI

31
28 1 E N G I N E SYSTEMS

C ran kcase O i l Se pa ra1tt,o r

��-------- -
- ­

V00086
-- -------
--=--==:�
Figu re 1 5 O i l M o d u le wo" t h C ra n kcase O)ii l Se pa ra to r
C oo lant s u pply line 5. o ; 1 fi lte , a ess a 9. CCOS ve ntilati o n t u b e heate r
cc c
�
�: cc o s ,e , t tu b 6. Engine Oil Tempe r tu ,e (ED n
;
. C rankcase 01 , eparato , Spee d sen� o r
3 .
(CCO SS) sens o r 7. Engine 011 P ressu re (EOP)
.
. C rankcase Cent r ifuge 0,1 sens o r
4 .
Sepa rat o r (CCOS) 8. C oo lant retu r n line

32
 1 ENGINE SYSTEMS 29

Crankcase ventilation is provided using the CCOS.
Excess crankcase vapors are filtered by the CCOS,
and are then vented to the atmosphere.
A centrifugal oil separator, driven by engine oil
pressure, separates and directs oil mist to the side of
CCOS housing. The separated oil mist drains from
the oil separator, through the crankcase, and into the
oil pan. The oil separator is an integral part of the oil
module.

33
30 1 ENG I N E SYSTEMS

Fuel Management System

Fuel System Components

i
2 3 4

12 11 10
V00087

Figure 1 6 Fuel system

1. I njector (6) 6. F u e l su pply t o OSI u n it 11. Fuel primer pump assembly
2. Fuel Rail 7. Fuel retu rn line 12. LP fuel pump
3. Fuel rail pressu re limiting valve 8. Fuel fi lter assembly 1 3. H P fuel pump
4. F u e l retu rn from cyl inder head 9. Drain screw 14. Fuel Rail Pressu re (FRP) sensor
5. Engine fuel return connection (to 1 0. Fuel Del ivery Pressure (FOP)
chassis filter) sensor

®
MaxxForce 1 1 and 1 3 engines are eq u i pped with
a h i g h pressu re common rai l i njection system .
T h e common rai l fuel i njection system provides
pressu rized fuel to the fuel i njectors for opti mal fuel
atomization i n the combustion chamber.
All excess fuel is retu rned t o t h e chassis mounted fi lter
separator, before retu rn i n g to the fuel tan k.
The fuel system is control led by the E C M , various
sensors, and the Fuel Pressu re Meteri ng U n it ( F P M U )
located i n t h e H P p u m p . F o r add itional informatio n ,
refer t o LP F u e l System and H P F u e l System i n th is
sectio n .

34
 1 E N G I N E SYSTEMS 31

Fuel Flow

3
...... 4 ...... 5 ......
6

7
12

10

V001 30

Fig u re 1 7 Fuel s u pply flow d iag ram

1. Fuel Retu rn 6. LP fuel pump 1 1 . Fuel rai l
2. Fuel su pply 7. Fuel filter assembly (eng ine 1 2 . Fuel i njectors
3. F u e l tank mou nted) 1 3 . Chassis mou nted fuel filter/water
4. Chassis mou nted fuel filter/water 8 . DSI u n it separator (bottom portion)
separator (Top portion) 9. H P fuel pump
5. Fuel primer pump assembly with 1 0 . I n let Air Heater Fuel Solenoid
fuel strainer element (IAHFS)

Fuel is p u m ped from the tan k, th rough the chassis
mounted fuel fi lter/water separator using the LP fuel
pump. Fuel is p u m ped from the LP fuel pump to
the engine mounted fuel fi lter assembly, before bei n g
su ppl ied t o t h e H P fuel p u m p . T h e h i g h pressu re fuel
pump suppl ies high pressu re fuel to the fuel rai l , which
feeds the i nj ectors th rough i n d ivid ual tu bes. The LP
fuel pump and HP fuel pump are assembled as one
gear d riven u n it, and are serviced as an assem bly.

35
32 1 E N G I N E SYSTEMS

Low Press u re Fuel System

2 5
1

24
23 21

Fig u re 1 8 Low pressu re (LP) fuel system

1. H P fuel pump 9. Fu� supp� to DSI u n it 1 8. Fuel retu rn from engine
2. Fuel Pressure Control Valve 1 0 . Chassis mounted primary fuel 1 9. Fuel supply to engine
(FPCV) fi lter access 20. Engine mou nted fuel mod u le
3. F u e l primer pump assembly w/ 1 1 . Fuel su pply to engine 21 . I n let air heater port
fuel strainer element 1 2 . Fuel return from engine 22 . Low pressu re fuel supply line
4. F u e l pressure test port 1 3 . Fuel su pply from tan k 23. LP fuel pump outlet
5. E n g i n e fuel su pply connection 1 4 . Chassis mou nted fuel filter/water 24 . LP fuel pump inlet
6. FD P sensor separator 25. H P fuel pump i nlet
7. Engine mounted secondary fuel 1 5 . Fuel Heater 26. H P fuel pump return
filter access 1 6 . Water I n Fuel (WI F) sensor
8. Engine fuel retu rn connection 1 7 . Fuel retu rn to tan k

The L P fuel pump pumps fuel from the tan k th rough
the chassis mounted fuel fi lter/water separator, fuel
strainer element and engine fi lter element, then to the
high pressu re fuel system, i n let air heater system , and
OSI .
I n add ition to provid ing h i g h pressu re fuel to the
i njectors, the fuel system provides fi ltered low
pressu re fuel to the downstream I njection and i n let
air heater systems.
Chassis Mou nted Fi lter/Water Separator
The chassis mounted filter/water separator removes
debris and water from the fuel before it enters the
fuel primer pump and low pressu re fuel p u m p . The
chassis mounted fi lter/water separator i ncludes a
Water I n Fuel (WI F) sensor and optional fuel heater.
Refer to Section 5 "Chassis Fi lter/Water Separator
Mai ntenance and I nspection" i n th is manual for more
information .
Fuel P rimer Pump Assem bly
D u ri n g fuel system pri m i n g , fuel is d rawn from the tan k
th rough the chassis mounted fi lter/water separator by
the fuel primer pump assembly. The fuel primer pump
assembly has an integ rated fuel strainer element that
can be cleaned . The fuel primer pump assembly
is manually operated , and is used to prime the low
pressu re fuel system anyti me the fuel system has
been emptied . The primer pump provides u n restricted
fuel flow to the low pressu re pump d u ri n g normal
e n g i n e operatio n .

36
 1 ENGINE SYSTEMS 33

Low Pressure ( L P) Fuel Pump assembly, which measures fuel pressure between the
LP fuel pump and the filter element. The fuel filter
The LP fuel pump and the HP fuel pump are housed as
assembly also has a drain screw that allows water
one assembly. Fuel is drawn through the fuel primer
and dirt to be drained periodically. Because water
pump assembly and into the LP fuel pump. The LP
may accumulate inside the fuel filter assembly, use the
pump supplies fuel to the fuel filter housing assembly
drain screw to drain water per maintenance schedule
at pressures varying between 496 kPa (72 psi) at idle,
in the Engine Operation and Maintenance Manual. An
and 896 kPa (130 psi) at rated speed. The LP fuel
additional function of the fuel filter assembly is fuel
pump is equipped with an internal pressure regulator
system self-deaeration. The air separated from fuel
that relieves the fuel pressure internally if the pressure
is pushed back into the fuel tanks through the return
exceeds 1300 kPa (189 psi).
line. The fuel filter assembly also provides filtered
fuel to the OSI and inlet air heater system. An orifice
Fuel Filter Assembly
regulator is integrated into the fuel filter assembly,
The fuel filter assembly is located on the left side of the and regulates the fuel pressure for the inlet air heater
engine and has a disposable filter element. An FOP system to 70 kPa (1 O psi).
sensor is installed on the front side of the fuel filter

37
34 1 E N G I N E SYSTEMS

High Pressure Fue l Sys tem

V00089

F i g u re 1 9 H i g h pressu re (HP) fuel sys tem

1. I nje ctor (6) . Fuel Pressu re Control Valve 6. F u e l retu rn - H P fuel pump
4
2. Rail p ressu re limiting valve (FPCV) 7. H P fuel pump
. Fuel Rail 5. Fuel i n let - HP fuel pump 8. FRP sensor
3

P ressu rization and i njection are separate in the
common ra i l i njection system . The optimal injection
pressu re is generated by the high pressu re pump at
any engine speed . H i g h pressu re fuel quantity from
high pressu re pump is control led by the F PCV. The
injection ti ming and q u antity are calcu lated in the
ECM and implemented by solenoid valve control led
injectors . The use of solenoid valve control led
injectors allows three i njections per cycle .
T h e fi rst i njection is used t o reduce combustion
noise and emissions by i ntrod ucing a small amount
of fuel into the cylinder, preventing a rapid rise
in cylinder pressu re when combustion beg i n s .
T h e second i njection is t h e m a i n injectio n . T h i s
injection allows high temperatu res t o be maintained
d u ring combustion, but not long enough to a llow
generation of large soot amou nts . The third inj ection
is done d u ring the power stroke to maximize cylinder
temperatu re and reduce engine soot generation.
The high pressu re fuel system consists of the
high pressu re pump with integ rated Fuel Pressure
M etering U n it ( F P M U ) , pressure pipe ra i l , high
pressu re fuel lines, i njectors , F R P sensor, and
pressu re relief valve .

38
 1 ENGINE SYSTEMS 35

High Pressure (HP) Pump Injectors

The HP pump supplies the necessary quantity of HP
fuel for all operating engine modes. The HP pump
is gear driven and is fuel lubricated . Fuel from the LP
fuel pump is forced through the fuel module assembly,
and into the HP pump. The flow of fuel to the suction
chamber of the HP pump is controlled by the FPCV, in
order to control HP fuel output.
Fuel Pressure Control Valve (FPCV)
The FPCV is a variable position actuator installed
on the suction side of the h igh pressure pump and
controls the output fuel pressure. The ECM sends a
PWM signal to control the FPCV. A 1 00% d uty cycle
PWM signal corresponds to minimum fuel pressure
delivery, while a 0% duty cycle PWM corresponds to
maximum fuel pressure delivery.
®
MaxxForce 1 1 and 1 3 eng ines are equipped with
electronically controlled injectors. During engine
operation, injectors are supplied at all times with
high pressure fuel, and the injector solenoid valves
open up to three times per cycle. The injectors are
positioned vertically in the center of the cylinder head
and are held in place by brackets. The seal between
the injectors and the combustion chamber consists of
a copper washer on the tip of each injector.
Inlet Air Heater System
Inlet Air Heater System Components

Fuel Rail
The fuel rail is a HP fuel storage unit. The storage
volume of the fuel rail is designed to reduce pressure
pulses caused by the HP pump and injectors, and to
maintain constant fuel pressure even when large fuel
quantities are injected into the cylinders. Connection
between the fuel rail and injectors are made through
two individual injection lines.

Fuel Rail Pressure (FRP) Sensor

The FRP sensor is a variable resistance sensor that
monitors fuel pressure in the HP fuel rail. The FRP
sensor is mounted in the front of the fuel rail, on the Figure 20 Inlet air heater system
left side of the engine. 1. Inlet Air Heater Fuel Igniter (IAHFI)
2. Inlet Air Heater Fuel Solenoid (IAHFS) valve
Rail Pressure Limiting Valve 3. Inlet Air Heater Relay (IAHR)
The rail pressure limiting valve maintains fuel pressure
inside the fuel rail below 260,000 kPa (37 ,71 0 psi). If
HP pump output exceeds 260,000 kPa (37,71 0 psi) , Inlet Air Heater Fuel Igniter (I AHFI)
the pressure relief valve opens and allows fuel to flow The inlet air heater system rapidly activates the heater
into the fuel return line. With the pressure relief valve element, vaporizing and igniting small quantities of
open, fuel pressure in the pressure pipe rail drops to fuel into the air inlet duct.
approximately 1 1 0,000 kPa (1 5,954 psi) .

39
36 1 ENG I N E SYSTEMS

I n let Air Heater Fuel Solenoid (IAH FS) Valve

The IAH FS valve is located on the left side of the
engine and is control led by the E C M . The IAH FS valve
is suppl ied with low fuel pressu re reg ulated fuel from
the fuel fi lter assembly.
When the ECM provides battery voltage to the IAH FS
valve, the solenoid opens and allows fuel to flow to the
IAH FI th rough the IAH F I fuel l i n e .

I n let Air Heater System Operation

The i n let air heater system operates o n ly in
P 4 32 1 0 temperatu res lower than 1 0 °C (50 ° F) .

Figure 2 1 I n let Air Heater Fuel Igniter (partial When t h e truck operator turns t h e i g n ition switch to
cut away view) O N , the wait-to-start lamp i n the i n stru ment cl uster
i l l u m i nates. Based on the temperatu re read ings from
1. Electrical connection the ECT sensor, the ECM activates the IAH R heater
2. I nsulation element. The !AH R then energ izes the IAH F I for
3. IAH F I fuel line connection approxi mately 35 seconds.
4. Meteri ng device
5. Vaporizer filter Once the IAH F I is heated to approxi mately 1 000 °C
6. Vaporizer tube ( 1 832 °F), the wait-to-start lamp starts to flash and
7. Heater element the operator needs to cra n k the engine. When the
8. Protective sleeve engine starts rotati n g , the IAH FS valve opens and
allows fuel to enter the IAH F I . I nside the IAH F I , fuel
passes th rough the vaporizer tube. The vaporized fuel
The IAH F I has an i nternal fuel meteri ng device, a then mixes with i n coming a i r and i g n ites i n contact
vaporizer fi lter, a vaporizer tube, a heater element, with the heater element.
and a protective sleeve. The protective sleeve has Once the engine starts, the IAH F I remains energ ized
holes that allow enough air to pass th rough the IAH FI and fuel conti n ues to be i njected , and the wait-to-start
to enable fuel vaporization and combustion . lamp conti n u es to flash for a maxi m u m of fou r m i n utes.
The IAH FI is i n stal led on the left front side of the When the wait-to-start lamp stops flash i n g , the IAH FI
engine, in the intake th rottle d u ct. and the IAH FS valve are deactivated . If the operator
accelerates while the wait-to-start lamp is flash i n g , the
I n let Air Heater Relay (IA H R) i n let air heater system wi l l sh utdown .

The !AH R is located on the left side of the engine at

the rear of the ECM. The !AH R provides voltage to the
IAH F I , and is control led by the ECM .

40
 1 ENG I N E SYSTEMS 37

Oil Flow and Com ponents

2
1

-- Filtered Oil
13
-= U nfi ltered Oil
P 1 2201

Figure 22 Oil flow

1. O i l fi lter element 7. Oil supply to air compressor 12. Oil su pply to front cover
2. O i l retu rn from cyli nder head 8. Oil supply to crankshaft main 1 3. Oil pump output
3. Oil supply to exhaust valve bearings 14. Oil pressure relief valve
bridge 9 . O i l su pply t o piston o i l sprayer 1 5. Oil su pply to oil module
4. O i l su pply to rocker gear nozzles 16. Oil retu rn sh utoff valve
5. O i l supply to camshaft bearings 1 0 . Oil supply to tu rbochargers 1 7. Oil cooler
6. O i l supply to i ntermediate gears 1 1 . Oil supply to drive housing

U nfi ltered oil is d rawn from the oil pan through the
picku p tube and front cover passage by the crankshaft
d riven gerotor p u m p . The pressu rized oil is moved
th rough a vertical cran kcase passage and i nto the oil
mod ule.
I nside the oil mod u le , u nfi ltered oil flows through
plates i n the oil cooler heat exchanger. E n g i n e coolant
flows around the plates to cool the s u rro u n d i n g o i l .
An oil return sh utoff valve , installed a t t h e exit from
the o i l cooler, prevents o i l from d rai n i n g through the
oil pump and back i nto the oil pan when the engine is
stopped . I f oil pressu re coming out of the oil pump is
too h i g h , a pressu re rel ief valve allows the excess oil
to retu rn through the cran kcase and i nto the oil pan
before enteri n g the oil cooler.

41
38 1 ENGINE SYSTEMS
Oil that exits the oil cooler flows through a return
shutoff valve that prevents the oil from draining back
into the oil pan. From the return shutoff valve, oil
enters the oil filter element and flows from the outside
to the inside of the filter element to remove debris.
When the filter is restricted, an oil filter bypass valve
opens and allows oil to bypass the filter so engine
lubrication is maintained. If the oil pressure inside
the oil filter element is too high, an oil pressure relief
valve, located at the bottom of the oil filter element
housing, allows the excess oil to return to the oil pan.
After passing through the oil filter element, oil flow is
directed to the cylinder head and crankcase.
Clean oil enters the cylinder head through an external
flange elbow connected directly to the oil module.
Inside the cylinder head, oil flows through passages to
lubricate the camshaft bearings, rocker arms, exhaust
valve bridges, and cylinder intermediate gear.
Clean oil enters the crankcase directly from the oil
module to lubricate the crankshaft, high pressure
pump, air compressor, intermediate gears, and
turbochargers. The crankshaft has cross-drillings that
direct oil to the connecting rods.
Oil sprayer nozzles continuously direct cooled oil to
the bottom of the piston crowns.
The turbochargers are lubricated with filtered oil from
an external supply tube that connects the main oil
gallery from the crankcase to the center housing of
each turbocharger. Oil drains back to the oil pan
through the low and high pressure turbocharger oil
return pipes connected to the crankcase.
A service oil drain valve, located at the bottom of the
filter element cavity, opens automatically when the
filter element is lifted for replacement, and allows the
oil from the oil filter element cavity to drain into the oil
pan.
®
Oil is also supplied to the MaxxForce Engine Brake
housings (under valve cover) through specially
designed rocker mounting bolts.
42
 1 ENG I N E SYSTEMS 39

Cran kcase O i l Separator

Fig u re 23 O i l mod ule with cran kcase oil separator assembly ( i n ner and outer views)
1. ccos 7. Oil return from cyl inder head 1 3. CCOS oil return
2. CCOS vent outlet 8. Oil supply t o cyl inder head 1 4. O i l module pressu re rel ief port
3. CCOSS sensor 9. Cran kcase gas inlet 1 5. O i l out to crankcase
4. Fi lter cover 1 0. Oil cooler i n let 1 6. O i l cooler outlet to crankcase
5. Oil filter assem bly 11. Oil su pply from oil pump 1 7. EOP sensor
6. EOT sensor 1 2. Reg ulator

The o i l mod u le contains a can ister style fi lter, oil d i rects cran kcase emissions to the CCOS . The o i l
cooler, EOP and EOT senso rs, a pressu re rel ief that separates from t h e cran kcase emissions, before
valve, an oil fi lter bypass valve , and an oil retu rn it reaches the CCOS, is d rained back i nto the o i l pan
shutoff valve. The o i l mod ule also collects, and then th rough the oil retu rn port.

43
40 1 ENG I N E SYSTEMS

Remote Mou nted Centrifugal O i l Fi lter (Optional)

The Remote Mou nted Centrifugal O i l Fi lter is used to
remove particulates from engine o i l , red ucing wear
and extending engine oil change intervals. D u ring
operation , d i rty o i l enters the oil su pply port to a
reg u l ator valve. When engine o i l pressu re exceeds
2 4 8 kPa (36 psi ) , the reg u lator valve opens, and o i l
enters t h e centrifugal element th rough t h e center
hol low spindle. I nside the element, centrifugal force
separates contaminants from o i l . Contaminants
accu mulate on the serviceable rotor su rface as a
solid cake. Clean o i l exits th rough opposing twi n
nozzles that power t h e centrifuge and returns t o the
cran kcase from the oil level control base. Oil level is
managed by the oil float. When the oil float raises,
compressed air enters the system to force oil back
to the cran kcase. When the oil float d rops, the a i r
su pply port is closed .

Fig u re 24 Remote Mou nted Centrifugal O i l Fi lter

1. Serviceable rotor
2. Oil supply port (reg ulator valve)
3. Oil return port
4. Oil float
5. Air supply port (reg ulator valve)

44
 1 ENG I N E SYSTEMS 41

E n g i ne Coo l i n g System
Cooling System Flow

Dual S u rge Tan k

Thermostats

- H i g h Temperatu re

+
EG R Cooler

EGR

+
Valve
ECT1 �

t
Low
Radiator

t
Temperatu re

+
E G R Cooler
t
ECT2 C FV

Cylinder Head

E n g i ne
C rankcase
Transmission
Cooler t Water

---
Pump

---
O i l Cooler

- -
Air Compressor

AFI
V00091

Fig u re 25 Cool ing system flow

45
42 1 ENGINE SYSTEMS
The water pump is installed on the water distribution
housing and draws coolant from the radiator through
the coolant inlet.
® through a bypass port inside the front cover into the
MaxxForce 11 and 13 engines have no coolant
passages between the crankcase and cylinder head
through the cylinder head gasket. This eliminates
the possibility of coolant leaks at the cylinder head
gasket. Coolant in and out of the crankcase and
cylinder head is directed through external passages.
Coolant flows through the crankcase and cylinder
head from front to rear. This coolant flows around the
cylinder liners and combustion chambers to absorb
heat from combustion.
Coolant exiting the crankcase and cylinder head at
the rear of the engine is directed through an external
coolant pipe to the high temperature stage of the
EGR cooler. Coolant passes between the EGR cooler
plates, travels parallel to the exhaust flow, travels
through a transfer passage in the left side of the
low temperature EGR cooler, into the EGR cooler
return manifold and into the thermostat housing. A
deaeration port on the top of the high temperature
EGR cooler directs coolant and trapped air to the
coolant deareation tank.
Coolant from the water pump also flows through the
low temperature EGR Cooler and then through the
LPCAC to regulate the charge air temperature. Flow
through the low temperature EGR cooler/charge air
cooler is controlled by the Coolant Mixer Valve (CMV)
and Coolant Flow Valve (CFV). Depending on the
coolant flow, CMV sends coolant through the low
temperature EGR Cooler, or bypass indirectly to the
LPCAC, after going through the LTR located in front
of the main coolant radiator. When the charge air
temperature is too low, CMV bypasses the LTR and
directs all the coolant through the CAC. When the
charge air temperature increases, CMV directs a
percentage of the coolant to the LTR before it enters
the CAC to cool the charge air. If the engine coolant
temperature is too high, CMV sends all of the coolant
flow through the LTR and through the LPCAC to help
cool the engine faster.
Both CMV and CFV are controlled by the ECM based
on signals from the Engine Coolant Temperature
(ECT) sensor, ECT2 sensor, and the Intake Manifold
Pressure (IMP) and Inlet Air Temperature (IAT)
sensors.
Coolant flow to the radiator is controlled by two
thermostats. When the thermostats are closed,
coolant flowing out of the EGR cooler is directed
water pump. When the thermostats are open the
bypass port is blocked, and coolant is directed from
the engine into the radiator.
Coolant passes through the radiator and is cooled
by air flowing through the radiator from ram air and
operation of the coolant fan. The coolant returns to
the engine first through the transmission cooler, then
through the engine coolant inlet elbow.
The air compressor is cooled with coolant supplied by
a hose from the left side of the crankcase. Coolant
passes through the air compressor cylinder head and
returns through a coolant return line to the engine
crankcase.
The oil module receives coolant from a passage in
the crankcase. Coolant passes between the oil cooler
plates and returns back to the water pump suction
passage.
Thermostat Operation
®
MaxxForce 11 and 13 engines are fitted with
two thermostats in a common housing to ensure
sufficient coolant flow in all operating conditions. The
thermostat housing is installed on top of the water
distribution housing.
The thermostat housing assembly has two outlets.
One directs coolant to the radiator when the engine is
at operating temperature. The second outlet directs
coolant to the water pump until the engine reaches
operating temperature. The thermostats begin to
open at 83 °c (181 °F) and are fully open at 91 °c
(196 °F).
When engine coolant is below 83 °c (181 °F), the
thermostats are closed, blocking coolant flow to the
radiator.
When coolant temperature reaches the opening
temperature of 83 °c (181 °F), the thermostats open
allowing some coolant to flow to the radiator. When
coolant temperature exceeds 91 °c (196 °F), the
lower seat blocks the bypass port directing full coolant
flow to the radiator.
46
 1 ENGINE SYSTEMS 43

Coolant Control Valve (CCV) assembly operation LPCAC. The CFV will close to reduce the coolant flow
through the LPCAC when the engine is operating at
The CCV is installed on the upper right side of the
high speeds.
water distribution housing and controls the coolant
flow to the CACs.
Coolant Mixer Valve ( C MV)
The CCV has two separate solenoid actuated valves
The CMV is installed on the upper side of CCV and
based on the charged air temperature and the two
controls the coolant flow through the LTR. When the
engine coolant temperature sensors: CMV, and CFV.
temperature of the charge air and coolant coming out
The CMV and the CFV are part of the CCV assembly
of the LPCAC is low, the CMV directs the coolant
and cannot be serviced separately. The CMV and
through a LTR bypass directly into the LPCAC.
CFV solenoids are controlled by two separate PWM
This helps the engine reach its normal operating
signals from the ECM. The PWM signal duty cycles
temperature faster. If the temperature of the charge
vary between 0% and 100% depending on the coolant
air and coolant coming out of the LPCAC is high, the
and charge air temperature. _
CMV directs the coolant flow through the LTR. This
prevents overheating of the LPCAC, which can result
Coolant Flow Valve (CFV)
in LPCAC failure.
The CFV is installed on the lower side of CCV and
controls the amount of coolant flow through the

47
44 1 E N G I N E SYSTEMS

E n g i n e Brake System
Engine Brake Control System Components

Fig u re 26 Engine brake control system components

1. U pper valve cover
2. I njector harness connector
3. Engine brake solenoid harness
connector lead (2)
4. Pass through harness
5. ECM E 1 connector
6. M aster piston roller assem bly (3 1 0 . Valve cover base
each housing) 1 1 . Engine brake solenoid (1 each
7. Engine brake master piston housing)
(within housing) 1 2 . Engine brake housing assembly
8. Exhaust valve bridge (2)
9. Engine brake slave piston

48
 1 ENGINE SYSTEMS 45

Engine Brake System Description 2. Activation of the engine brake is

® ® communicated by the ECM using the J1939
The MaxxForce Engine Brake by Jacobs brakini
data link. When activated, the energized
system 1s standard equipment on the ProStar
® solenoid valve permits engine lube oil to flow
and optional equipment on the TranStar and
® ® . under pressure through the control valve
WorkStar for the MaxxForce 11 and 13 engines.
to both the master piston and slave piston
The braking system is a hydro-mechanical device
circuits.
that mounts under the engine's valve cover. It
turns your power-producing diesel engine into a 3. Oil pressure causes the master piston roller
power-absorbing air compressor. assembly to move down, picking up the
motion of the cam (dedicated braking lobe)
Here's how: when the driver releases the accelerator
pushing the piston back into the housing
pedal, the forward momentum of the truck continues
creating high pressure oil.
to turn the drivetrain and engine. The pistons continue
to move up and down. Once activated, the engine 4. The high pressure oil flows back through the
brake opens the exhaust valves near the peak of the master piston, slave piston, and control valve
compression stroke, releasing the highly compressed circuits.
air through the exhaust systems. Little energy is
5. The check ball in the control valve seats,
returned to the piston, and as the cycle repeats, the
trapping oil in the circuit creating a high
energy of the truck's forward motion is now directed
pressure link between the slave piston and
toward motoring the diesel engine, thus reducing the
master piston.
forward motion causing the truck to slow down.
6. Once the high pressure link is created, the
master piston follows the cam profile causing
Engine Brake System Operation the slave piston to move down, momentarily
opening exhaust valve (single valve opening),
The engine brake system consists of two hydraulic
while the engine piston is near its top
braking housings, activated using two ECM actuated
dead center position, releasing compressed
brake solenoids, and an exhaust bridge (pin). The
cylinder air to the exhaust manifold.
engine brake depends on engine oil for operation;
minimum oil temperature for retarder activation is 40 7. Compressed air escapes to atmosphere
�C (104 °F). completing compression braking cycle.
The operation of the engine brake is fully automatic NOTE:
once it is turned on by an ON/OFF switch by the ® • ®
1. The MaxxForce Engme Brake by Jacobs
operator. When the clutch is fully engaged and you
will disengage during Anti-lock Brake
remove your foot completely from the throttle, the
System (ABS) braking.
engine brake is automatically activated.
2. Will interact with the vehicle cruise control
NOTE: The operator can select various retarding
for smooth operation during engine
levels by pressing a HIG H/M EDI UM/LOW switch
braking
depending on the retarding performance required.
®
3. Will interact with the Eaton UltraShift
Activation occurs through the following steps:
Transmission for smooth up-shifts under
1. Engine oil pressure filIs the housing passages fueling conditions
up to the solenoid.

49
46 1 ENGINE SYSTEMS
Electronic Control System
Electronic Control System Components
®
MaxxForce 11 and 13 engines are equipped with one
control module; the Engine Control Module (ECM).
Operation and Function
The ECM monitors and controls engine operation
to ensure maximum performance and adherence
to emissions standards. The ECM, performs the
following functions:
Provide reference voltage (VREF)
Condition input signals
Process and store control strategies
Control actuators
Reference Voltage (VREF)
The ECM supplies 5 volt VREF signals to various
input sensors in the electronic control system. By
comparing the 5 volt VREF signal sent to the sensors
with their respective returned signals, the ECM
determines pressures, positions, and other variables
important to engine and vehicle functions.
Signal Conditioner
Signal conditioning circuitry in the ECM converts
analog signals to digital signals, squares up sine
wave signals, and amplifies low intensity signals.
Microprocessor
The microprocessor, located inside the ECM,
processes stored operating instructions (control
strategies) and value tables (calibration parameters).
The microprocessor compares stored instructions
and values with conditioned input values to determine
the correct strategy for all engine operations.
Diagnostic strategies are also programmed into the
ECM. Some strategies monitor inputs continuously
and command the necessary outputs for correct
performance of the engine.
Diagnostic Trouble Codes
Diagnostic Trouble Codes (DTCs) are stored by
the ECM if inputs or conditions do not comply with
expected values. Diagnostic codes for the 2010
MY are communicated using the Suspect Parameter
Number (SPN) and Failure Mode Indicator (FMI)
identifiers, and are accessed using an electronic
service tool with ServiceMaxx ™ diagnostic software
or a generic scan tool as well.
Microprocessor Memory
The ECM microprocessor includes Read Only
Memory (ROM) and Random Access Memory (RAM).
ROM
ROM stores permanent information for calibration
tables and operating strategies. Permanently stored
information cannot be changed or lost when the
ignition switch is turned to OFF or when power to
the control modules is interrupted. ROM includes the
following:
Vehicle configuration, modes of operation, and
options
• Engine Family Rating Code (EFRC)
• Engine warning and protection modes
RAM
RAM stores temporary information for current engine
conditions. Temporary information in RAM is lost
when the ignition switch is turned to OFF or power
to control module is interrupted. RAM information
includes the following:
Engine temperature
Engine rpm
Accelerator pedal position
50
 1 ENGINE SYSTEMS
Actuator Control
The ECM controls the actuators by applying a low
level signal (low side driver) or a high level signal (high
side driver). When switched on, both drivers complete
a ground or power circuit to an actuator.
Actuators are controlled in one of the following ways,
depending upon type of actuator:
• pneumatic cylinder actuates the valve (in the exhaust
Duty cycle (percent time on/off)
• PWM
Switched on or off
Actuators
The ECM controls engine operation with the following:
• CCV
• EBPV
• EGRV
• ACV
• IAHR
Inlet Air Heater Fuel Solenoid (IAHFS) valve
ETV
FPCV
AFTFD
AFTFSV
• IAHFI relay
Coolant Control Valve (CCV)
The CMV and CFV are a combined solenoid assembly
that regulates coolant flow and temperature through
the LPCAC and the low temp EGR cooler. The CMV
and CFV are housed in the CCV assembly.
CFV controls the rate of coolant flow through the
CAC, and the CMV regulates the temperature of the
coolant, by directing the coolant either through the
LTR or through an internal bypass. Both valves are
controlled by the ECM.
The CCV is installed on the water distribution housing.
47
Exhaust Back Pressure Valve ( E B PV) Control
The EBPV is controlled using the ACV assembly. The
ACV assembly contains the EBPV control valve, and
the TC1TOP sensor. Both are used by the ECM to
control EBPV operation.
The EBPV regulates the amount of air pressure
applied to the EBPV pneumatic actuator. The
system) in response to commands by the ECM.
The EBPV actuator is mounted on a bracket, on the
right side of the engine, after the turbocharger exhaust
connection.
Exhaust Gas Recirculation (EGR) Valve
The EGRV is mounted on the rear of the EGR cooler,
on top of the engine. The EGRV assembly receives
the desired valve position from the ECM. The EGRV
regulates the flow of exhaust gases through the EGR
system.
Air Control Valve (ACV)
The ACV contains solenoids used for the control of
the HP turbocharger wastegate, LP turbocharger
wastegate, and EBPV. It also contains the TC1TOP
sensor.
ACV solenoids are controlled through pulse width
modulated signals sent by the ECM.
The ACV is located on the right side of the engine,
mounted near the center of the EGR cooler.
Inlet Air Heater Relay (IAHR)
The inlet air heater system aids cold engine starting by
warming the incoming air supply prior to, and during,
cranking, and also up to four minutes for cold engine
warm-up.
The ECM is programmed to energize the IAHFI
heater element through the IAHR while monitoring
certain programmed conditions for engine coolant
temperature, inlet air temperature, engine oil
temperature, and atmospheric pressure.
51
48 1 E N G I N E SYSTEMS

The IAH R del ivers battery voltage to the heater Aftertreatment Fuel Doser (AFTFD)
element for a set time, depending on engine coolant
The AFTF O is used to provide HP fuel flow to the
temperatu re and altitude. The g ro u n d ci rcu it is
aftertreatment fuel i njector. The AFTF O is control led
suppl ied d i rectly from the battery g round at all times.
th rough an PWM signal sent by the E C M . The AFTF O
The relay is control led by switch ing on a voltage
is housed i n the OSI u n it, wh ich is located to the rear
sou rce from the E C M , and is instal led to the rear of
of the fuel fi lter assembly.
the E C M .

Aftertreatment Fuel Sh utoff Valve (AFTFSV)

I nlet Air Heater F u e l Solenoid (IAHFS) Valve
The AFTFSV is used to prevent fuel flow to the
The IAH FS valve controls fuel flow to the IAH F I d u ring
aftertreatment fuel i njector (AFI ) , and prevents all
i n let air heater operation .
u n control led fuel del ivery for the aftertreatment
When i n let air heater is req u i red , the ECM provides system d u ring a AFTFO valve malfunction. The
voltage to open the IAH FS valve d u ring cranking. AFTFSV is control led th rough an on-off signal sent
by the ECM. The AFTFSV is housed in the OSI u n it,
The IAH FS valve is mou nted on the intake th rottle
wh ich is located to the rear of the fuel filter assembly.
d u ct, on the top left side of the engine.

Engine and Vehicle Sensors

Engine Th rottle Valve (ETV)
Therm istor Sensors
The ETV controls the flow of fresh air (boosted and
cooled) into the engi ne's air intake path th rough
the CAC to help heat the exhaust aftertreatment Temperature
d u ring regeneratio n , and to assist when heavy sensor
5 volts
EGR is req uested . The electronic portion of the

Q
ECM
ETV contains a microprocessor that mon itors valve
positi o n , electronic chamber temperatu re, controls
the electric motor, and reports d iag nostic fau lts to the
E C M . The ETV changes position i n response to ECM 0 volts
signals.
The ETV is integ rated into the intake th rottle d u ct, on
the top left side of the engine.

Grou nd J31 032

Fuel Press u re Control Valve (F PCV)
The FPCV is a variable position actuator that controls
the flow of fuel to the suction side of the high pressu re
pump.
T h e FPCV changes valve position th rough pu lse width
mod ulated signals from the ECM .
The FPCV is mou nted on the u pper side of the
h i g h pressu re pump. The FPCV and fuel p u m p are
serviced as an assembly.
Fig u re 27 Thermistor
A thermistor sensor changes electrical resistance with
changes in temperatu re. As temperatu re changes
at the thermistor, voltage at the ECM wi l l change
accord i n g ly. Thermistors work with the control mod ule
to prod uce a voltage signal d i rectly proportional to
temperatu re values.
A thermistor sensor has two electrical con nectors,
signal retu rn and g rou n d . The output of a thermistor
sensor is a non-li near analog signal.
Thermistor type sensors include the fol lowin g :
Aftertreatment temperatu re sensors

52
 1 ENGINE SYSTEMS 49

Engine Coolant Temp sensors gauge, coolant temperature compensation, charge

air temperature control, EGR system control, optional
EOT sensor
Engine Warning Protection System (EWPS), and the
TC2CIS wait to start lamp. The ECM uses ECT1 sensor input
as a backup, if EOT sensor values are out of range.
CACOT sensor
The ECT1 sensor is installed in the underside of
IMT sensor
the EGR coolant crossover manifold, at the back of
EGRT the engine. The ECT2 sensor is installed in the low
• temperature stage of the EGR cooler, on the right
Ambient Air Temperature (AAT) sensor
side of the engine.
Aftertreatment Temperature Sensors
Engine Oil Temperature (EOT) Sensor
Four sensors used in the Aftertreatment System
The EOT sensor is a thermistor sensor that detects
include the following:
engine oil temperature. The EOT sensor is installed
• Aftertreatment Fuel Inlet Sensor (AFTFIS) in the side oil module flange, behind the oil filter cover,
on the right side of the engine.
DOCIT
DOCOT Turbocharger 2 Compressor Inlet Sensor
(TC2CIS)
DPFOT
The TC2CIS sensor includes a thermistor sensor that
The AFTFIS provides a feedback signal to the ECM
monitors the temperature of charge air entering the
indicating temperature of the fuel supplied to the
HP turbocharger. This sensor also monitors boost
Downstream Injection (OSI) unit. The AFTFIS is
pressure for the LP turbocharger.
a dual function sensor and also provides inlet fuel
pressure values for the OSI unit. The AFTFIS sensor The TC2CIS sensor is monitored by the ECM, and is
is installed in the OSI unit. used for calculating fuel delivery and controlling LP
wastegate operation.
The DOCIT sensor provides a feedback signal to the
ECM indicating DOC inlet temperature. The DOCIT The TC2CIS is installed in the piping between the LP
sensor is the first temperature sensor installed past compressor outlet and the HP compressor inlet.
the turbocharger and just before the main DOC.
Charge Air Cooler Outlet Temp (CACOT) Sensor
The DOCOT sensor provides a feedback signal to
the ECM indicating DOC outlet temperature. The The CACOT sensor is a thermistor sensor that
DOCOT sensor is the second temperature sensor monitors the temperature of charge air entering the
installed past the turbocharger and just after the main intake air duct.
DOC.
The CACOT signal is monitored by the ECM.
The DPFOT sensor provides a feedback signal to the
The CACOT sensor is installed on the intake air duct,
ECM indicating DPF outlet temperature. The DPFOT
before the ETV.
sensor is the third temperature sensor installed past
the turbocharger and just after the DPF.
Intake Manifold Temperature (IMT) Sensor
During a catalyst regeneration, the ECM monitors all
The I MT sensor is a thermistor sensor that monitors
three temperature sensors.
temperature.
Engine Coolant Temperature ( ECT) Sensors The I MT sensor is installed in the intake side of the
cylinder head, on the left side of the engine.
The ECT1 and ECT2 sensors are thermistor-type
sensors that detect engine coolant temperature.
The ECT1 signal is monitored by the ECM for
operation of the instrument panel temperature

53
50 1 E N G I N E SYSTEMS

Exhaust Gas Reci rcu lation Temperatu re (EGRT) FOP sensor

Sensor
EOP sensor
The EGRT sensor is a thermistor sensor that detects
FRP sensor
the exhaust gas temperatu re enteri ng the EGR cooler.
I M P sensor
The EGRT signal is mon itored by the ECM.
AFTFIS
The EGRT sensor is instal led i n the front of the low
temp EGR cooler on the left side. AFTFP2 sensor
TC 1 TO P sensor
Ambient Air Temperatu re (AAT) Sensor
The AAT sensor is a thermistor sensor that detects the DPF Differential Press u re (DPFDP) Sensor
temperatu re of ambient.
The O P F O P sensor provides a feed back signal to the
The AAT signal is mon itored by the ECM. ECM ind icati ng the pressu re difference between the
i n let and outlet of the particulate fi lter.
The AAT sensor is instal led i n various places on the
veh icle. The O P F O P sensor is a differential pressu re sensor
with two tap-offs i n stal led at the O P F. A tap-off is
located before and after the O P F.
Variable Capacitance Sensors
Fuel Del ivery Press ure (FDP) Sensor
Pressu re The FOP sensor is a variable capacitance sensor that
sensor meas u res fuel supply pressu re.
5V
ECM The FOP sensor provides feed back to the ECM for the
LP fuel system.
The FOP sensor is instal led in the front of the fuel fi lter
Ground
ov assembly on the left side of the engine.

Engine O i l Pressu re (EOP) Sensor

The EOP sensor is a variable capacitance sensor that
K351 57 detects engine oil pressu re.
Fig u re 28 Variable capacitance sensor example The EOP signal is mon itored by the ECM for operation
of the i n stru ment panel pressu re gauge and optional
EWPS.
Variable capacitance sensors measure pressu re. The
The EOP sensor is instal led i n the oil mod u le, on the
pressu re measured is appl ied to a ceramic material.
right side of the e n g i n e .
The pressu re forces the ceramic material closer to a
th i n metal d isk. Th is action changes the capacitance
Fuel Rai l Pressu re ( F R P ) Sensor
of the sensor.
The FRP sensor is a variable capacitance sensor that
The sensor is con nected to the control mod ule th rough
mon itors fuel pressu re in the HP fuel rai l .
the VREF, sig nal, and signal g round wires.
T h e FRP sensor measures fuel pressu re just before
The sensor receives the VREF and retu rns an analog
i njection .
signal voltage to the ECM. The ECM compares the
voltage with pre-prog rammed values to determ ine The FRP sensor is mou nted i n the front of the fuel rai l
pressu re. on t h e left s i d e o f t h e engine.
Variable capacitance sensors i nclude the followi n g :
O P F O P sensor

54
 1 E N G I N E SYSTEMS 51

I ntake Man ifold Press u re (IMP) Sensor
The I M P sensor is a variable capacitance sensor that
monitors the pressu re of charge air enteri ng the intake
a i r duct.
The I M P signal is mon itored by the ECM for control of
the EGR system and tu rbocharger wastegates.
The I M P sensor is instal led on the intake air d u ct, after
the ETV.
Aftertreatment Fuel In let Sensor (AFTFIS)
The sensor measures back pressu re in the exhaust
system. A tap for the TC 1 TO P is located i n the
exhaust, between the LP tu rbocharger and E B PV.
The TC 1 TO P sensor is located i n the Air Control
Valve , on the right side of the engine.
Mag netic Pickup Sensors
CMP signal Camshaft �
with peg �

The AFTFI S is a dual fu nction sensor and i ncludes a

thermistor sensor that mon itors i n let fuel Temperatu re
for the OSI u n it.
CKP Sensor
The AFTF I S i ncludes a variable capacitance sensor
that measures fuel pressu re supplied by the OSI
u n it, and is used to mon itor fuel del ivery to the
aftertreatment system .
T h e AFTFIS is located in t h e OSI u n it, to t h e rear of CKP signal
the fuel fi lter assembly.
c:::::::J
c:::::::J ECM
c:::::::J
Aftertreatment Fuel Press u re 2 (AFTFP2) sensor
The AFTFP2 sensor is a variable capacitance sensor CKP Sensor N35 1 06
that monitors fuel pressu re after the Aftertreatment
Shutoff Valve (AFTFSV) . F i g u re 29 Mag netic picku p sensor example
The AFTFP2 sensor meas u res fuel pressu re suppl ied
by the AFTFSV to the AFTFO valve, and is used to
mon itor fuel del ivery to the aftertreatment system. A mag netic picku p sensor contains a permanent
mag net core that is su rrou nded by a coi l of wire .
The AFTFP2 sensor is located in the OSI u n it, to the T h e sensor generates a voltage s i g n a l th rough the
rear of the fuel filter assembly. collapse of a mag netic field created by a moving metal
trigger. The movement of the trigger then creates
Tu rbocharger 1 Tu rbine Outlet Pressu re (TC 1 TOP) Alternate Cu rrent (AC) voltage in the sensor coi l .
The TC 1 TO P sensor is a variable capacitance sensor Mag netic picku p sensors used include the fol lowin g :
that mon itors exhaust back pressu re.
C K P sensor
CMP sensor
vss
CCOSS sensor

55
52 1 E N G I N E SYSTEMS

Crankshaft Position (CKP) Sensor Potentiometer Sensors

The CKP sensor is a mag netic picku p sensor that
ind icates crankshaft speed and position . ECM

The CKP sensor sends a pu lsed signal to the Engine

Control Mod ule (ECM) as the cra n kshaft turns. The
CKP sensor reacts to holes d ri l led into the flywheel
adjacent to the ring gear. For crankshaft position
reference , teeth 59 and 60 are miss i n g . By compari ng
the CKP signal with the CMP sig nal, the ECM Microprocessor
calculates engine rpm and ti ming req u i rements.
The CKP sensor is instal led in the top left of the
flywheel housi n g . N�����+--� VREF 2

Camshaft Position ( C M P ) Sensor

The CMP sensor is a mag netic picku p sensor that
ind icates camshaft speed and positi o n .
T h e C M P sensor sends a pu lsed signal t o t h e E C M
a s a toothed wheel on t h e camshaft rotates past the 5V
CMP sensor. The ECM calcu lates camshaft speed
and position from CMP signal freq uency.
The C M P sensor is installed in the left rear of the
cyl i nder head . APP ov
T35039

Veh icle Speed Sensor (VSS)

The VSS provides the ECM with transmission tai l shaft
speed by sensi ng the rotation of a 1 6-tooth gear on
the rear of the transmissi o n . The detected sine wave
signal (AC) received by the ECM, is used with tire size
and axle ratio to calculate veh icle speed . The VSS is
located on the left side of the transm ission housing for
automatic transmissions, or at rear of the transmission
housing for manual transmissions.
Cran kcase Oil Separator Speed (CCOSS) sensor
The CCOSS sensor sends the ECM information
about the speed of the cran kcase oil separator
i nternal components. The detected sine wave
signal (AC) received by the ECM is used to mon itor
proper operation of the cyclonic oil separator, located
inside the breather assembly on the engine oil fi lter
assembly.
Fig u re 30 Potentiometer example
A potentiometer is a variable voltage d ivider that
senses the position of a mechan ical component.
A reference voltage is appl ied to one end of the
potentiometer. Mechanical rotary or l i near motion
moves the wiper along the resistance material,
changing voltage at each point along the resistive
material. Voltage is proportional to the amount of
mechan ical movement.
The engine has two potentiometers, both contai ned i n
the Accelerator Pedal Position (AP P) Sensor.
Accelerator Pedal Pos ition (APP)
The APP provides the ECM with a dual feed back
signal (dual l i near analog voltages) that indicate the
operator's demand for power. The APP contains two
potentiometers, and provides two i n d ividual signals
(AP P 1 and APP2) to the ECM. The APP is instal led
in the cab on the accelerator pedal assembly.

56
 1 ENGINE SYSTE MS
Switches
VIGN
...------1(Microprocessor)
DDS
ECM
Ground Ground
T35006
Figure 31 Switch exam ple
Switch sensors i ndi cate position, level, or status.
They operate open or closed, regulati ng the flow of
current. A switch sensor can be a voltage i n put switch
or a grounding switch. A voltage i n put switch suppl ies
the control module with a voltage when it is closed.
A grounding switch grounds the circuit when closed,
causi ng a zero voltage signal. Grounding switches
are usually i nstalled i n series with a current limiting
resistor.
Switches i ncl ude the foll owi ng:
Driveline Disengagement Switch (DDS)
Engine Coolant Level (ECL)
Oil Level Sensor (OLS)
Driveline Disengagement Switch (DDS)
The DDS determi nes if a vehicle is in gear. For
manual transmissions, the clutch switch serves as
the DDS. For automatic transmissions, the neutral
indicator switch functions as the DDS. The DDS signal
is sent to the Body Controller ( BC) and transmitted on
the J 1 939 datalink to the engine ECM.
53
Engine Coolant Level (ECL) Switch
The ECL switch is part of the EWPS. The ECL switch
is located on the deaeration tank. When the magnetic
switch is open, the tank is considered ful l of coolant.
If engine coolant is low, the switch closes and the red
ENGI NE lamp on the i nstrument panel is i l l u mi nated.
Oil Level Sensor (OLS)
The OLS is part of the EWPS. The OLS is located on
the engine oil pan . The OLS measures the volume of
oil i n the oil pan and broadcast the percentage vol ume
over J 1 939 CAN.
If the level of engine l u be oil is low, the red ENGI NE
lamp on the i nstrument panel is illumi nated.
Additional Sensors
Oxygen Sensor (02S)
The 02 S monitors oxygen levels i n the exhaust.
The 02 S is used to control the EGR flow to a specified
ai r-to-fuel rati o by monitori ng the level of u n used
oxygen in the exhaust stream .
The 02 S compares oxygen levels i n the exhaust
stream with oxygen levels in the outside air. The
sensor generates an analog voltage and is monitored
by the ECM. The level of voltage generated by the
02S di rectly corresponds to the oxygen levels in the
exhaust stream.
The 02 S is i nstalled i n the turbocharger exhaust pi pe,
di rectly after the EBPV.
Hum idity Sensor (HS)
The HS measures the moisture content of filtered air
entering the i ntake system .
Usi ng the H S , the E C M wil l adjust i n order to prevent
condensation of airborne water particles (moisture).
The HS also houses the IAT sensor, which is used by
the ECM for calculati ng fuel delivery.
57
54 1 ENGINE SYSTEMS

58
 2 ENGINE AND VEHICLE FEATURES 55

Table of Contents

Standard Electronic Control Features...............................................................................57

Aftertreatment (AFT) System................................................................................57
Cold Ambient Protection (CAP).............................................................................57
Inlet Air Heater..................................................................................................57
Coolant Temperature Compensation (CTC)...............................................................57
Data Plate........................................................................................................57
Electronic Speedometer and Tachometer.................................................................58
Engine Crank Inhibit (ECI)....................................................................................58
Engine Electronic Governor Control.......................................................................58
Engine Fan Control (EFC)....................................................................................58
Event Logging System .......................................................................................58
Fast Idle Advance..............................................................................................58
J1939 Datalink .................................................................................................59
Password Protection..........................................................................................59
Service Diagnostics ...........................................................................................59
Trip Reporting..................................................................................................59
Vehicle Setup...................................................................................................59

Optional Electronic Control Features ................................................................................60

Cruise Control. .................................................................................................60
Driver Reward..................................................................................................60
®
MaxxForce Engine Brake...................................................................................60
Engine Warning Protection System ( E W PS)..............................................................60
Gear Down Protection (GDP)................................................................................60
Idle Shutdown Timer ( 1ST)....................................................................................61
Progressive Shift...............................................................................................61
Power Take Off (PTO) - In Cab...............................................................................61
Power Take Off (PTO) - Remote.............................................................................61
Service Interval.................................................................................................62
Traction Control................................................................................................62
Up-Shift Indicator..............................................................................................62
Road Speed Limiter...........................................................................................62

59
56 2 ENGINE AND VEHICLE FEATURES

60
 2 ENGINE AND VEHICLE FEATURES
Standard Electronic Control
Features
NOTE: For the latest complete feature operation,
®
and parameter information, use the MaxxForce
11 and 13 Engine Feature Documentation
found under the Body Builder Website Link
®
within Navistar Service Portal. This includes
parameter details of description, possible values,
whether or not it is customer programmable, and
recommended settings.
Aftertreatment (AFT) System
The AFT system, part of the larger exhaust system,
processes engine exhaust so that it meets tailpipe
emission requirements. The AFT system traps
particulate matter (soot) and prevents it from leaving
the tailpipe. The trapped particulate matter is
then rendered to ash by heating the exhaust and
injecting fuel through a process called regeneration.
Regeneration reduces the frequency of AFT system
maintenance without adversely affecting emissions.
For additional information, see Aftertreatment (AFT)
System in the "Engine Systems" section of this
manual.
Cold Ambient Protection (CAP)
CAP protects the engine from damage caused by
prolonged idle at no load condition during cold
weather.
CAP maintains engine coolant temperature by
increasing engine rpm. CAP also improves cab
warm-up.
CAP is standard on trucks without an Idle Shutdown
Timer (1ST).
Inlet Air Heater
The inlet air heater feature improves engine start-up
in cold weather. The Engine Control Module (ECM)
controls the Inlet Air Heater Relay (IAHR) and
monitors the Engine Oil Temperature (EOT), Inlet Air
57
Temperature (IAT) and Engine Coolant Temperature
2 (ECT2) sensors. When the key is turned to the
ON position, the ECM monitors the ECT2 and IAT
sensors. If either sensor is below 11 °c (52 °F), the
ECM enables the IAHR. The IAHR energizes the
Inlet Air Heater Fuel Igniter (IAHFI). When the IAHFI
reaches the proper operating temperature, the wait to
start lamp flashes. As the engine is cranked, the ECM
energizes the Inlet Air Heater Fuel Solenoid (IAHFS)
valve, introducing fuel into the IAHFI, which ignites
and warms the air being drawn into the engine. Do
not accelerate the engine until the wait to start lamp
goes out.
For additional information, see Inlet Air Heater System
in the "Engine Systems" section of this manual.
Coolant Temperature Compensation (CTC)
NOTE: CTC is disabled in emergency vehicles and
school buses that require 100 percent power on
demand.
CTC reduces fuel delivery if the engine coolant
temperature is above cooling system specifications.
Before standard engine warning or optional
warning/protection systems engage, the ECM
begins reducing fuel delivery when engine coolant
temperature reaches approximately 107 °C (225 °F).
A rapid fuel reduction of 15 percent is achieved when
engine coolant temperature reaches approximately
11 0 °C (230 °F).
Data Plate
The ECM stores data to help identify the vehicle and
engine components. The data plate feature is used
to display text data descriptions in order to assist with
reports and make data tracking easier.
The parameters associated with this feature only
need to be modified when a related component is
replaced, and can only be updated through your
authorized dealer.
61
58 2 ENGINE AND VEHICLE FEATURES

Electronic Speedometer and Tachometer The primary purpose of the engine fan is to allow the
engine to run at its regulated operating temperature
The engine control system calibrates vehicle speed
increasing engine performance. It is also used to
up to 157,157 pulses per mile. The calculated vehicle
assist in cooling the refrigerant in the A/C condenser.
speed is a function of transmission tail shaft speed,
Factory set parameters within the ECM provide
number of teeth on the tail shaft, rear axle ratio, and
engine fan control based on the fan type installed in
tire revolutions per mile. Use the Electronic Service
the vehicle. Choosing whether the fan is engaged
Tool (EST) with ServiceMaxx ™ software to program
during engine speed control, commonly referred
new speed calibrations into the ECM.
to as PTO, operation is a customer programmable
The tachometer signal is generated by the ECM by parameter. For additional information, see EFC
computing the signals from the Camshaft Position (Engine Fan Control) in the "Electronic Control
(CMP) sensor and the Crankshaft Position (CKP) Systems Diagnostics" section of this manual.
sensor. The calculated engine speed is then sent to
the instrument cluster through the J1939 CAN Data
Link. Event Logging System
The event logging system records vehicle operation
above the maximum speed setting (overspeed) and
Engine Crank Inhibit (ECI)
engine operation above maximum rpm (overspeed),
The ECI will not allow the starting motor to engage coolant temperature out of operational range, low
when the engine is running and the drivetrain is coolant level, or low oil pressure. The readings for
engaged. the odometer and hourmeter are stored in the ECM
memory at the time of an event and can be retrieved
The ECI will not allow the starting motor to engage
using the EST.
with the engine running if the key is turned to START
while the clutch pedal is pressed.
Fast Idle Advance
Engine Electronic Governor Control The ECM monitors the Engine Coolant Temperature
(ECT) sensor. If the engine coolant temperature is
The governor controls engine rpm within a safe and
below 10 °c (50 °F), the ECM activates the fast idle
stable operating range.
advance.
The low idle governor prevents engine rpm from
Fast idle advance increases engine idle speed to 700
dropping below a stable speed to prevent stalling
rpm for a period of up to 100 seconds to assist in faster
when various loads are demanded on the engine.
warm-up to operating temperature. This occurs by the
The high idle governor prevents engine rpm from ECM monitoring the engine coolant temperature and
going above a safe speed that would cause engine adjusting the fuel injector operation accordingly.
damage.
Low idle speed is resumed when engine coolant
temperature reaches temperatures above 10 °c (50
°F), or the 100 second period times out.
Engine Fan Control ( E FC)
The engine fan control feature is designed to allow
configuration of the engine for various fan control
features on a particular vehicle application.

62
 2 ENGINE AND VEHICLE FEATURES 59

J1939 Datalink password protection feature provides protection to

prevent unauthorized users from changing parameter
The vehicle is equipped with an SAE standard J1939
values in the ECM. With the password set, the service
CAN datalink:
tool will prompt for the current password and will
• The J1939 datalink is used for diagnostics and not allow any parameter to be changed until that
calibration communications for the Engine Control password is entered. The password parameter is
Module (ECM). customer programmable.
The J1939 datalink is used for communications
between the ECM, Electronic Gauge Cluster
Service Diagnostics
(EGC), and Body Controller (BC).
The EST provides diagnostic information using the
The J1939 datalink is accessed through the cab
J1939 datalink.
diagnostic connector pins C and D. The datalink
provides communication between the ECM and the Faults from sensors, actuators, electronic
Electronic Service Tool (EST). components, and engine systems are detected
by the ECM. The faults are accessed by the EST
The J1939 data link supports:
through the Diagnostic Connector, and are displayed
• Transmission of engine parameter data as Diagnostic Trouble Codes (DTCs) on the EST
• Effective engine diagnostics require and rely on
Transmission and clearing of Diagnostic Trouble
DTCs.
Codes (DTCs)
Diagnostics and troubleshooting
Trip Reporting
Programming engine and vehicle features
The trip reporting feature is designed to monitor,
Programming calibrations and strategies
collect, and store engine related operational
• Inter- module communications between the: information. This information can be downloaded and
• organized into useful reports using a service tool. Trip
Engine Control Module (ECM)
reporting operational data is recorded in two ways:
• Body Controller (BC) non-resettable cumulative data, which consists of
• running totals, and resettable trip data, which consists
Electronic Gauge Cluster (EGC)
of data collected since the last trip reset.
• Automatic Transmission Controller
Electronic Service Tool (EST)
Vehicle Setup
For additional information, see J1939 Datalink in the
The vehicle setup feature consists of various
"Electronic Control Systems Diagnostics" section in
parameters within the ECM, which are based
this manual.
on the vehicle configuration. Most parameters
are pre-programmed by the original equipment
manufacturer (OEM) and will not require any
Password Protection
adjustment for the life of the vehicle.
The ECM allows the vehicle to be configured to help
the owner optimize fuel economy and reliability. The

63
60 2 ENGINE AND VEHICLE FEATURES
Optional Electronic Control
Features
NOTE: For the latest complete feature operation,
and parameter information, use the MaxxForce
® Programmable parameters within the ECM provide
11 and 13 Engine Feature Documentation
found under the Body Builder Website Link
®
within Navistar Service Portal. This includes
parameter details of description, possible values,
whether or not it is customer programmable, and
recommended settings.
Cruise Control
Cruise Control is a well-known feature that offers
driving comfort by providing a method for an operator
to set and maintain a constant vehicle speed without
using the accelerator pedal. It is especially useful
when the operator is required to drive on highways at
a constant speed for many miles.
This cruise control feature is unique due to a
parameter, which allows the cruise control set speed
to be maintained in the ECM memory. Additional
programming flexibility is included to allow a trade-off
to be made between performance and fuel economy.
Driver Reward
The driver reward feature is designed to give the
operator incentives for driving more efficiently. The
feature accomplishes this by measuring the driver's
habits based on fuel economy, time at idle, or both.
The rewards include higher maximum vehicle speed
and higher cruise control speed limit. Lower maximum
vehicle speed or cruise control speed limits may result
as a penalty for failing to meet the standards.
Customer programmable parameters within the ECM
provide driver reward related options that can be
adjusted to suit the customer's needs.
®
MaxxForce Engine Brake
The engine brake feature is a hydro-mechanical
device designed to help decelerate the vehicle by
providing additional engine load. It mounts under the
engine valve cover and turns your power-producing
diesel engine into a power-absorbing air compressor.
This will reduce brake wear in vehicles which
require frequent braking. This feature assumes the
vehicle is equipped with a factory installed engine
brake system; otherwise there may be engine
components, additional switches, harnesses, and
software modifications which may also be required.
engine brake related options that can be adjusted
to suit the customer's needs. Choosing whether the
engine brake is activated by pressing the service
brake pedal or by releasing the accelerator pedal
is one example. For a detailed feature description,
see Engine Brake System in the "Engine Systems"
section of this manual.
Engine Warning Protection System (EWPS)
NOTE: Emergency vehicles are not equipped with
EWPS.
The Engine Warning and Protection System (EWPS)
feature is designed to protect the engine from damage
by monitoring critical engine data such as the engine
speed, temperature, oil pressure, and coolant level.
The EWPS feature will alert the operator by using a
combination of visual and audible warnings if critical
engine parameters are exceeded. Depending on the
severity of the problem, there may be a reduction in
power associated with the visual warnings. EWPS
also visually alerts the operator with an amber warning
lamp if the vehicle speed exceeds a threshold. The
vehicle overspeed incidents are logged and can be
downloaded into a report. Refer to the "Trip Reporting"
feature for more information.
Customer programmable parameters within the ECM
provide EWPS related options that can be adjusted to
suit the customer's needs. For example the customer
may choose that the EWPS feature activate a flashing
red lamp and audible warning 30 seconds before
engine shut down, to provide an additional level of
engine protection.
Gear Down Protection (GDP)
The Gear Down Protection (GDP) feature is designed
to encourage the driver to operate in the engine's
most efficient range for fuel economy. This is done
by limiting the vehicle speed until the driver shifts into
a higher gear. This encourages the driver to upshift
to the next highest gear, and helps to maintain the
engine's most efficient speed range for fuel economy.
There are several customer programmable
parameters for this feature.
64
 2 ENGINE AND VEHICLE FEATURES
Idle Shutdown Timer ( 1ST)
The idle shutdown timer is used to limit the amount
of engine idle time by automatically shutting down
the engine after a pre-programmed time has
expired. Programmable parameters within the ECM
determine the time and conditions required before the
engine shuts down. Some customer programmable
parameters provide idle shutdown related options that
can be adjusted to suit the customer's needs.
Thirty seconds before engine shutdown occurs, there
will be an amber lamp illuminated in the instrument
panel (if equipped) and an audible warning will sound.
This will continue until the engine shuts down or the
idle shutdown timer is reset. This feature shuts down
the engine, but the vehicle electrical system and
accessories will remain active until the key switch is
turned off.
Progressive Shift
The progressive shift feature is designed to limit the
engine speed to encourage the driver to up-shift early,
which in turn improves fuel economy. This feature
provides engine speed limit parameters optimized for
each transmission gear, to encourage the use of the
higher gears during cruise control and low engine load
operations.
Customer programmable parameters within the ECM
provide progressive shift related options that can be
adjusted to suit the customer's needs.
Power Take Off (PTO) - In Cab
The engine speed control feature, commonly referred
to as "PTO", provides a method for an operator to
set and maintain a constant engine speed without
using the accelerator pedal. It is commonly used for
powering auxiliary devices.
61
The in-cab engine speed control feature provides
three conditions under which the operator may select
PTO speeds:
• Stationary Preset - Permits the operator to select
up to six preset speeds while the vehicle is
stationary
• Stationary Variable Speed - Permits the operator
to select any engine speed within the PTO
boundaries
• Mobile Variable Speed - Permits the operator to
select a desired variable speed for moving or
stationary PTO operations
Customer programmable parameters within the ECM
provide in-cab engine speed control related options
that can be adjusted to suit the customer's needs.
Choosing whether the operator is allowed to increase
the engine speed using the accelerator pedal without
disengaging the PTO is one example.
Power Take Off (PTO) - Remote
When control over engine speed is required from
outside the vehicle's cab, remote mounted switches
must be used to turn on PTO engine speed control and
select the desired engine speed. This functionality is
referred to as Remote Engine Speed Control (RESC).
The engine speed can be ramped up and down with
RESC similar to the way the in cab PTO feature works;
however, the RESC feature includes two additional
switches (remote preset & remote variable), which
allow the operator to choose the mode of engine
speed control operation.
Customer programmable parameters within the ECM
provide RESC related options that can be adjusted
to suit the customer's needs. Choosing whether a
remote throttle pedal is used for PTO operation is one
example.
65
62 2 ENGINE AND VEHICLE FEATURES

Service Interval Up-Shift Indicator

The service interval feature is designed to provide The up-shift indicator feature provides an indication to
a visual reminder to the operator of service interval the operator that the transmission should be shifted
information such as, oil change interval has expired, into a higher gear. This helps to maintain the engine's
and that routine maintenance procedures should be most efficient speed range for fuel economy.
performed. The term "interval" in this case is used
The feature is commonly used on manual
to describe the distance, time, or fuel used between
transmissions and automated manuals in manual
the last maintenance performed on the vehicle and the
mode.
next maintenance, which is due.
Customer programmable parameters within the
ECM provide options that can be adjusted to suit Road Speed Limiter
the customer's needs. For example, the engine
Road Speed Limiter (RSL) is a feature with customer
hours, fuel used, and vehicle distance can be used
programmable parameters designed to regulate
individually or in combination to determine the service
the maximum vehicle speed as controlled by the
interval.
accelerator pedal.
It is essential that operators are trained to know the
The following additional features are available with
maintenance schedules and instructions regarding
RSL:
the operation and reset functionality of the service
interval for the feature to be effective. Refer to Adjustable RSL: Provides a customer
Integral Digital Display in Section 3 - Instruments, programmable secondary vehicle speed limit,
®
Indicators, and Switches of the MaxxForce 11 and lower than the limit provided by RSL, useful for
13 Engine Operation and Maintenance Manual for spreader applications and construction, etc.
more information. • RSL Override: Raises the vehicle speed limit
provided by the RSL feature to a customer
programmable speed when the driver identifies a
Traction Control
"passing situation."
Traction control is a system that identifies when a • RSL Anti-Tampering: Customer selectable
wheel is spinning faster than the other wheels during
option, which checks whether the vehicle speed
acceleration.
signal (VSS) input is valid or if it has been subject
When a traction control condition occurs, a datalink to tampering.
message is sent to the ECM to limit fuel for the
These options can be enabled by programmable
purpose of reducing engine torque.
parameters within the ECM.
Vehicles must have a transmission and an Antilock
Brake System (ABS) that supports traction control.

66
 3 DIAGNOSTIC SOFTWARE OPERATION 63

Table of Contents

Session Files.............................................................................................................65

Diagnostic Trouble Code ( DTC).......................................................................................65

Suspect Parameter Number (S P N) .........................................................................65
Failure Mode Indicator ( F MI).................................................................................65
Pending ..........................................................................................................65
Active............................................................................................................65
Previously Active..............................................................................................65
Freeze Frame Data .............................................................................................65

ECM Programmable Features ........................................................................................66

Connecting EST with ServiceMaxx ™ Software to Engine.......................................................66

Service Bay Tests .......................................................................................................66

Engine Off Tests ...............................................................................................66
Actuator Test..........................................................................................66
Continuous Monitor Test............................................................................66
D P F Servicing.........................................................................................66
Relative Compression Test.........................................................................67
Engine Running Tests .........................................................................................67
Air Management Test ................................................................................67
High Pressure Pump Test ...........................................................................68
Cylinder Cutout Test.................................................................................69
Multi- Cylinder Cutout Test ..........................................................................70
Hot Run Sensor Comparison Test .................................................................72
On board Filter Cleanliness Test ...................................................................74

Service Tool Procedures...............................................................................................75

Engine Off Procedures ........................................................................................75
Inlet Air Heater........................................................................................75
Oxygen Sensor Calibration.........................................................................75
Injector Quantity Adjustment ......................................................................75
Engine Running Procedures .................................................................................75
Engine Fan............................................................................................75

67
64 3 DIAGNOSTIC SOFTWARE OPERATION

68
 3 DIAGNOSTIC SOFTWARE OPERATION 65

Session Files Suspect Parameter Number (SPN)

A Session file is a window into the Engine Control The SPN identifies the individual component causing
Module (ECM) . Sessions can display veh icle and the OTC.
engine information, such as module calibration,
sensor signals, and actuator command signals.
Special engine and vehicle features can also be Failure Mode Indicator (FMI)
programmed using these sessions.
The FMI identifies the fault or condition effecting the
ServiceMaxx ™ software has many default sessions, ind ividual component.
that load automatically when ru nning any Service Bay
Test or Service Tool Procedure. Users are not limited
to any default session. Users are able to build their Pending
own session and save or load it at anytime . See the
Pending DTCs are possible emission faults that were
ServiceMaxx ™ Users Guide for details.
detected on the first drive cycle.
ServiceMaxx ™ software has a few added sessions
that do not load automatically, but can be selected
from the Sessions drop-down men u . These sessions Active
are available to help diagnose common systems and
Active DTCs are codes that are active now.
program special features:
Hard Start No Start
Previously Active
Performance
Previously Active DTCs are historical faults that may
Programming
be caused by intermittent signals, or an operating
condition, which is not cu rrently present.

Diagnostic Trou ble Code (DTC) Freeze Frame Data

NOTE: 2010 model year vehicles no longer utilize
DTC identification by number. DTCs are now
identified using the SPN and FMI identifiers only.
These two identifiers, known as the Suspect
Parameter Number (SPN) and the Failure Mode
Indicator (FMI), are displayed in the DTC Window.
Freeze Frame Data is a snapshot of all influencing
signals at the time the code was set. Th is can help
diagnose hard to duplicate failures. Freeze Frame
Data is cleared as soon as the DTC is cleared.

V00 1 34a

Figure 32 DTC window

1. Suspect Parameter Number (SPN)
2. Failure Mode Indicator (FMI)
3. Fault Code Type
4. Permanent Diagnostic Trouble Codes tab
5. Freeze Frame
6. Clear DTCs button
7. Refresh DTCNehicle Events button

69
66 3 DIAG NOSTIC SOFTWARE OPERATION

ECM P rog rammable Featu res
Many featu res can be prog ram med into the
E n g i n e Control Mod ule (ECM) to fit many d ifferent
applications. To make prog ramming changes using
ServiceMaxx ™ software, load the Prog ramming
sessio n . See t h e Body B u i lder website for fu rther
details.
Connecti ng EST with
ServiceMaxx ™ Software to
E n g i ne
To con nect the Electronic Service Tool ( EST) with
ServiceMaxx ™ software to the engine, the NAVCoM
or NAVLink I nterface Cable must be con nected
command any g iven d u ty cycle percent. A tech n ician
can use a Dig ital M u lti meter ( D M M ) to meas u re
changes i n voltage or duty cycle, or visually mon itor
actuator movement while actuator is commanded .
Conti n uous Mon itor Test
The Conti n uous Mon itor Test helps detect intermittent
circu it fau lts. D u ri n g this test, signals are conti n uously
mon itored and fau lts are i m med iately logged . Th is
test provides a g raphical view of a l l signals and allows
the tech n ician to easily detect intermittent spiking or
momentary loss of sig nal. Perform th is test while
manipu lati ng con nectors, wiri n g , and harnesses of the
suspected fau lty component.
File View Sessions Tests Tools Help

between the EST and the Diagnostic Connector. The i �I • • • Sessions: Default I Parameters I SiQna� I Stop Tests I
Diagnostic Con nector is located inside the veh icle
cab, above the clutch pedal.

Service Bay Tests

T021 1 7
Engine Off Tests
E n g i n e Off Tests can be selected i n the Tests Fig u re 34 Conti n uous Mon itor Test - Fau lty
d rop-down menu u nder E n g i n e Off Tests. Signal

NOTE : Ru n the Conti nuous Mon itor Test wh ile

mon itoring sensor voltages . Wiggle the wi ri ng
Actuator Test harness and con nections wh ile looki ng for signal
• Continuous Monitor Test spikes.
• Relative Compression Test
V39001 DPF Servicing
The DPF Servicing proced u re is used to u pdate the
Figure 33 ServiceMaxx ™ Test Menu - Engine
i n stallation date and serial n u mber (if replaced ) of
Off Tests
the Diesel Particulate Fi lter (DPF). Th is proced u re
should be ru n any time the D P F has been replaced or
removed for clean i n g . Fol low on-screen i n structions.
Actuator Test
The Actuator Test enables the tech n ician to cycle
any selected actuator h i g h and low and , if avai lable,

70
 3 DIAGNOSTIC SOFTWARE OPERATION 67

Relative Compression Test

./ Load Test Specific Session
The Relative Compression Test measures cylinder KOEO Tests
balance based on the compression stroke of each KOER Tests •

cylinder. KOER Aftertreatment Tests J Air Management Test

High Pressure Pump Test
Th is test helps determine cylinder integrity. The ECM Engine Fan Test
Cylinder Cutout Test
measures the time it takes for each piston to travel de
Multiple Cylinder Cutout Test
upward during the compression stroke. Timing is
based on information from the Camshaft Position 0000049006

(CMP) sensor and Crankshaft Position (CKP) sensor.

A cylinder with low compression allows the piston to Figure 35 ServiceMaxx ™ Tests Menu - Engine
travel faster during the compression stroke. Running Tests

Test results are displayed by either numerical text or

graphical d isplay. Assuming there are no mechanical
problems with the engine, the numbers or graphs
displayed should be approximately the same value or
height. A smaller number or lower level g raph would
indicate a problem with that particular cylinder.
NOTE: The Relative Compression Test must be
run before running the Cylinder Cutout Test.
Engine Running Tests
Engine Running Tests can be selected in the Tests
drop-down menu under Engine Running Tests.
Air Management Test
The Air Management Test validates operation and
performance of the Exhaust Gas Recirculation (EGR)
valve, Turbocharger 2 Wastegate Control (TC2WC)
valve, and Exhaust Backpressure Valve (EBPV) ,
based on I ntake Manifold Pressure (IMP) . This
test is unable to validate the performance of the
turbocharger, due to the amount of engine load
required .

71
68 3 DIAGNOSTIC SOFTWARE OPERATION

High Pressure Pump Test

The High Pressure Pump Test validates performance
of the Fuel Rail Pressure System. The test
accelerates the engine in three steps while
commanding a higher rail pressure on each step.
When the test is complete, the ECM sends the test
results to the Electronic Service Tool (EST) .

... & T�R4C)o,t...

nu ttst
syst(m
Tbe Fuel Pressure Con:tol v. e (fPCV) u ,oc:mandcd
low 11 '4 �cnaucs e Fud Rail Prcmwe(FRP)
sensor ss moasotcd The � ll e to blald

V00143

Figure 36 High Pressure Pump Test

72
 3 DIAGNOSTIC SOFTWARE OPERATION 69

Cylinder Cutout Test 2. Verify fuel system pressure is not below

specification and fuel is not aerated.
The Cylinder Cutout Test isolates a low contributing
cylinder due to an injector circuit fault.

Before starting the Cylinder Cutout Test, follow the

steps below:
1. Run Relative Compression Test.

73
70 3 DIAGNOSTIC SOFTWARE OPERATION

Multi- Cylinder Cutout Test NOTE: Before starting the Multi-Cylinder Cutout
°
Test, coolant temperature should be above 160 F
The Multi-Cylinder Cutout Test is used to highlight an
(71 "C) and engine load should be stable ( Example:
over- or under-performing cylinder. This test monitors
A/C, PTO, and Engine Fan should not be cycling
engine load while disabling 3 cylinders at a time in
on and off throughout the test).
a pre-determined sequence. The results of each
combination are collected and used in calculating the
end result.

74
 3 DIAGNOSTIC SOFTWARE OPERATION 71

-, --...�....11rnmm1� •16'•-...
in.*,l�c. �n,,.-,...
AutoiMttdM.h<)tnd«CUtoutTttt ITGt-O.t.1IGr.-..0

..
TestRe:u=I
Autol'ft!tedT�tl
Multi-Cylinder Cutout Test , '°"' 0. 0 0.2 o., OA
.,_
0�
....
00 07 o• 0� "'
Tbe Automated Mulfi.-Cyhndet Cutout Test v.111 �utati:ally
disable 3 cylmdefs at a tune m a contto!lcd groupmg, while

---,
collocting data on engine load �·crage.s. Resu.lts atecakulated
En,,,oT\,x, """""""' 'l/13(lOIO•l01l) from the combmattons.
Sofbltlre idt01!1ication� ....
Vd*:leJdenlibli«l Nll'!M: .•. ....... For best resulls'

..
.. .. • Coolan, ttmptr31U1e thould be abovo160degreoes F.
SX:�liitr-urbtr: • Eop,e Load sboul4be otablo: ExampleA/C,PTO a"4 EngiM
r,�rw,e::
,.......,,
Totl!i"*5.:
fan sMllld 001 be cyeling •• ""'offduougbout dM, ,,.,.
Tof.M�U!Sed:.
6-<ln-;.

Tl.._ - Iv .... ,.....,

� - r�teona�1
ContrdPafldI
TINam< ,...., lw�

O•

- 1...
Q2
o,
,� ·-
, ....,,..,,1 �bGTrot#t(;ode$f���tsl SqtrafisJ
O• I fl,ITc,1 I Tl..... . U,t,

Qs CNW)Tatj 1� Pnuuro
........... r
........... o•l
···········
O•
� l J f.: 1ac U le ...
_...
f'\lel Del1\."e!"V Pressure
........... r
...... ..... 51
Swit.Ched B6t;U!'V
W•vtr ln f\lel ...........
. . . . . . . . . . .iv

41

0000049007
Figure 37 Multi-Cylinder Cutout Test

75
72 3 DIAGNOSTIC SOFTWARE OPERATION

Hot Run Sensor Comparison Test Interface cable (RP121 OB compliant supporting
J1939 and J1708)
Purpose
NOTE: This test is not dependent on engine
Check for failed aftertreatment system temperature temperature.
sensor.
1. Turn ignition switch to ON position.
Tools Required
2. Connect Electronic Service Tool (EST) with
Electronic Service Tool (EST) with ServiceMaxx ™ ServiceMaxx ™ software to vehicle's diagnostic
software connector.

76
 3 DIAGNOSTIC SOFTWARE OPERATION 73

i
2

ServkeMaxx Pro • Default.,.;

- �II � � [4' J Cfil m m J � e J 8Jv.-. .

File View Sessions Tests Procedures Tools Help

8J r,;, R-t. ..

VC!Hdt Information I T.......,.,.,...,a r...,.,..... I •.,....ISwitthcsI Al""""'l

Caroe<tion I v.- s..... I .........

T(Nalnc - Vduc l>its

.nm"ient Air Temt> .. f
CAC OUtlet temo .• f
DEF Tank Ti!mp .• f
DOC Inlet TellD .• f
DPF Inlet TelDD .• f
DPF OUtlet temp .• f
DP£ Re:aen Taraet Temoerature .. f
EGR TemD .• f
Enaine Coolant Tem, 1 .• f
Enaine Coolant Team 2 .. f
Inlet Air tempe rature .• f
Intake Manifold T91D .• f
Engine Type: N13 SCR (2013 · ) 02S Temo .. f
SCR Inlet temp .• f
Softw,ye Ideitification: <16&Na.J8
SCR OUUet tezo .• f
ACM calbration Identification: •• TC2 Como. Inlet Temp .• f
Vet.de Jdenbbtion l'urber: 1SifriiNAXFCRCEJ6ENG
Engine Serial /'l.mbe": '16&fo121J3000000
EDC CUstome:r lht tt..n'lber: 0000000000
Transnission Type:
RatedPower: 271.S �
Total Mies: 1,0n,605.1 "*5
Total Fuel Used: 87,552,907.0 gail
&1Qhe On Tme: 231,675. 19 �

Dlaglostic TrCJUJI!. � I Datalr« Traffic!

T(DTC
""N/J
N/
N/
SPN
Sl
111
222
7137
- FMl Type
3 PendinQ
JlAcUve
2 Previouslv Active
10 Pendinq
F<CC2Cfran-e -
ETP :!liQnal Out of Ranae HIGH
Unknown DIC 111 : 3 l Enaine Coolant Level - Voltaae above normal, or sho . . . 3
Unknown ore 222 : 2 r Unknown SPN 1222 1 - Deu erruic intermittent or i. . .
Unlcnown MC 7137 : 10 ( EGRP Desired - Abnormal rate of chanoe )
••
C:OU,t

••
63
-
tnaine
Enaine
Eliaine
Enoine

Eu1d v38. 17.20L30924'1L36 Er,oile Clia!1lOSt:icTest Status

I Oca,OTC,
I I Refi'esh OTC/Vet.de Events I
0000060730
...
Figure 38 Default Session
1. Temperature tab 2. All Signals tab

3. Go to Default Session: Sessions > Default > 4. Start and run engine at 1 400 - 1 500 rpm for 1 0
Temperature tab. minutes.

A WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

77
74 3 DIAGNOSTIC SOFTWARE OPERATION

5. Monitor the following signals in the All Signals tab: sensor and / or circuit (see Electronic Control
Systems Diagnostics ).
Compare the following three signals:
DOC Inlet Temp
Onboard Filter Cleanliness Test
DOC Outlet Temp
The Onboard Filter Cleanliness Test increases engine
DPF Outlet Temp
speed to measure pressure differential across the
After 10 minutes, if any of these three Diesel Particulate Filter (DPF). This includes running
aftertreatment temperature sensors are not within a complete Parked Regen.
77 °F (25 °C) of each other, diagnose appropriate

78
 3 DIAG NOSTIC SOFTWARE OPERATION 75

Service Tool Proced u res i njector, th roug hout the operati ng range of the engine.
I njector mechanical tolerances, h i g h flow to low
These proced u res are not Service Bay Tests, but
flow, can be eve n ly balanced with ECM cal i b ration .
special ECM controls that al low the tech n ician to
® Each i njector has an encrypted label and must be
perform specific proced u res. MaxxForce 1 1 and
prog rammed into the ECM, whenever an i njector has
1 3 engi nes have fou r special proced u res: I n let Ai r
been replaced . I QA can be prog rammed using the
Heater, Oxygen Sensor Cal ibration, E n g i n e Fan , and
I njector Quantity Adj ustment proced u re.
I njector Quantity Adj ustment ( I QA) .
E n g i n e Off P roced u res can be selected i n the
P roced u res d rop-down men u . Engine Ru n n ing P roced u res
E n g i n e R u n n i n g P roced u res can be selected in the
P roced u res d rop-down men u .
Engine Off Proced u res

../ Load Test Specific Session

KOEO Tests
KOER Tests >
KOER Aftertreatment Tests J Air Management Test
Aftertreatment Proceck.res •
High Pressure Pump Test
V39003 Engine Fan Test
Cylinder Cutout Test
Fig u re 39 Engine Off Proced u res Multiple Cylinder Cutout Test ck

0000049006

I n let Air Heater Engine Ru n n i ng Proced u res

Fig u re 40
The I n let Ai r Heater proced u re g ives the tech n ician the
abil ity to command the I n let Ai r Heater to ru n at any
tem peratu re. Fol low the on screen instructions when Engine Fan
ru n n i ng ServiceMaxx ™ software proced u res.
The E n g i n e Fan proced u re commands the engine
fan to d ifferent states and operati ng speeds to help
d iag nose fan fai l u res. The viscous engine fa n takes
Oxygen Sensor Calibration m i n utes to respond to changes in the commanded
The Oxygen Sensor Cal i b ration proced u re cal i b rates speed .
the Oxygen Sensor (0 2 S ) . Anyti me the 0 2 S is
replaced , this proced u re needs to be performed .

I njector Quantity Adj ustment

I njector Quantity Adj u stment ( I QA) is a fu nction that
i njects the correct amount of fuel for each i n d ivid ual

79
76 3 DIAGNOSTIC SOFTWARE OPERATION

80
 4 ENGINE SYMPTOMS DIAGNOSTICS 77

Table of Contents

Coolant System ..........................................................................................................79

Coolant Loss....................................................................................................79
Coolant Overflow..............................................................................................80
Coolant Leak to Exhaust .....................................................................................82
Aftertreatment Fuel Injector (AFI) Coolant Leak Inspection..................................83
EGR Cooler Leak Inspection.......................................................................83
Coolant Leak to Fuel ..........................................................................................84
Coolant Leak to Intake........................................................................................84
Coolant Leak to Lube Oil.....................................................................................85
Lube Oil Contamination Inspection...............................................................85
Cylinder Head Leak Test............................................................................87
Coolant Over-Temperature...................................................................................87
Coolant Over-Temperature Conditions Inspection.............................................87
Coolant Over-Temperature - Engine Cooling...................................................89
Cooling System Components ...............................................................................90
Cooling System Flow..........................................................................................91
Thermostat Operation.........................................................................................91
Coolant Control Valve (CCV) Assembly and Coolant Mixer Valve (CMV) Operation...............92
Coolant Control Valve (CCV) Test ...........................................................................93

Lubrication System.....................................................................................................95
Visual Oil Level Inspection...................................................................................95
Incorrect Maintenance ........................................................................................95
Dilution from Coolant .........................................................................................95
Power Steering Fluid Leak to Lube Oil.....................................................................95
Lube Oil to Coolant............................................................................................95
Lube Oil to Intake..............................................................................................96
Lube Oil to Exhaust ...........................................................................................96
Low Oil Pressure ...............................................................................................97

Fuel System.............................................................................................................100
Excessive Fuel Consumption..............................................................................100
Fuel in Coolant ................................................................................................101
Fuel in Lube Oil...............................................................................................102
Fuel to Intake..................................................................................................103
Fuel to Exhaust...............................................................................................103
Fuel Pressure and Aeration................................................................................103
Water in Fuel..................................................................................................104
Priming the Fuel System....................................................................................105

Engine Brake System.................................................................................................107

Engine Brake Inspection....................................................................................107

81
78 4 ENGINE SYMPTOMS DIAGNOSTICS

82
 4 ENGINE SYMPTOMS DIAGNOSTICS
Coolant System
111111 GOVERNMENT REGULATION: Engine
fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g., filters rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.
Coolant Loss
Symptom
Consistent need to refill deaeration tank and active or
previously active DTCs related to the cooling system.
Possible Causes
External leaks
I mproper servicing
Loose or failed coolant hoses
Damaged or failed deaeration cap
Damaged or failed deaeration tan k
Damaged or failed radiator
Damaged or failed heater core
Failed breather tube heater
Failed Aflertreatment Fuel I njector (AFI)
Failed Coolant Control Valve (CCV)
Failed Coolant Flow Valve (CFV)
Failed Low Temperature Radiator (LTR)
Failed air compressor
Failed Low Pressure Charge Air Cooler (LPCAC)
Failed Exhaust Gas Recirculation (EGR) cooler
Damaged or failed distributor housing
Failed oil cooler
79
Cracked cylinder head
Porous or cracked cylinder liner
Tools
ZTSE2384 - Radiator Pressure Testing Kit
Surge Tank Cap Adaptor
Procedure
1. Check the service records to determine the
frequency and quantity of coolant added .
If the vehicle's cooling system is being
overfilled , there will be a small coolant loss
everyday. Educate the driver on correct
coolant level.
If the cooling system maintenance is correct,
continue to next step.
NOTE: Before running engine, ensure engine oil
and coolant are within normal operating ranges
and there is no visible evidence of coolant on the
oil level gauge (dipstick).
2. Start engine. With engine at operating
temperature and operating at high idle speed ,
inspect for coolant overflow.
If coolant overflow is detected , go to Coolant
Overflow (page 80).
If coolant overflow is not detected, continue to
next step.
A WARNING: To prevent personal injury
or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more.
Wrap a th ick cloth around radiator cap or
deaeration cap.
Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
Pause for a moment to avoid being scalded by
steam.
Continue to turn the cap counterclockwise to
remove .
83
80 4 ENGINE SYMPTOMS DIAGNOSTICS

3. Remove deaeration tank cap. Check sealing If there is no evidence of coolant in the intake
surfaces of deaeration cap and deaeration tank manifold or coolant is detected in the LPCAC
for damage. outlet, continue to next step.
• If sealing surfaces are damaged, install new 9. Obtain an oil sample from the engine and test for
components as necessary. Retest cooling coolant contamination.
system.
If oil sample is contaminated with coolant, go
• If sealing surfaces are not damaged, continue to Coolant Leak to Lube Oil (page 85).
to next step. • If oil sample is not contaminated with coolant,
4. Connect Radiator Pressure Testing Kit ZTSE2384 go to Coolant Leak to Exhaust (page 82).
with Surge Tank Cap Adaptor to deaeration cap.
Pressurize deaeration cap to its rated pressure.
Coolant Ove rflow
If deaeration cap does not hold rated
pressure, install a new deaeration cap.
Symptom
Retest cooling system.
Coolant flowing or bubbling from the deaeration tank.
If deaeration cap holds rated pressure,
continue to next step. Possible Causes
5. Connect Radiator Pressure Testing Kit ZTSE2384 . Failed air compressor
with Surge Tank Cap Adaptor to deaeration tank. . Failed LPCAC
Pressurize cooling system to 117 kPa (17 psi) for
15 minutes. . Failed EGR cooler
6. Visually inspect all components and hoses for . Cracked cylinder liner
external coolant leaks. . Cracked cylinder head
If an external coolant leak is identified, repair
as necessary. Retest cooling system.
. Failed oil cooler

• Tools
If no external leak is detected, continue to
next step. ZTSE2384 - Radiator Pressure Testing Kit
7. Obtain a fuel sample from the fuel tank and test EGR Cooler Leak Detection Test Kit 12-892-02
for coolant contamination.
Surge Tank Cap Adaptor
• If fuel sample is contaminated with coolant, go
One inch pipe plug
to Coolant Leak to Fuel (page 84).
• Suitable hose with one inch inside diameter
If fuel sample is not contaminated with
coolant, continue to next step. • Regulated air pressure
8. Inspect the intake manifold, Low Pressure Charge • Shut off valve
Air Cooler (LPCAC) outlet, and EGR Cooler for
evidence of coolant.
• If there is evidence of coolant in the intake
manifold, LPCAC outlet, or EGR Cooler, go
to Coolant Leak to Intake (page 84).
NOTE: The EGR Cooler can be inspected by
removing the cold side tubes at the intake.

84
 4 ENGINE SYMPTOMS DIAGNOSTICS 81

Procedure CAUTION: To prevent engine damage, do not run the

A WARNING: To prevent personal injury

or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more.
Wrap a th ick cloth around radiator cap or
deaeration cap.
Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
Pause for a moment to avoid being scalded by
steam.
Continue to turn the cap counterclockwise to
remove .
1. Partially drain cooling system.
engine for more than one min ute. This can overheat
the air compressor.
7. Start and run engine for a maximum of one
minute.
If coolant contin ues overflowing from
deaeration tank, continue to next step.
If coolant stops overflowing from deaeration
tank, install a new air compressor following
procedures in the Engine Service Manual.
A WARNING: To prevent personal injury
or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more.
Wrap a th ick cloth around radiator cap or
deaeration cap.
Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
Pause for a moment to avoid being scalded by
steam.
Continue to turn the cap counterclockwise to
remove .
8. Remove deaeration tank cap.
9. Connect Radiator Pressure Testing Kit ZTSE2384
with Surge Tank Cap Adaptor to deaeration tank.
1 0. Pressurize cooling system to 1 1 7 kPa (1 7 psi) for
1 5 minutes.

Figure 41 Air compressor coolant test 1 1 . I nspect intake manifold and LPCAC outlet for
evidence of coolant.
1. Rear coolant port
2. Air compressor connector If there is no evidence of coolant in intake
3. Front coolant line manifold or coolant is detected in LPCAC
outlet, go to Coolant Leak to Intake (page
84) .
2. Remove coolant line from rear coolant port (1 ) . If there is no evidence of coolant in the intake
3. Remove coolant line from a i r compressor manifold or coolant is detected in the LPCAC
connector (2) . outlet, continue to next step.

4. Tape off both air compressor connectors. 1 2. Drain engine coolant.

5. I nstall front coolant line (3) into rear coolant port 1 3. Disconnect both coolant hoses from LPCAC.
(1 ) . 1 4. Using a suitable hose with a one inch inside
6. Refill cooling system to proper operating level. diameter and a plug , block off LPCAC coolant
outlet port.

85
82 4 ENGINE SYMPTOMS DIAGNOSTICS

A WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Coolant Leak to Exhaust

Limit compressed air pressure to 207 kPa (30 psi).
1 5. Attach an air pressure regu lator to a pressurized
air source and reg ulate pressure to 207 kPa (30
psi) .
1 6. Using a suitable hose with a one inch inside
diameter and a shut off valve, con nect air
pressure regulator with pressurized air source to
LPCAC coolant inlet port.
Symptoms
Coolant leaks to the exhaust may be detected
externally or internally. See the following list of
symptoms for identification of coolant leaks to the
exhaust.
Coolant residue at exhaust manifold flanges
Observation of coolant loss without engine
overheating

1 7. Pressurize LPCAC to 207 kPa (30 psi) and close
shut off valve.
1 8. Remove air pressure source.
1 9. Monitor air pressure in LPCAC for a period of 5
minutes.
If air pressu re in the LPCAC drops, install
a new LPCAC following procedures in the
Engine Service Manual.
Coolant smell in exhaust
Coolant leaking from exhaust
Severe case - engine hydraulic lock
Failed Aflertreatment Fuel I njector (AFI)
Restricted Diesel Particulate Filter (DPF) or Diesel
Oxidation Catalyst (DOC) .
Possible Causes

If air pressure in the LPCAC remains Failed EGR cooler

constant, continue to next step. Failed AFI

A WARNING: To prevent personal injury or

death, make sure the engine has cooled before
Cracked cylinder head
Cracked cylinder liner
removing components.
NOTE: If a coolant leak to exhaust is determined

A WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
20. Pressure test EGR cooler, in veh icle, following
procedures in the Engine Service Manual.
from one of the listed possible causes, the Oxygen
Sensor (02S) must be replaced. See the Engine
Service Manual for 02S replacement procedures.
Perform 02S Calibration Procedure (page 75)
anytime 02S is replaced.
Tools
ZTSE2384 - Radiator Pressure Testing Kit

If a leak is detected , install a new EGR cooler Surge Tank Cap Adaptor
following procedures in the Engine Service EGR Cooler Leak Detection Test Kit 1 2-892-02
Manual.
If a leak is not detected , go to Coolant Leak
to Lube Oil (page 85) .
If EGR cooler is leaking coolant internally,
replace Oxygen Sensor (02S) following
procedures in the Engine Service Manual.
Perform 02S Calibration Procedure (page
75) anytime 02S is replaced .

86
 4 ENGINE SYMPTOMS DIAGNOSTICS 83

Aftertreatment Fuel Injector ( AFI) Coolant Leak

Inspection

A WARNING: To prevent personal injury

or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more.
Wrap a th ick cloth around radiator cap or
deaeration cap.
Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
Pause for a moment to avoid being scalded by
steam.
Continue to turn cap counterclockwise to remove. Figure 42 AFI nozzle

1. Remove deaeration tank cap.

2. Connect Radiator Pressure Testing Kit ZTSE2384 5. I nspect inside of exhaust pipe at AFI nozzle.
with Surge Tank Cap Adaptor to deaeration tank. If coolant is evident at AFI nozzle inside

A
exhaust pipe, install a new AFI following
WARNING: To prevent personal injury or Hydrocarbon Injector installation procedure
death, make sure the engine has cooled before in the Engine SeNice Manual and retest.
removing components. If no coolant is evident at AFI nozzle inside

A WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
the exhaust pipe , continue to next test.

Clean skin and nails using hand cleaner and wash EGR Cooler Leak Inspection

with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
3. Disconnect exhaust pipe at Pre-DOC assembly.
4. Pressurize cooling system to 1 1 7 kPa (1 7 psi) for
1 5 minutes.
A
WARNING: To prevent personal injury or
death, make sure the engine has cooled before
removing components.
A WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
1. Visually inspect EGR cooler for cracks or leaks.
If an external leak or crack is identified , install
a new EGR cooler following procedures in the
Engine SeNice Manual and retest.
If no external leaks or cracks are identified ,
continue to next step.

87
84 4 ENGINE SYMPTOMS DIAGNOSTICS

2. Pressure test EGR cooler, in veh icle, following 4. Disconnect fuel line from AFI. I nspect AFI for
procedures in the Engine SeNice Manual. coolant leaking from fuel inlet.
If a leak is detected , install a new EGR cooler If coolant is leaking, install a new AFI following
following procedures in the Engine SeNice Hydrocarbon Injector installation procedure in
Manual. the Engine SeNice Manual.
If a leak is not detected , go to Cylinder Head If coolant is not leaking, continue to next step.
Leak Test (page 87) .
5. Restore fuel system to proper operating condition.
6. Remove fuel return port at rear of cylinder head .
Coolant Leak to Fuel
7. Pressurize cooling system to 1 1 7 kPa (1 7 psi) for
a minimum of 30 minutes.
Symptom
Noticeable coolant separation in fuel sample. 8. Monitor fuel return port in cylinder head for
coolant.
Possible Causes
NOTE: It may take 12-24 hours for a coolant
Coolant heater auxiliary fuel filter (if equ ipped) leak to become visible.
Failed AFI If coolant is present in the fuel return
Cracked cylinder head port, install a new cylinder head following
procedures in the Engine SeNice Manual.
Tools
If no coolant is present in the fuel return
ZTSE2384 - Radiator Pressure Testing Kit port, fuel in the fuel tan k may have been
Surge Tank Cap Adaptor contaminated . Drain contaminated fuel from
supply tanks and replace fuel filters following
procedures in the Engine Operation and
Procedure

A
Maintenance Manual.
WARNING: To prevent personal injury
or death, do the following when removing the
Coolant Leak to Intake
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more. Symptom
Wrap a thick cloth around radiator cap or Coolant overflowing from deaeration tank or air
deaeration cap. bubbles in coolant.
Loosen cap slowly a quarter to half turn Possible Causes
counterclockwise to vent pressure.
Failed LPCAC
Pause for a moment to avoid being scalded by
Failed EGR cooler
steam.
Cracked cylinder head
Continue to turn cap counterclockwise to remove.
Tools
1. Remove deaeration tank cap.
ZTSE2384 - Radiator Pressure Testing Kit
2. Connect Radiator Pressure Testing Kit ZTSE2384
with Surge Tank Cap Adaptor to deaeration tank. Surge Tank Cap Adaptor
3. Pressurize cooling system to 1 1 7 kPa (1 7 psi) . EGR Cooler Leak Detection Test Kit 1 2-892-02

88
 4 ENGINE SYMPTOMS DIAGNOSTICS 85

Procedure Coolant Leak to Lube Oil

1. Determine location of coolant leakage.
Symptom
If coolant is leaking from LPCAC outlet,
Engine oil with a light gray and sludgy appearance.
continue to next step.
The crankcase may also be overfilled.
• If the coolant leakage is from intake manifold,
Possible Causes
skip to step 5.
Failed oil cooler
2. Drain cooling system.
• Failed air compressor
3. The LPCAC can be left on the vehicle to be tested
or removed as described in the Engine Service • Cracked cylinder head
Manual. • Cracked or cavitation in front cover
4. Test LPCAC following procedures in the Engine • Cracked cylinder liner
Service Manual.
• Cracked crankcase
• If LPCAC is leaking, install a new LPCAC
following procedures in the Engine Service Cracked oil cooler housing
Manual.
Missing/damaged oil module gasket
• If LPCAC is not leaking, continue to next step.
Missing/damaged oil cooler gaskets
5. Visually inspect EGR cooler for cracks or leaks.
Missing mounting bolts for the oil module to the
• If an external leak or crack is identified, install crankcase
a new EGR cooler following procedures in the
Tools
Engine Service Manual.
• ZTSE2384 - Radiator Pressure Testing Kit
• If no external leaks or cracks are identified,
continue to next step. • Surge Tank Cap Adaptor
6. Remove front tubes from EGR cooler and
pressure test EGR cooler, in vehicle, following
Lube Oil Contamination Inspection
procedures in the Engine Service Manual.
• 1. Check lube oil for proper level and visible
If a leak is detected, install a new EGR cooler
contamination.
following procedures in the Engine Service
Manual. • Oil contaminated with coolant generally
• causes the oiI to thicken and coagulate, giving
If no leak is found, continue to next step.
the oil a light gray sludgy appearance.
7. Test cylinder head for coolant leaks in the intake • If contamination cannot be verified, take an oil
area. Go to Cylinder Head Leak Test (page 87).
sample for analysis.
If a coolant leak is identified in cylinder
2. Remove oil sump following procedures in the
head, install a new cylinder head following
Engine Service Manual.
procedures in the Engine Service Manual.
If a coolant leak is not identified in cylinder
head, restore engine to operational condition
and retest cooling system.

89
86 4 E N G I N E SYM PTOMS DIAG NOSTICS

A WA RN I N G : To prevent personal i nj u ry
or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 m i n utes or more.
Wrap a thick cloth around rad iator cap or
deaeration cap.
Loosen cap slowly a quarter to half tu rn
counterclockwise to vent pressu re.
Pause for a moment to avoid bei n g scalded by
steam.
Conti n u e to tu rn cap counterclockwise to remove.
3. Remove deaeration tan k cap.
Fig u re 43 Water d istri butor housing
4. I n stal l Rad iator Pressu re Testi ng Kit ZTS E238 4
with S u rge Tan k Cap Adaptor on deaeration tan k.
5. P ressu rize coo l i n g system t o 1 1 7 k P a ( 1 7 psi) for 8. I nspect g e a r tra i n area for coolant leaks.
a m i n i m u m of 1 5 m i n utes. If coolant is leaki ng i nto gear train area,
NOTE : It may take 1 2-24 hours for a coolant leak i nspect d i stri butor housing for leak sou rces.
to become visi ble. Repair as necessary.

6. I nspect the inside of the cran kcase for evidence
of coolant leakage.
If coolant leak is at the a i r compressor
d ra i n , instal l a new air compressor fol lowi ng
proced u res i n the Engine Service Manual.
If no coolant is leaki ng i nto the gear tra i n area,
i nspect water d istri butor housing and gasket
for leak sou rces. Repa i r as necessary.
If no coolant is leaki ng from water d istri butor
housing or gasket, conti n u e to next step.

If coolant leak is from o i l cooler, i n stal l a new 9. I nspect lower edges o f cyl i nder l i ners for coolant
o i l cooler fol lowi ng proced u res i n the Engine leaks. Note cyl i nder n u m ber(s) where coolant
Service Manual. leakage is identified .

If coolant is evident at the front cover area
conti n u e to next step.
If coolant is evident at the rear gear train area,
i nspect freeze plug on rear of cyl i nder head
and repai r as necessary.
If coolant is evident on the bottom edge of a
cyl i nder l i ner(s) , skip to step 1 0 .
If coolant leak is from cracks i n the cran kcase
replace cran kcase followi ng proced u res in th�
Engine Service Manual.
7. Remove water d i stri butor housing fol lowi ng
proced u res i n the Engine Service Manual.
If coolant is leaki ng on the outside of a
cyl i nder l i ner, instal l new cyl i nder l i n e r 0-ri ngs
fol lowi ng proced u res i n the Engine Service
Manual.
• If coolant is leaki ng i n side of cyl i nder l i ner,
conti n u e to next step.
1 0 . Remove front and rear tu bes from EGR cooler
and pressu re test EGR cooler, i n veh icle, following
proced u res i n the Engine Service Manual.
• If a leak is detected , instal l a new EGR cooler
fol lowi ng proced u res i n the Engine Service
Manual.
• If no leak is fou n d , conti n u e to next step.
1 1 . Test cyl i nder head for coolant leaks. Go to
Cyl i nder Head Leak Test.
1 2 . Test cooling system aga i n to val idate repai r.

90
 4 ENGINE SYMPTOMS DIAGNOSTICS 87

Cylinder Head Leak Test • Internal or external radiator blockage

Winter front installed
Procedure
Water pump failure
1. Drain oil and remove oil pan see Engine Service
Manual. One or both coolant thermostats stuck (closed)
2. Pressure test cooling system to 117 kPa (17 psi). Internal coolant leak
3. Inspect all cylinder liners and crankcase coolant Coolant Mixer Valve (CMV) failure
passages following procedures in the Engine • EGR cooler failure
Service Manual.
• LPCAC failure
If cylinder liners are damaged, repair or
replace as necessary following procedures in • Chassis effects, transmission, or aftermarket
the Engine Service Manual. equipment
If crankcase is damaged or cracked, repair or Tools
replace as necessary following procedures in
ZTSE2384 - Radiator Pressure Testing Kit
the Engine Service Manual.
Surge Tank Cap Adaptor
4. Test cooling system again to validate repair.
Electronic Service Tool (EST) with ServiceMaxx ™
software
Coolant Over-Temperature
J1939 and J1708 RP121 OB Compliant Device
Symptom Digital Multimeter (DMM)
Coolant over-temperature is identified by the water Hose pinch off pliers
temperature gauge amber indicator illuminating and
flashing and the audible alarm sounding, or the
cooling system setting Diagnostic Trouble Codes Coolant Over-Temperature Conditions Inspection
(DTCs).
1. Connect Electronic Service Tool (EST) with
Possible Causes ServiceMaxx ™ software to vehicle's Diagnostic
• Connector.
Wrong parts installed
2. Check for active and previously active DTCs
Low engine coolant level
related to coolant over- temperature.
External coolant leaks
3. Correct any sensor DTCs before proceeding.
Damaged fan belt See "ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS."
Broken/worn accessory drive belt
4. If engine has not been operated for eight to
Accessory belt tensioner failure
12 hours, use Electronic Service Tool (EST)
• Damaged fan shroud with ServiceMaxx ™ software to compare
• Engine Coolant Temperature 1 (ECT1 ), Engine
Cooling fan blade assembly wrong or damaged
Coolant Temperature 2 (ECT2), and Engine Oil
• Slipping cooling fan drive clutch Temperature (EOT) with Key ON, Engine OFF
• (KOEO). All of the sensors should read within 5
Inoperative cooling fan 0
c ( 1 O °F) of each other.
• Electronic gauge cluster error
5. Check deaeration tank for correct fill level.
• Engine Coolant Temperature (ECT) sensor • If coolant level is low and a coolant leak is
biased
suspected, fill cooling system and repair leak.
Incorrect or damaged radiator See Coolant Loss (page 79).

91
88 4 ENGINE SYMPTOMS DIAGNOSTICS
If coolant level is low and other
over-temperatu re conditions are still
suspected , refill cooling system and continue
to next step.
6. I nspect cooling fan blade, shroud, accessory
drive belt(s) , accessory drive belt tensioner(s) ,
and radiator for damage. I nspect Cooling fan
drive clutch for free rotation. Key OFF does fan
free wheel in both directions?
If fan drive is damaged , replace fan drive
following procedures in the Engine SeNice
Manual.
If vehicle is new or recently repaired,
verify correct part number for any replaced
component related to the cooling system.
Verify cooling fan blade, cooling fan drive
clutch , and radiator are clean of debris and
dirt build-up. Clean areas as required .
A WARNING: To prevent personal injury
or death, do the following when removing the
radiator cap or deaeration cap:
Allow engine to cool for 1 5 minutes or more.
Wrap a thick cloth around radiator cap or
deaeration cap.
Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
Pause for a moment to avoid being scalded
by steam.
Continue to tu rn cap counterclockwise to
remove.
7. Remove deaeration tank cap.
8. Connect Radiator Pressure Test Kit ZTSE2384
with Surge Tank Cap Adaptor to deaeration
tank cap. Pressurize deaeration cap to its rated
pressure.
If deaeration cap does not hold rated
pressure , install a new deaeration cap.
If deaeration cap holds rated pressure,
continue to next step.
9. Connect Radiator Pressure Testing Kit ZTSE2384
with Surge Tank Cap Adaptor to deaeration tank.
Run engine at elevated idle. Monitor pressure
in system using Radiator Pressure Testing Kit
gauge.
If pressure is higher than pressure rating of
the cap, go to Coolant Overflow (page 80) .
If pressure is below rating of cap, continue to
next step.
1 0. Using EST with ServiceMaxx ™ do Tests > KOER
Tests > Engine Fan Test.
If fan does not operate properly, verify air or
electrical supply to fan drive. If air or electrical
supply to fan drive is damaged , repair as
necessary.
If fan operates properly, continue to next step.
1 1 . Start and run engine up to operating temperature.
Verify cooling fan clutch engages at desired
temperature.
If fan does not operate properly, verify air or
electrical supply to fan drive. If air or electrical
supply to fan drive is damaged , repair as
necessary.
lffan operates properly, continue to next step.
1 2. Attempt to duplicate the operator's concern of
coolant over-temperature.
CAUTION: To prevent radiator damage, do not
hold wand of high-pressure hose too close to
radiator fins.
If concern cannot be duplicated , clean
radiator fins (if not done previously) . Flush
radiator fins with water on cooling fan side of
the radiator. Do not continue with diagnostics.
If coolant over-temperature is du plicated,
continue to next step.
1 3. Using EST with ServiceMaxx™ software, mon itor
ECT1 and ECT2 sensor temperature readings.
If the temperature value for ECT2 sensor is
below ECT1 sensor reading, continue with
next test.
If the temperature value for ECT2 sensor
is above ECT1 sensor reading , continue
with Coolant Over-Temperature - Charge Air
Cooling.
92
 4 E N G I N E SYM PTOMS DIAG NOSTICS 89

Coolant Over-Temperatu re - Engine Cooling

P roced u re

A WARN I N G : To prevent personal i nj u ry

or death , do the following when removing the
rad iator cap or deaeration cap:
• Allow engine to cool for 1 5 m i n utes or more.
• Wrap a thick cloth around rad iator cap or
deaeration cap.
• Loosen cap slowly a quarter to half tu rn
counterclockwise to vent pressu re.
• Pause for a moment to avoid being scalded by
steam. Fig u re 44 Thermostat elements
• Conti n u e to tu rn cap counterclockwise to remove. 1. Thermostat housing assembly
1. Remove deaeration tan k cap. 2. 6 0 x 4 0-ring (2)
3. Thermostat element (2)
2. R u n engine and observe rad iator and aeration 4. Ball valves (part of thermostat elements)
l i nes for coolant flow.
NOTE : Coolant flow cannot be seen u n less
thermostats are open. 6. Remove and i nspect thermostats following
proced u res i n the Engine Service Manual. Ensure
• If no coolant flow is observed i n rad iator and the ope n i n g temperatu re on both thermostats
aeration l i nes, conti n u e to next step. match the rati ng of the thermostats.
• If coolant flow is observed i n rad iator and • Replace thermostats as needed . Retest to
aeration l i n es, go to step 6 . validate repai r.
3. Drain engine coolant. • If both thermostats pass test, conti n u e to next
4. Remove water p u m p fol lowi ng proced u res i n the step.
Engine Service Manual. 7. If the veh icle is eq u i pped with an automatic
5. Visually inspect water pump for damage, such as transmissio n , use appropriate veh icle
broken vanes, damaged i m peller, or a damaged service/d iag nostics manual to review automatic
shaft. transmission d iag nostics.
8. If over-temperatu re cond ition remains, remove
rad iator and have flow checked at rad iator repai r
faci lity. Retest engine for over-temperatu re
cond ition with repaired or replaced rad iator.

93
90 4 E N G I N E SYM PTOMS DIAG NOSTICS

Cooling System Components

V00 1 59

Figure 45 Cooling System Components

1. Coolant manifold 7. Dual thermostats 1 3. LTR coolant return line
2. H igh-temperature E G R cooler 8. CMV and C FV 14. LTR coolant supply line
3. EGR coolant retu rn 9. Water P u m p 1 5. LPCAC
4. EGR coolant su pply 1 0. Water inlet 1 6. LTR coolant return line
5. Low-tem perature E G R cooler 11. Heater coolant 1 7. Coolant return (cab heater)
6. Coolant manifold outlet 1 2. S u rge tank line con nector

94
 4 ENGINE SYMPTOMS DIAGNOSTICS 91

Cooling System Flow Coolant flow to the radiator is controlled by two

thermostats. When the thermostats are closed,
The water pump is located on the distributor case and
coolant flowing out of the EGR cooler is directed
draws coolant from the radiator through the coolant
through a bypass port inside the front cover into the
inlet at the lower right side of the distributor case.
water pump. When the thermostats are open, the
The engines have no coolant passages between the
bypass port is blocked, and coolant is directed from
crankcase and cylinder head through the cylinder
the engine into the radiator.
head gasket. This design eliminates the possibility
of coolant leaks at the cylinder head gasket. Coolant Coolant passes through the radiator and is cooled
in and out of the crankcase and cylinder head is by air flowing through the radiator from ram air and
directed through external passages. Coolant flows operation of the coolant fan. The coolant returns to
through the crankcase and cylinder head from front the engine through the inlet elbow.
to rear. This coolant flows around the cylinder liners
The air compressor is cooled with coolant supplied by
and combustion chambers to absorb heat from
a hose from the left side of the crankcase. Coolant
combustion.
passes through the air compressor cylinder head and
Coolant exiting the crankcase and cylinder head at returns through a passage inside the crankcase to the
the rear of the engine is directed through an external distributor case.
coolant elbow to the Exhaust Gas Recirculation (EGR)
The oil module receives coolant from a passage in
module. Coolant passes between the EGR cooler
the crankcase. Coolant passes between the oil cooler
plates, travels parallel to the exhaust flow, and exits
plates and returns back to the water pump suction
into the distributor case. A deaeration port on the top
passage located in the front cover.
of the EGR module directs coolant and trapped air
towards the coolant deareation tank.
Coolant from the pump also flows through the air to Thermostat Operation
air and the Low Pressure Charge Air Cooler (LPCAC)
The engines are fitted with two thermostats in a
to regulate the charge air temperature. Coolant flow
common housing to ensure sufficient coolant flow in
through the charge air coolers is controlled by the
all operating conditions. The thermostats are located
Coolant Mixer Valve (CMV) and Coolant Flow Valve
at the top of the distributor case.
(CFV). Depending on the coolant temperature, CMV
sends coolant through the LPCAC, or indirectly to the The thermostat housing assembly has two outlets.
LPCAC, after going through the Low Temperature One directs coolant to the radiator when the engine is
Radiator (LTR) located in front of the main coolant at operating temperature. The second outlet directs
radiator. When the charge air temperature is too low, coolant to the water pump until the engine reaches
CMV bypasses the LTR and directs all the coolant operating temperature. The thermostats begin to
through the LPCAC. When the charge air temperature open at 83 °c (181 °F) and are fully open at 91 °c
increases, CMV directs a percentage of the coolant (196 °F).
to the LTR before it enters the LPCAC to cool the
When engine coolant is below the 83 °c (181 °F), the
charge air. If the engine coolant temperature is too
thermostats are closed, blocking coolant flow to the
high, CMV sends all of the coolant flow through the
radiator. Coolant is forced to flow through a bypass
LTR and through the LPCAC to help cool the engine
port back to the water pump.
faster.
When coolant temperature reaches the opening
Both coolant valves are controlled by the Engine
temperature of 83 °c (181 °F), the thermostats open
Control Module (ECM) based on signals from
allowing some coolant to flow to the radiator. When
the Engine Coolant Temperature 1 (ECT1)
coolant temperature exceeds 91 °c (196 °F), the
sensor, ECT2 sensor, and the Intake Manifold
lower seat blocks the bypass port directing full coolant
Pressure/Turbocharger 2 Compressor Inlet Sensor
flow to the radiator.
(I MP!TC2C1S) sensors. The ECT1 sensor is located
in the underside of the EGR coolant crossover
manifold, at the back of engine.

95
92 4 ENGINE SYMPTOMS DIAGNOSTICS
Coolant Control Valve (CCV) Assembly and
Coolant Mixer Valve (CMV) Operation
The CCV assembly is installed on the upper right
side of the distributor housing. The CCV has tvvo
separate solenoid actuated valves; CMV, and CFV.
The CMV and the CFV are part of the CCV assembly
and cannot be serviced separately. CFV controls
the coolant flow through the CACOTs while the CMV
controls the coolant flow through the LTR. The CMV
and CFV solenoids are controlled by two separate
Pulse Width Modulated (PWM) signals from the
ECM. The PWM signal duty cycles vary betvveen 0%
and 100% depending on the coolant and charge air
temperature. The CMV is installed on the upper side
of CCV and controls the coolant flow through the LTR.
The CFV is installed on the lower side of CCV and
controls the amount of coolant flow through the LTR
and LPCAC. The CFV helps protect the LTR circuit
from over-pressure at high engine speeds. If the
engine coolant temperature is too low, the CFV closes
to reduce the coolant flow through the LPCAC.
When the temperature of the charge air and coolant
coming out of the LPCAC is low, the CMV directs
the coolant through a LTR bypass directly into the
LPCAC. This helps the engine reach its normal
operating temperature faster. If the temperature of
the charge air and coolant coming out of the LPCAC
is high, the CMV directs the coolant flow through the
LTR. This prevents an overheating of the charge air
cooler which can result in failure of the LPCAC.
96
 4 ENGINE SYM PTOMS DIAG NOSTICS 93

Coolant Control Valve (CCV) Test 5. Start engine and allow to reach operating
temperature.
1. Turn ignition switch to O N , engine OFF.
'11 ServKeMaxx Pro - Coolant Control Valve Tm
2. Connect EST t o vehicle's Diagnostic Connector.
3. Start ServiceMaxx ™ software. I Cfil [IH I] I
Instructions I Tempe,-abxe sq>als [
� ServiceMaxx Pro - Default
- -
�I �
Coolant Valve Test � Lode

�
File View �sions Testsl Procedur6 Tools H_ •l�
p 1.00 1.00
----,------------­
- ,--

' S'4 �
! I
fel. ',
Vende Information
,/
loadTest: Specific S6sion
KOEOTosts
Ej
,rsµ W .:jJ Vende. . dCJ Tro>Repo,

Coolant Control Valve Test

t. ..

........-... Status I Pressu"e I Positio

Entry conditions:
- Engine Coolant Temp (Above 160 F)
..: 0.75
0.75

KOERT,sts - Brake Switch (Released)

� 0.50
KOEO Aftertre:atment Tests Air Management Tm - Acee! Pedal Position (0 %) 0.50

KOER Aftertreatment Tests High Pr6sure Pump Test - Vehicle Speed (0 11-!PH)
Engine Fan Test 0.25 020

Cylinder Cutout T6t is a Engine Electronic Con Use this test to validate the performance of the coolant control

�
Multiple Cylinder Cutout Test
- - -nrn=,gan;-n'OCc Detection:
- Pre 2007 engines can only Auto-Decec
valves and cooler.

NOTE: Actuator control will only actuate 5 seconds per cycle. You
= 0.00 0.00
.:,o .29 .21 .2e .2

engine type, you must selecc the correcl

will need to run the test over and over to see it's effect on ECI'2.
Later calibrations will allow longer run time.
Connection (Sniffer) TIName
- Displays all electronic control modules Enaine Coolant Temp 1
• The Coolant Mixer Valve controlled to 95% will by-pass the low Engine Coolant Temp 2
temperature radiator to help engine warm up. Controlling the valve IC2 Comp. Inlet Temp
to 5% will cool the coolant going to the EGR Cooler.
Software Identification: 4661fl2U8 w
A01 calibration Identification:
1) Run engine up to nonnal operating temperature.
Vehicle Identification funber: 1Sif'IMAXFORCEI6ENG
Engs,e Serial /'brtler: 466tfo12J3000000
8)C Customer Lnt tunber: 0000000000 2) With either valve at (95%) ECTl and ECT2 should be ""thin 5 .
TransrrissionType: Testlmotors
Rated Powe-: 736.3 � Coolant Control Valv0< I
Total �: 2,211,698.Smles
Total Pue Used: 61,584,412.6 gal
Connection (Snffo<)
Actuator fU>Olant Flow v«ve •I TIName
T I Protocol II Accel Pedal Position l
Engine: On Tme: ·551,953.23 1T J1939
J1939 61
I!
1,
@ On (9 ...
!CoolantRow Valve I Brake Switch
!Vehicle Speed
J1939 249 IC ,0 Off (5% Duty Cyde)

I StartTest II StopTest I
l>agnostic Trot.l,JeCodes I Snffer I DTC Logl
TI SPN FM! Type Freeze Frame Message
Diag'losl:icTrol.ble Codes I DatalinkTrafficl 111 3 Active Unknown OTC
TIDTC SPN . FM! r,,,. Freeze Frcl'Tle
222
7137
2 Previouslv Active
10 Pendina
Unknown OTC
Unknown OTC
N/ 51 3 Pendina ETP sianal 4 51 3 Pending ETP signal 4
N/ Ill 31Active Unknown OTC
N/ 222 2 Previouslv Active Unknown OTC
N/ 7137 10 Pendina Unknown DTC
0000063192

0000063193
Figure 47 Coolant Control Valve Test
Figure 46 Key-On Engi ne-Ru n n i ng Tests

6. Select Coolant Mixer Valve or Coolant Flow Valve

4. Select Test > KOE R Tests > Coolant Control Valve from Actuator drop-down men u .
Tests.

97
94 4 ENG I N E SYMPTOMS DIAG NOSTICS

Instructions I
L--------------------, TC2CIS, and ECT2 sensors. Record readings on
Coolant Valve Test � Lock Performance Diagnostics Form.
Entry conditions: 1 0. Calculate secondary radiator cooling by
- Engine Coolant Temp (Above 160 F) subtracting coolant inlet temperature from coolant
- Brake Switch (Released) outlet temperature. Record this number as
- Acee! Pedal Position (0 %) secondary radiator difference.
- Vehicle Speed (0 MPH)
1 1 . Calculate LPCAC cooling by subtracting
Use this test to validate the performance of the coolant control TC2CIS sensor temperature from ECT2 sensor
valves and cooler. temperature. Record this number as cooler
�OTE: Actuator control will only actuate 5 seconds per cycle. You temperature difference.
will need to run the test over and over to see it's effect on ECT2. 1 2 . Use recorded data to determine if CFV and CMV
Later calibrations will allow longer run time.
are operating correctly.
* The Coolant l\ofixer Valve controlled to 95% will by-pass the low If cooler difference is higher than secondary
temperature radiator to help engine warm up. Controlling the valve radiator difference, or is within 3 °C (5 ° F)
to 5% will cool the coolant going to the EGR Cooler.
of secondary radiator difference, the Coolant
1) Run engine up to normal operating temperature. Flow Valve (CFV) is stuck in the fully closed
position. I nstall a new Coolant Control Valve
2) With either valve at (95%) ECTl and ECT2 should be within 5 (CCV) assembly following procedures in the
Engine Service Manual.
Coolant Control Valves !�------------�
Actuator �ooiant Mxer Vaive! ·•J If the ambient temperature is lower than 4 °C
(40 ° F) , add 2 °C (4 ° F) to ECT and ECT2 .
@ On {95% Duty Cyde)

e) Off {5% Duty Cyde)

If ECT sensor reading is higher than ECT2
sensor reading by less than 1 1 °C (20 ° F) , the
Coolant Mixer Valve (CMV) is stuck in the fully
closed position . I nstall a new CCV assembly
following procedures in the Engine Service
Manual.

I Star t Test II Stop Test I If cooler difference is lower than secondary

radiator difference and ECT sensor reading is
0000063194 higher than ECT2 reading by 1 1 °C (20 ° F) , the
CCV is functioning normally. Continue to next
Figure 48 Coolant M ixer Valve actuator session step.
1 3. If over-temperature condition remains, remove
7. Set actuator to ON (95% Duty Cycle) and click on secondary radiator and have flow checked
the Start Test button. at radiator repair facility. Retest engine for
over-temperature condition with repaired or
8. Using an infrared thermometer, measure and replaced secondary radiator.
record coolant inlet and outlet temperatures at
the secondary radiator.
9. Using EST with ServiceMaxx ™ software, monitor
and record temperature readings from ECT,

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 4 ENGINE SYMPTOMS DIAGNOSTICS 95

Lubrication System Power Steering Fluid Leak to Lube Oil

Symptom

111111 GOVERNMENT Oil level increases while power steering fluid level
REGULATION: Engine
decreases.
fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment. Possible Causes
Handle all fluids and other contaminated
Power steering pump leak
materials (e.g., filters rags) in accordance
with applicable regulations. Recycle
Procedure
or dispose of engine fluids, filters, and
other contaminated materials according to 1. Adjust oil level to full range.
applicable regulations.
2. Adjust power steering fluid to full range.
3. Start and run engine for a minimum of 10 minutes.
4. Stop engine and inspect lube oil and power
Visual Oil Level Inspection steering fluid levels.
NOTE: If engine has been running, allow a 15 If power steering level is decreasing and lube
minute oil drain down period before checking oil oil level is increasing, install a new power
level. steering pump following procedures in the
Park vehicle on level ground and use oil level gauge Engine Service Manual.
(dipstick) to check oil level. If power steering level is not decreasing and
lube oil level is not increasing , power steering
fluid is not leaking into lube oil.
Incorrect Maintenance
1. Check service maintenance records and discuss
with customer to determine if the lube oil has been Lube Oil to Coolant
overfilled unintentionally.
Symptom
If maintenance is unknown, change engine
oil and filter and retest to see if complaint An oily resid ue in engine coolant, that is apparent in
reoccurs. the deaeration tank.
Possible Causes
Dilution from Coolant Oil cooler
Lube oil with coolant dilution can be described Oil modu le
different ways, depending on the quantity of coolant Cracked oil mod ule housing
that has been introduced into the oil.
Missing/damaged oil module gasket
A milky substance left under the valve cover and
in the oil fill tube is the result of ethylene glycol Missing/damaged oil cooler gaskets
based coolant which has not had the moisture Missing mounting bolts for the oil module to the
evaporated from the coolant/oil mixture. crankcase
When the moisture has evaporated from the
coolant contaminated oil, a light g ray, thick, Tools
sludgy consistency is present. If lube oil exhibits Oil drain pan
signs of coolant dilution, go to Coolant Leak to
Lube Oil (page 85) .

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96 4 ENGINE SYMPTOMS DIAGNOSTICS

Procedure 3. Inspect for lube oil at LPCAC inlet and CAC.

1. Verify coolant is contaminated by inspecting If lube oil residue is present at LPCAC inlet,
deaeration tank for presence of oil residue. check and repair low-pressure turbocharger
• assembly following procedures in the Engine
If coolant is contaminated, continue to next
Service Manual.
step.
If lube oil residue is present at CAC and not
If no contamination is found, no repairs are
the LPCAC, check and repair high-pressure
necessary.
turbocharger assembly following procedures
2. Place a drain pan under oil module. in the Engine Service Manual.
3. Remove oil module from engine following
procedures in the Engine Service Manual.
Lube Oil to Exhaust
4. Remove oil cooler from oil module following
procedures in the Engine Service Manual. Symptom
5. Pressure test oil cooler following procedures in High lube oil consumption or restricted Diesel
the Engine Service Manual. Particulate Filter (DPF) or Diesel Oxidation Catalyst
(DOC). If the complaint is "wet exhaust" or leakage
If oil cooler fails pressure test, install a new
of exhaust system joints, verify Aftertreatment Fuel
oil cooler following procedures in the Engine
Injector (AFI) and/or system is functioning properly.
Service Manual and reinstall oil module.
Possible Causes
If oil cooler passes pressure test, replace both
oil cooler gaskets following procedures in the High-pressure turbocharger
Engine Service Manual.
Low-pressure turbocharger
• Internal engine damage
Lube Oil to Intake
NOTE: If lube oil to exhaust is determined from
one of the listed possible causes, the Oxygen
Symptom
Sensor (02S) must be replaced. See the Engine
Customer complaint of high lube oil consumption. Service Manual for 02S replacement procedures.
Perform 0 2S Calibration Procedure (page 75)
Possible Causes
anytime 0 2S is replaced.
High pressure turbocharger
Procedure
Low pressure turbocharger
1. Remove exhaust manifold with butterfly from
High crankcase pressure
low-pressure turbocharger following procedures
in the Engine Service Manual. Identify if lube
Procedure
oil is present at turbine side of low-pressure
1. Verify volume of lube oil entering intake system. turbocharger.
If residue of lube oil is present at intake air If no oil is present at exhaust outlet of
inlet, continue to next step. low-pressure turbocharger, the leak into the
• exhaust is most likely fuel. Verify the AFI
If no lube oil residue is present at intake air
and Downstream Injection (OSI) system is
inlet, the system is operating as designed and
functioning properly. Go to Fuel to Exhaust
no repair is necessary.
(page 103).
2. Remove Low Pressure Charge Air Cooler
(LPCAC) assembly following procedures in the
Engine Service Manual.

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 4 ENGINE SYMPTOMS DIAGNOSTICS 97

• If oil is present at exhaust outlet of Symptom

low-pressure turbocharger, remove
Oil pressure indicator lamp will illuminate and an alarm
low-pressure turbocharger following
will sound if oil pressure is less than 48 kPa (7 psi) with
procedures in the Engine Service Manual
engine running at or above 325 rpm.
and continue to next step.
Possible Causes
2. Inspect turbine housing on high-pressure
turbocharger and identify if lube oil is present at • Low oil level
turbine side of high-pressure turbocharger.
• High oil level/oil contamination
• If no oil is present, the leak into exhaust is
• Incorrect oil viscosity
from the low-pressure turbocharger. Install
a new low-pressure turbocharger following • Inaccurate Engine Oil Pressure (EOP) sensor or
procedures in the Engine Service Manual. circuit
• If oil is present, remove high-pressure • Restricted oil filter
turbocharger following procedures in the
• Oil sump/oil suction line damage
Engine Service Manual and continue to next
step. • Scored or damaged oil pump
3. Inspect the inside of the high-pressure turbine • Oil pressure regulator wear/damage
inlet and exhaust manifold for presence of lube
• Broken, missing, or loose piston cooling tube(s)
oil.
• Internal engine bearing wear/damage

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• If no oil is present, the leak into exhaust is
from the high-pressure turbocharger. Install • Camshaft bearing wear/damage
a new high-pressure turbocharger following
• Missing oil gallery cup plugs (front or rear)
procedures in the Engine Service Manual.
• Missing oil filter
• If oil is present, remove exhaust manifolds
from cylinder head following procedures in the • Clogged oil filter
Engine Service Manual. Pinpoint the power
• Damaged oil cooler
cylinder of concern and continue to next step.
• No rotor in the centrifuge
4. Repair power cylinder following procedures in
the Engine Service Manual for repair of specific • Soot in centrifuge filter
component.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
Low Oil Pressure software
NOTE: Oil pressure depends on oil temperature • J1939 and J1708 RP1210B Compliant Device
and on engine speed (and thus, oil pump speed).
• ZTSE4409 – Pressure Test Kit
To check oil pressure differences, unless there
is a dramatic change, you have to know the oil • Oil pressure test coupler (obtain locally)
temperature and engine speed. A typical engine
• Clean oil drain pan
speed is idle. A typical warm oil temperature is
110 °C (230 °F).

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 98 4 ENGINE SYMPTOMS DIAGNOSTICS

Procedure 4. Connect EST to vehicle's Diagnostic Connector.

WARNING: To prevent personal injury or
death, make sure the parking brake is set, the
transmission is in neutral or park, and the wheels
are blocked when running the engine in the
service bay,
WARNING: To prevent personal injury or
death, when routing test leads, do not crimp
leads, run leads too close to moving parts, or let
leads touch hot engine surfaces.
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
NOTE: Engine oil level varies depending on
temperature of engine.
5. Start ServiceMaxx™ software.
6. Using EST, verify Engine Oil Pressure (EOP),
Engine Oil Temperature (EOT) , and engine
speed differences.
• If EOP is within specification, investigate
failed or malfunctioning oil pressure gauge
on vehicle's dashboard. See appropriate
chassis service manual for diagnosing oil
pressure gauge.
• If EOP is below specification, continue to next
step.
1

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NOTE: If engine has been running, allow a 15
minute oil drain down period before checking oil
level.
1. Park vehicle on level ground and use oil level
gauge (dipstick) to check oil level.
• If lube oil is contaminated with coolant, go to
Coolant Leak to Lube Oil (page 85).
• If lube oil is contaminated with fuel, go to Fuel
in Lube Oil (page 102).
• If oil level is in specification and oil is not
contaminated, but oil pressure remains low,
continue to next step. 0000048047

2. Verify low engine oil pressure complaint by Figure 49 Oil pressure gauge connection
checking oil pressure gauge on vehicle's 1. Oil pressure test coupler.
dashboard.
• If oil pressure is within specification, no repair
7. Remove EOP sensor and install oil pressure test
is necessary.
coupler (obtain locally).
• If oil pressure is below specification, continue
8. Connect test line between oil pressure test
to next test.
coupler and 0 to 160 psi gauge on Pressure Test
3. Turn ignition switch to ON, engine OFF. Kit ZTSE4409.

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 4 ENGINE SYMPTOMS DIAGNOSTICS
9. Start engine and run to operating temperature.
Measure oil pressure at both low and high idle,
and under no load conditions.
• If oil pressure is within specifications
listed in ”APPENDIX: A PERFORMANCE
SPECIFICATIONS” and the oil pressure
gauge indicates low pressure, perform
Engine Oil Pressure (EOP) Sensor
(page 635) diagnostics in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS."
• If oil pressure is not within specification,
continue to next step.
10. Remove oil filter and inspect for debris.
• If oil filter has debris, install a new oil filter.
Inspect oil bypass valve located in oil module
housing. If debris is present in oil bypass
valve, clean bypass valve and retest system.
• If oil filter does not have debris, install new oil
filter and retest system.
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• If engine fails test, continue to next step.
11. Drain oil from engine using a clean drain pan.
Inspect oil drain plug magnet and drained oil for
debris. An oil sample can be taken to determine
level of engine wear and contaminants in oil.
12. Remove oil sump following procedures in Engine
Service Manual.
13. Inspect oil suction line for damage.
• If oil suction line is damaged, install a new
oil suction line following procedures in the
Engine Service Manual. Retest the engine for
correct oil pressure.
• If oil suction line is not damaged, install a new
oil sump following procedures in the Engine
Service Manual. Continue to next step.
99
14. Visually inspect for missing, loose, or damaged
O-rings, piston cooling tubes, and bearing inserts.
• If visual inspection identifies any concerns,
repair as necessary and retest system.
• If visual inspection does not identify any
concerns, proceed to next step.
15. Connect regulated shop air line to the oil filter
module diagnostic coupling assembly.
16. Slowly apply air pressure in 34.5 kPa (5 psi)
increments up to 345 kPa (50 psi).
NOTE: There will be loss of air at many lube
points; however, the amount of loss should not
be excessive.
17. Check for audible loss of air pressure. If air loss is
identified in the following areas, inspect and repair
the associated components as necessary:
• Front of engine right side – oil pressure
regulator, oil galley plugs
• If a continuous flow of lube oil is coming out
of the oil return port, remove and replace oil
pressure relief valve.
• Rear of engine – oil galley plugs
• Main and rod bearings
• Upper engine – camshaft bearings (removal
of the valve cover is required)
• If no leak has been found, remove front cover
of engine and inspect oil pump following
procedures in the Engine Service Manual.
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 100 4 ENGINE SYMPTOMS DIAGNOSTICS

Fuel System Chassis effects

......
iiiiii GOVERNMENT
•==• REGULATION: Engine
fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.
Excessive Fuel Consumption
Symptom
More fuel is required to perform the same task.
• Brake drag
• Cooling fan clutch locked ON
• Transmission slippage/shifting
• Fuel tank plumbing or venting
• Intake or exhaust restriction
• Aftertreatment restriction
• Clutch slipping
Engine effects
• Incorrect or inoperative thermostat(s)
• Failed turbocharger control system
• Fuel system performance loss
• Fuel system leaks
• Base engine performance loss
• Exhaust Gas Recirculation (EGR) system failure

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Possible Causes
Operator effects
• Inaccurate record keeping or tank filling
• Winter blend, kerosene, or number one diesel fuel
• Unrealistic expectations
• Excessive transient behavior
Application effects
• Heavy loading Gross Vehicle Weight (GVW)
• Low rear axle ratio
• Large frontal area
• Accessory usage (such as Power Takeoff)
• Additional equipment drawing fuel from vehicle
fuel tanks
• Extended idle applications
• Tire size, tire condition, or air pressure
• Engine Throttle Valve (ETV) system failure
Procedure
1. Review operator records and fueling procedures.
Measurement errors are common. Fuel
consumption taken only from one tank of use is
susceptible to significant error because of filling
procedures and vehicle application differences
during operation. Accurate fuel consumption
must be measured over time with a record of what
the vehicle was doing during the measurement
period.
NOTE: Loss of fuel economy is normal if winter
blend fuel, kerosene, or number one diesel fuel is
being used.
2. Review vehicle specifications to determine if fuel
consumption is normal for type of application and
use of vehicle. Compare consumption with similar
vehicles in the same application and TCAPE
report.

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 4 ENGINE SYMPTOMS DIAGNOSTICS 101

3. Do all tests on Performance Diagnostics form or in Procedure

“PERFORMANCE DIAGNOSTICS” section (page
1. Isolate and test any add-on coolant heated
147).
auxiliary fuel filter per manufacturer's instructions.
These tests verify the operating condition of the
• If leak is found, install a new coolant
following engine and chassis systems:
heated auxiliary fuel filter per manufacturer's
• Intake system instructions.
• Exhaust system • If no leak is detected, continue to next step.
•
•
Fuel delivery and filtration
High pressure fuel system
A WARNING: To prevent personal injury
or death, do the following when removing the
• Injector operation radiator cap or deaeration cap:

• EGR system operation • Allow engine to cool for 15 minutes or more.

• ETV system operation • Wrap a thick cloth around radiator cap or

• Boost pressure actuator operation
• Base engine condition
• Electronic control system condition
If all tests are passed, engine is operating
deaeration cap.
• Loosen cap slowly a quarter to half turn
counterclockwise to vent pressure.
• Pause for a moment to avoid being scalded by
steam.

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normally. • Continue to turn the cap counterclockwise to
remove.

Fuel in Coolant 2. Remove deaeration tank cap.

3. Fill deaeration tank with coolant to a level above
Symptom deaeration tank inlet.
Coolant has a diesel fuel odor. NOTE: Do not reinstall deaeration cap at this time.
Possible Causes 4. Disconnect electrical connector to Aftertreatment
• Leaking coolant heated auxiliary fuel filter (if Fuel Injector (AFI).
equipped) 5. Disconnect fuel supply line from AFI.
• Cracked or porous cylinder head casting in fuel 6. Connect a regulated air pressure source to fuel
return area inlet of AFI and pressurize to 207 kPa (30 psi) for
• AFI up to 20 minutes.

Tools • If air bubbles are observed at deaeration

tank, install a new AFI following Hydrocarbon
• ZTSE4409 – Pressure Test Kit Injector installation procedure in the Engine
• Regulated air pressure Service Manual.
• If no air bubbles are present at deaeration
tank, continue to next step.

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 102 4 ENGINE SYMPTOMS DIAGNOSTICS
Figure 50 Compressed air source connected to
cylinder head
7. Remove hollow screw at the rear of cylinder head
and adapt compressed air source to cylinder
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head.
8. Pressurize cylinder head to 550 to 690 kPa (80 to
100 psi) for up to 20 minutes.
9. Observe deaeration tank for air bubbles or loss
of pressure at gauge. If air bubbles are observed
at deaeration tank, install a new cylinder head
following procedures in the Engine Service
Manual.
Fuel in Lube Oil
Symptom
Oil has a diesel fuel odor and engine oil level in
consistently increases.
Possible Causes
• Fuel injector(s)
• Cylinder misfire (wash down)
• High pressure fuel lines
Tools
• ZTSE4618 – UV Leak Detection Kit
• 15-637-01 – Clean Fuel Source Tool
• UV Leak Detection Fluorescent Dye Cartridge
Procedure
1. If engine has a misfire, see Special Test
Procedures (page 165) in ”PERFORMANCE
DIAGNOSTICS." Use procedures in the Engine
Service Manual for repair of specific components.
2. Verify oil contamination by performing a white
paper test or oil analysis. Place one drop of
suspected diluted oil on a clean sheet of printer
or copier paper.
• If oil wicks away rapidly into the paper, there
is fuel contamination.
• If oil maintains a uniform and slow expanding
stain, there is no fuel contamination.
3. Inspect fuel system for leaks.
NOTE: The UV Leak Detection Kit ZTSE4618
requires warm-up time. Turn on UV Leak
Detection Kit.
NOTE: Before starting dye test, verify there is no
dye in oil.
4. Using Clean Fuel Source Tool 15-637-01, supply
engine with an alternate supply of clean diesel fuel
with dye mixed to manufacturers specification.
5. Start and run engine at high idle for a maximum
of 5 minutes. Turn engine OFF.
6. Using the UV Leak Detection Kit ZTSE4618,
inspect for leaks in the following areas:
• High-pressure pump front seal. If a leak
is found, replace fuel pump following
procedures in the Engine Service Manual.
To prevent damage to a newly installed fuel
pump and to verify high back pressure did not
cause fuel pump to fail, perform HP Pump
Fuel Return Pressure Test (page 139) any
time fuel pump is replaced.
• Injector body. Remove valve cover following
procedures in the Engine Service Manual.
If a leak is found, replace fuel injector and
pressure pipe neck following procedures in
the Engine Service Manual.
• If no leaks are found, take an oil sample for
analysis and monitor engine oil level.
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 4 ENGINE SYMPTOMS DIAGNOSTICS 103

Fuel to Intake Procedure

1. Disconnect fuel line from AFI.
Symptom
Fuel leaking into the intake results in black smoke and
eventual Diesel Particulate Filter (DPF) Diagnostic
A WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Trouble Codes (DTCs). Limit compressed air pressure to 207 kPa (30 psi).

Possible Causes 2. Connect regulated air pressure with a shut off

• Inlet Air Heater Fuel Solenoid (IAHFS) valve
• IAHFS valve control
Procedure
1. If engine has a misfire, see Special Test
Procedures (page 165) in “PERFORMANCE
DIAGNOSTICS."
2. Disconnect electrical connector from IAHFS
valve.
3. Disconnect fuel supply line from Inlet Air Heater
Fuel Igniter (IAHFI).
valve to fuel inlet of AFI and pressurize to 207 kPa
(30 psi).
3. Close shut off valve and monitor air pressure for
two minutes.
• If air pressure drops, install a new AFI
following Hydrocarbon Injector installation
procedure in the Engine Service Manual.
• If pressure remains constant, continue to next
step.
4. If engine has a misfire, see Special Test
Procedures (page 165) in “PERFORMANCE
DIAGNOSTICS”.

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4. Pump fuel primer pump while checking IAHFS 5. Remove exhaust manifold from cylinder head
valve for fuel leakage. following procedures in the Engine Service
5. Start engine and run at low idle. Check for fuel Manual and pinpoint the power cylinder of
leakage from IAHFS valve. concern.

• If leakage is observed, install a new IAHFS

valve following procedures in the Engine Fuel Pressure and Aeration
Service Manual.
• If no leakage is observed, check the IAHFS Symptom
valve control circuit. See IAHFS (Inlet Fuel aeration exhibits one or more of the following
Air Heater Fuel Solenoid) (page 421) in characteristics:
“ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS”. • Engine stall during operation
• Rough running engine
Fuel to Exhaust • Extended engine crank time (hard start)
• Fuel pressure slow to build while cranking
Symptom
• Excessive fuel pressure while cranking
Wet exhaust system and possible damage to the
Diesel Particulate Filter (DPF). • Pulsating fuel pressure during crank or engine
running at idle.
Possible Causes
• Difficulty priming fuel system
• AFI
Possible Cause
• Internal engine damage
• Leaks in fuel supply to fuel pump
Tools • Loose fuel injector hold down
Regulated air pressure source with shut off valve • Missing/damaged fuel injector sealing washer

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 104 4 ENGINE SYMPTOMS DIAGNOSTICS

Procedure 1. Place drain pan under filter housing.

If aeration is suspected, go to Fuel System (page 126)
in “HARD START AND NO START DIAGNOSTICS.”
Water in Fuel
Symptoms
Water in fuel exhibits one or more of the following
characteristics:
• Water in fuel shown in Integral Digital Display
• Low power
• Engine stall during operation
• Rough running engine
• No start if water has frozen
Possible Causes
• Water in fuel supply system
2. Drain water separator following procedures in the
Engine Operation and Maintenance Manual.
3. Check fuel in drain pan for engine coolant or other
contamination. Dispose of the contents in the
drain pan in accordance with local requirements.
• Excessive water or contaminants may
indicate the tank and fuel system need to be
flushed and cleaned.
• Some sediment and water may be present
if fuel filter has not been replaced for a long
period of time, or if sediment and water have
not been drained recently.
• Fuel should be clear and not cloudy. Cloudy
fuel indicates that fuel is not a suitable grade
for cold temperatures.
• The fuel should not be dyed red or blue, these
colors indicate off-highway fuel.

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• Fuel should not show evidence of waxing
• Ice in fuel lines
or gelling. Waxing or gelling of some fuels
in cold weather could clog fuel filters and
Tools
fuel pump and cause restrictions or low fuel
Clean, flat drain pan with a wide opening pressure.
4. If fuel sample indicates water in fuel, obtain a fuel
Procedure
sample from fuel tanks.
WARNING: To prevent personal injury or • If fuel sample indicates water in fuel, drain fuel
death, do not let engine fluids stay on your skin. tanks, and refill tanks with clean fuel.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

WARNING: To prevent personal injury or

death, do not mix gasoline, gasohol, or alcohol
with diesel fuel. An open heat source, spark, cell
phone, or electronic device can ignite these fuel
mixtures. This creates a fire hazard and possible
explosion.

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 4 ENGINE SYMPTOMS DIAGNOSTICS
Priming the Fuel System
WARNING: To prevent personal injury or
death, do not smoke and keep fuel away from
flames and sparks.
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.
CAUTION: To prevent engine damage, do not
manually actuate the Fuel Pressure Control Valve
(FPCV) to build fuel rail pressure, if the engine will
not start. This can damage internal parts in the
high-pressure pump.
CAUTION: To prevent damage to engine, plug
component connections immediately after each fuel
line is removed using clean fuel system caps.
NOTE: If fuel system will not prime during
diagnosis and engine exhibits pulsating fuel
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pressure, see Low Pressure Fuel System
(page 127) in “HARD START AND NO START
DIAGNOSTICS”.
Procedure
Prime fuel system when the following conditions
occur:
• Fuel tank is drained or runs dry
• Primary fuel filter is removed or replaced
• Any fuel connection between fuel tank and
secondary fuel filter is broken
• Secondary fuel filter is removed or replaced
• High-pressure fuel system is serviced
1. Ensure all fuel system connections are secure
and proper fuel filters are installed.
2. Ensure battery is fully charged or install battery
charger.
105
3. Turn ignition switch to ON, engine OFF.
4. Connect EST to vehicle's Diagnostic Connector.
5. Start ServiceMaxx™ software.
6. Prime suction side of low-pressure fuel system:
a. Tighten primary fuel filter components that
were removed (canister filter element, seals,
or bowl) to specified torque values.
b. Unscrew piston knob on fuel primer pump
assembly and start pumping until fuel
pressure builds up on delivery side of fuel
primer pump. Pressure build up is indicated
by higher pumping force on piston knob.
c. Fully screw piston knob back in when priming
is complete.
CAUTION: To prevent damage to the starter, if engine
fails to start within 20 seconds, release ignition switch
and wait two to three minutes to allow starter motor to
cool.
7. Engage starter for 20 seconds and allow starter to
cool for two minutes.
8. If engine does not fire during the first two cranking
attempts, use EST to monitor Fuel Delivery
Pressure (FDP) during third cranking attempt.
a. If pressure does not build up during third
cranking attempt, unscrew primary filter cap
and separate filter element from filter cap.
b. Ensure filter element is fully seated on
standpipe.
c. Reassemble primary fuel filter assembly.
9. Engage starter for 20 seconds and monitor FDP
sensor using EST with ServiceMaxx™ software.
• If engine does not start and there is no
increase in pressure, allow starter to cool for
two minutes, then repeat steps 6 and 7.
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 106 4 ENGINE SYMPTOMS DIAGNOSTICS

10. Using EST with ServiceMaxx™ software, prime 11. Engage starter for 20 seconds to purge any
fuel system. If engine does not fire after five trapped air from high-pressure pump. Allow
crank events, using EST with ServiceMaxx™ starter to cool for two minutes.
software, select Tests > KOEO Tests > Actuator
12. Reenergize FPCV. Engage starter for 20 seconds
Test. Then select Fuel Pressure Control Valve
and allow starter to cool for two minutes.
from the drop down menu, de-energize the FPCV
in the high-pressure pump by setting the duty
cycle to 5%.
NOTE: De-energizing the FPCV closes the valve
and controls the valve at the lower limit of 6.7%
Pulse Width Modulation (PWM) signal. This allows
all fuel delivered by the internal transfer pump
to go to the high-pressure pump and allows for
minimum high-pressure pump outlet pressure,
making refilling easy.

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 4 ENGINE SYMPTOMS DIAGNOSTICS
Engine Brake System
Engine Brake Inspection
Symptom
Engine exhibits no de-accelerator in vehicle
performance.
WARNING: To prevent personal injury or
death, read all safety instructions in the Engine
Service Manual.
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.
WARNING: To prevent personal injury or
death, make sure that the engine has cooled
before removing components.
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WARNING: To prevent personal injury or
death, do not let engine fluids stay on the skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
Possible Causes
The engine brake exhibits one or more of the following
characteristics:
• ON/OFF switch malfunctioning
• Engine Brake lash adjustment (one or more
cylinders out of adjustment)
• Low engine oil pressure (insufficient supply of oil
pressure to operate engine brake)
• Engine boost pressure is low while braking, below
20 psi @ 2100 rpm with the engine brake on high
• Lubricating oil is too cold or thick
• Improper slave piston adjustment or slave piston
binding in bore
• Master piston not moving in bore
• Control valves defective or binding in housing
bore
• Engine brake housing plugs leaking
107
• Outer control valve springs broken or engine oil
pressure extremely high
• Housing pipe plug(s) missing
• Aeration in lubricating oil
• Lubricating oil being diluted by fuel oil
• Low engine oil level
• Worn engine rocker lever bushings
• Restrictions in the engine oil passages leading to
engine brake
Tools
• ZTSE4357 – Digital Multimeter (DMM)
• ZTSE6076–5A – Lash Gauge (0.50mm)
• ZTSE6076–7A – Lash Gauge (0.80mm)
Preliminary Steps
WARNING: To prevent personal injury or
death, wear safely glasses with side shields.
1. Before starting engine brake troubleshooting
procedures, check the following:
a. Check engine oil level on dipstick. Over or
under filled condition in crankcase will cause
aeration in the engine brake hydraulic system.
b. Check the condition of engine lubricating oil
for presence of fuel, water, or both. This
indicates engine problems and must be
corrected.
c. Check turbocharger, air cooler, piping, and
intake manifold leakage. Any loss of pressure
will cause a reduction in engine brake power
output.
2. Before inspecting engine brake housing,
remove over-engine equipment such as air
intake, turbocharger crossover pipes, and valve
mechanism upper covers. Follow procedures in
the Engine Service Manual.
a. Inspect pipe plugs on housing ends where
applicable, to make sure none are missing.
Use Jacobs pipe plugs, Part Number 028317
torqued to 11 N•m (100 lb-in).
b. Remove upper valve cover, following
procedures in the Engine Service Manual.
111
 108 4 ENGINE SYMPTOMS DIAGNOSTICS
c. Check for cracks in engine brake housing.
d. Check for loose, damaged, brittle, or cracked
wiring, or connections at engine brake
solenoid.
e. Check for loose or damaged hold down bolts.
f. Check exhaust bridges and actuator pins.
Actuator pins should move freely with no
signs of distress.
g. Check engine brake slave piston setting of 0.8
mm and engine valve settings.
NOTE: When operating the engine brake with the
valve cover removed, be aware that there will be
a significant amount of oil spray in this area. This
engine brake has separate drilling to lubricate
the master piston roller area. This adds to the oil
spray in the area, but does not indicate leakage
or a problem with the oil supply needed for
engine brake operations. These are two separate
systems within the engine brake housing.
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A WARNING: To prevent personal injury or
death, wear safely glasses with side shields.
A WARNING: Whenever engine is running and
valve cover is removed, lubrication oil splashing
in the engine brake could cause personal injury.
Engine Brake does not Turn on/Slow to Turn On
3. If supplied voltage to engine brake solenoids is 8.4
V DC or lower, check ECM input sensors.
a. Harness failure: Check continuity from each
engine brake solenoid to engine ground.
Must be “open” (no connection). Repair
harness as required.
b. Engine brake solenoid resistance: Between
8.7 and 10 Ω at 25 °C (77 °F). If resistance
is out of specifications, replace engine brake
solenoid assembly.
Engine Brake Solenoid Specifications
Engine Temperature Ohms
Cold: 25 °C (77 °F) 8.7 – 10
Hot: 121 °C (250 °F) 12 – 15.5
4. Check resistance from ECM 96-pin to ECB
harness connector.
5. Check resistance from Engine Compression
Brake 1 (ECB1) and Engine Compression Brake
2 (ECB2) to ECB harness connector.
6. Check resistance from each terminal to engine
brake solenoid can. This should be an "open
circuit." If a resistance is measured, replace
engine brake solenoid assembly.
7. Check continuity from each engine brake solenoid
to engine ground. Must be “open circuit” (no
connection). Repair harness if required.
8. Check upper and lower engine brake solenoid
seal rings for leaks or damage. Replace if
necessary.
9. Check engine brake solenoid valve, screen, and
engine brake solenoid seal rings. Replace if
necessary.
• Shake the engine brake solenoid, a distinct
rattle should be heard. This will indicate free
component movement. Move poppet stem
(the pin exposed on the bottom of the engine
brake solenoid) to confirm it moves freely. If
poppet stem does not move freely or a distinct
rattle can not be heard, replace engine brake
solenoid.
Engine Brake does not Turn Off/Slow to Turn Off
10. Check ECM input sensors, repair if necessary.
11. Check undercover wiring and engine brake
solenoid connectors for short(s).
• Check continuity from each engine brake
solenoid to engine ground. Must be “open
circuit” (no connection). Replace wiring
harness or engine brake solenoid if required.
12. Check for low Engine Oil Pressure (EOP).
• Determine oil pressure at engine brake
housing using procedures given in this
section. If EOP is below specifications, but
engine brake housing oil pressure is 138
kPa (20 psi) and engine is at operating
temperature, engine should be repaired
before proceeding to next step.
Engine Fails to Start
13. If engine brake solenoid valve is stuck in the ON
position, see diagnostics above.
112
 4 ENGINE SYMPTOMS DIAGNOSTICS 109

Engine Brake Weak in Effect or Low on Engine
Brake Power
14. Check engine boost pressure while braking. If
boost pressure is below 138 kPa (20 psi) @ 2100
rpm with the engine brake on high, check engine
brake adjustment. If out of specification, see
procedure below.
NOTE: To get boost pressure, the vehicle has
to be road tested.
15. Check turbocharger for proper output. Inspect
Charge Air Cooler (CAC) and piping for any
exhaust leakage or intake restrictions.
Engine Brake Slow to Operate or Weak in Effect
NOTE: Allow engine to warm before operating
engine brakes.
16. Check for improper slave piston adjustment or
slave piston binding in bore.
• If slave piston adjustment is incorrect or
slave piston is binding in bore, readjust slave
piston clearance lash setting to 0.8 mm.
Ensure slave piston responds smoothly to
the adjusting screw by loosening jam nut and
moving adjusting screw through its full travel
and for a full slave piston motion. Ensure
piston travels full range without any binding
or sticking.
NOTE: Master Piston Assembly – This is not a
serviceable group. No attempt should be made to
disassemble this group from the brake housing.
17. Check control valves for binding in housing bore.
• Remove control valve. If body is
scored, replace control valve. Check for
contaminants in lube oil. Clean housing and
control valve. If binding continues, replace
housing.

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18. Check control valve for defects.
• Remove control valve. Ensure check ball
is seated in bore and can be moved off
seat. Ensure there is spring pressure against
ball. Flush in cleaning solvent. Replace if
necessary.
19. Check engine brake housing plugs for leakage.
• If leaks are present, remove plug, clean
threads, and install at 11 N•m (100 lbf-in).
20. Check outer control valve springs for damage.
Figure 51 Engine Brake Assembly
1. Adjusting screw
2. Jam nut
3. Actuator pin (in exhaust valve bridge)
4. Slave piston

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 110 4 ENGINE SYMPTOMS DIAGNOSTICS

Oil Pressure Dropping Below Minimum Required 24. Check engine oil level. See Visual Oil Level
for Engine Brake Operation Inspection (page 95).
25. Check for worn engine rocker lever bushings.
Engine Brake Oil Pressure Requirements
Replace if necessary.
Model Control Control Full Over
26. Check for restrictions in engine oil passages
Valve Valve Flow Pressure
leading to engine brake. Inspect all passageways.
Spring PSI PSI
Repair if necessary.
5783 11930 037215 20-55 80
/ One or More Cylinders Fail to Stop Braking or
019632 Engine Stalls

NOTE: For proper engine brake operation, oil
pressure at engine brake housing must be 138
to 172 kPa (20 to 25 psi) with engine at operating
temperature and running between 1000 rpm and
governed engine speed.
21. Check for missing housing pipe plug(s).
• Check all housing pipe plugs, replace as
needed, and torque to 11 N•m (100 lbf-in).
27. Check control valve inner spring for damage.
Replace if necessary.
28. If one or more control valves are stuck in the ON
or UP positions, check control valves for binding.
• Remove, clean, or replace if necessary.
• Inspect lubricating oil for contaminants.
Engine Misses or Loses Power

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22. Aeration of lubricating oil.
• Check for aeration, activate, and then
deactivate engine brake. Watch escape oil
coming from control valve cover. If there are
air bubbles in the oil, or if the oil is white and
foamy, air is present in system. Aeration can
be caused by the crankcase being too full
of oil, too low on oil, or a problem with the
engine oil pump or pick up tube.
23. Lubricating oil being diluted by fuel oil.
29. If slave piston adjustment is tight, readjust slave
piston clearance to lash setting of 0.8 mm.
30. If engine brake solenoid is stuck in ON position,
see procedure above.
31. If control valve is sticking or dragging in bore,
clean control valve and bore. Replace if
necessary.
32. Check control valve spring for damage. Replace
if necessary.

• Obtain an oil sample to determine if fuel

is present. See Engine Operation and
Maintenance Manual for procedures on
obtaining an oil sample.

114
 5 HARD START AND NO START DIAGNOSTICS 111

Table of Contents

Diagnostics Form EGED-475. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Diagnostics Form Vehicle Information and Complaint Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Required Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

1. Initial Key ON Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
2. Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Engine Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Intake Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Charge Air Cooler (CAC) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Air Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Fuel Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Fuel Line Routing and Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Primary Fuel Filter Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

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Fuel Quality Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
3. Electronic Service Tool (EST) Connection and Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
4. Check for Diagnostic Trouble Codes (DTCs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
5. Engine Cranking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Special Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Low-pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Fuel Delivery Pressure (FDP) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Fuel Dead Head Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Fuel Aeration Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Fuel Restriction Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
High-pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Fuel Rail Pressure (FRP) Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
High-pressure Pump Inlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Fuel Rail Pressure (FRP) Return Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Fuel Rail Pressure (FRP) Leak Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
HP Pump Fuel Return Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
HP Pump Return Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Inlet Air Heater System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Inlet Air Heater Fuel Igniter (IAHFI) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Fuel Supply at Inlet Air Heater Fuel Solenoid (IAHFS) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Fuel Supply at Inlet Air Heater Fuel Igniter (IAHFI) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

115
 112 5 HARD START AND NO START DIAGNOSTICS

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116
 5 HARD START AND NO START DIAGNOSTICS 113

Diagnostics Form EGED-475

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V001688

Figure 52 Diagnostics Form EGED-475 (Hard Start and No Start)

The Hard Start and No Start Diagnostics Form directs out of sequence can cause incorrect results. If the
technicians to systematically troubleshoot a hard start customer complaint is found and corrected, it is not
or no start condition and avoid unnecessary repairs. necessary to complete the remaining tests.
This Diagnostic Manual section shows detailed See appropriate section of this manual for Diagnostic
instructions of the tests on the form. The manual Trouble Codes (DTC's) and engine specifications.
should be used with the form and referenced for
To order technical service literature, contact your
supplemental test information. Use the form as a
International dealer.
worksheet to record test results.
Do Required Test Procedures in sequence, and do
Special Test Procedures when needed. Doing a test

117
 114 5 HARD START AND NO START DIAGNOSTICS

Diagnostics Form Vehicle Information and

Complaint Page

Note: This form must be completed before calling for technical assistance.
Technician: Date: Rated Power:

Software Identification: Total Miles:

Vehicle Identification Number:

Engine Serial Number:

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EDC Customer Unit Number:

Transmission Type (select one) :

• Automatic

Complaint:

0000047998

118
 5 HARD START AND NO START DIAGNOSTICS 115

1. Fill in the following information: • EDC Customer Unit Number

• Technician • Complaint (driver interview)
• Date NOTE: Remaining information will be filled in later
using information from the Electronic Service Tool
• Vehicle Identification Number (VIN)
(EST) with ServiceMaxx™ software.

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119
 116 5 HARD START AND NO START DIAGNOSTICS

Required Test Procedures 1. Initial Key ON Check

NOTE: The engine requires a starting aid when
Purpose
temperatures are below 11°C (52°F). If this is an
inlet air heater problem, verify that the Inlet Air Determine if Engine Control Module (ECM) is powered
Heater is working before continuing. See Inlet Air up and if water is in fuel supply.
Heater System Test (page 140).
Tools
....... None
iiiiii GOVERNMENT REGULATION: Engine
•==•
fluids (oil, fuel, and coolant) may be a hazard Procedure
to human health and the environment. NOTE: Water in Fuel (WIF) sensor is optional.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance 1. Turn ignition switch to ON, engine OFF. Observe
with applicable regulations. Recycle the following:
or dispose of engine fluids, filters, and • Wait to Start Lamp
other contaminated materials according to
applicable regulations. • Water In Fuel Lamp
2. Record results on Diagnostics Form.
• If Water In Fuel Lamp stays ON, go to Fuel
WARNING: To prevent personal injury or Quality Check (page 120).

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death, read all safety instructions in the “Safety
Information” section of this manual.
2. Visual Inspection
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin. Purpose
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing Check all fluid levels and inspect engine systems
and rags contaminated with engine fluids. for problems such as leaks, open connections, and
harness chaffing.
WARNING: To prevent personal injury or
Tools
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing None
diagnostic or service procedures.

WARNING: To prevent personal injury or Engine Oil

death, do not smoke and keep fuel away from 1. Park vehicle on level ground and check oil level.
flames and sparks.
NOTE: API CJ-4 oils are recommended for
high speed diesel engines with advanced
WARNING: To prevent personal injury or
exhaust aftertreatment systems that meet
death, provide proper ventilation when operating
2007 and beyond on-highway exhaust
an engine in a closed area. Inhalation of exhaust
emission standards.
gas can be fatal.

120
 5 HARD START AND NO START DIAGNOSTICS
Figure 54 Lube oil requirements label
2. Use oil level gauge (dipstick) to verify engine oil
level.
3. Check engine oil quality. Check for contamination
or fuel dilution.
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NOTE: If oil is contaminated or diluted, oil and
filter must be replaced.
4. Record results on Diagnostics Form.
• If level is below specification, inspect for
leaks, oil consumption, or improper servicing.
If engine oil level is low, fill to specification.
• If level is above specification, inspect for
fuel dilution, coolant contamination, or
improper servicing. If engine oil level is
above specification, drain to proper level and
diagnose contamination.
117
Engine Coolant Level
1. Park vehicle on level ground.
NOTE: Turn engine OFF and allow to cool.
Ensure coolant temperature has stabilized to safe
temperature and pressure.
2. Check coolant level that is indicated on deaeration
tank level window.
NOTE: Coolant in the exhaust could damage the
DPF. Inspect DPF for damage. See AFT System
(page 217) in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS” for inspection of the DPF.
3. Record results on Diagnostics Form.
• If coolant level is above or below deaeration
tank fill level, inspect for leaks, coolant in oil,
coolant in combustion exhaust, or improper
servicing.
• If coolant is contaminated, replace coolant.
Electrical System
1. Inspect batteries and electrical system (engine
and vehicle) for poor or loose connections,
corroded terminals, or broken and damaged
wires.
2. Record results on Diagnostics Form.
• If electrical system problem is found, make
necessary repairs.
Intake Air
NOTE: Intake air restriction should be less than
172.3 kPa (51 in Hg) at full load, rated speed.
1. Inspect air filter gauge, located on air filter housing
or dashboard.
2. Record results on Diagnostics Form.
• If gauge indicates air filter requires
replacement, verify there are no other
restrictions in the air inlet or filter housing
before replacing air filter.
Charge Air Cooler (CAC) System
1. Inspect CAC, interstage cooler, and all piping for
leaks.
121
 118 5 HARD START AND NO START DIAGNOSTICS

2. Inspect all CAC connections and clamps. 2. Check instrument panel fuel gauge, look into fuel
tanks to verify fuel level, and make sure fuel levels
• If CAC system problem is found,
are equal in both tanks.
make necessary repairs. See Coolant
Over-Temperature Conditions Inspection 3. Record results on Diagnostics Form.
(page 87) in “ENGINE SYMPTOMS
• If fuel gauge reads above empty, but fuel
DIAGNOSTICS.”
tanks are empty, diagnose fuel gauge. Verify
sufficient fuel level before diagnosing a
pressure problem.
Exhaust System
• If fuel tanks is empty, add fuel and prime
1. Inspect exhaust system (engine and vehicle) for
fuel system. See Fuel System Priming (page
restrictions, leaks, or damage.
128).
2. Record results on Diagnostics Form.
• If fuel level is within specification, go to
• If exhaust system problem is found, make Primary Fuel Filter Inspection.
necessary repairs.

Fuel Line Routing and Condition

Air Tanks 1. With engine OFF, visually inspect the condition
1. Inspect vehicle air tanks for water. and routing of fuel lines.

• If water is found, drain water from air tanks. • If fuel lines are damaged or routed incorrectly,

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repair or replace as necessary.
• If fuel lines are in good condition and routed
Fuel Level correctly, go to Primary Fuel Filter Inspection.

A WARNING: To prevent personal injury or

death, do not smoke and keep fuel away from Primary Fuel Filter Inspection
flames and sparks.
Visually inspect primary fuel filter condition following
1. Park vehicle on level ground. the inspection table on next page.

122
 5 HARD START AND NO START DIAGNOSTICS 119

Fuel Level Visual Indication Possible Solution

Fuel level below top of fuel Normal - no repair necessary.

C
filter.

V1502 1

Fuel level above top of fuel Change primary fuel filter element.

Q V150 13
filter. May cause loss of
power complaint.

Fuel level is to top of fuel 1. Change primary fuel filter element

filter and looks to be full of
2. Run engine for a minimum of 25 minutes at idle. Do not
wax.
run at high idle.

V 150 14

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Bubbles are seen flowing 1. Check all fittings and lines from between fuel tank and
ff] within fuel. chassis fuel filter assembly.
2. Check upper and lower connector O-rings.

M V 15015

Loss of power complaint. 1. Check for missing grommet at lower end of filter.

Q V150 16
Fuel level is below fuel filter
housing collar.
2. Check for missing or broken spring at top of primary fuel
filter element.

Water is seen (noticeable 1. Inspect fuel tank(s) for water contamination.

Q V150 17
separation) in fuel filter
assembly.
2. Drain a full cup of fuel from chassis fuel filter assembly.
NOTE: Do not drain with engine running.
3. Restart engine. Shut off engine and drain chassis fuel filter
assembly.
4. Repeat step 3 until ALL water is removed.
Fuel drains back to fuel tank 1. Remove and inspect check valve assembly.
when changing fuel filter or
2. Repair (clean) or replace as necessary, and retest.
draining water separator.

123
 120 5 HARD START AND NO START DIAGNOSTICS

Fuel Quality Check

Purpose
Check for poor fuel quality or contaminants.
Tools
• Clear diesel fuel container
• Clear plastic hose

Procedure
NOTE: Ultra Low Sulfur Diesel (ULSD) fuel is
®
required for MaxxForce 11 and 13 diesel engines
used with advanced aftertreatment systems.

ULTRA-LOW SULFUR
HIGHWAY DIESEL FUEL
(1 S ppm Sulfur Maximum) Figure 56 Fuel sample
Required for use in all model year

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2007 and later highway diesel
vehicles and engines. 1. Install clear plastic hose on fuel drain valve.
Recommended for use in all diesel
vehicles and engines.
2. Route clear plastic hose into clear diesel fuel
container.
K35145
3. Open fuel drain valve to fill container.
Figure 55 Fuel requirements label NOTE: If fuel does not flow, crank engine.
4. Check for water, waxing, icing, sediment,
NOTE: WATER IN FUEL indicator illuminates ON, gasoline, kerosene, or Diesel Exhaust Fluid (DEF)
then OFF, on the Integral Digital Display if there by shaking fuel sample container and letting
is no water in the system. If WATER IN FUEL contents settle. Record results on Diagnostics
indicator stays ON, water is detected. Form.
NOTE: Do not continue diagnostic procedures
with contaminated fuel.
• Sediments will fall to bottom of fuel sample
container.
• Gasoline and kerosene will separate from
diesel fuel.
• Waxing or icing will prevent diesel fuel from
flowing out of fuel drain valve.
• If fuel quality is questionable, repair as
necessary. Take another sample to verify fuel
quality is satisfactory.
• If fuel quality is satisfactory, continue to
Electronic Service Tool (EST) Connection
and Data Recording test.

124
 5 HARD START AND NO START DIAGNOSTICS
5. Inspect fuel strainer for debris. The fuel strainer
is located in the fuel primer pump assembly.
3. Electronic Service Tool (EST) Connection and
Data Recording
Purpose
Check Engine Control Module (ECM) software,
sensor signals and DTCs, and to record additional
vehicle information on Diagnostics Form.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
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121
• J1939 and J1708 RP1210B Compliant Device
Procedure
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
• If unable to communicate with the ECM, see
the ServiceMaxx™ Users Guide.
• If unable to communicate with the ECM
and no problems are found using the
ServiceMaxx™ Users Guide, go to J1939
Data Link (page 804) in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.”
125
 122 5 HARD START AND NO START DIAGNOSTICS

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l'Wl II.ell fttNQtt lH.4 'Dal
Idle Vtl1datlQCI MCCII Zdl•
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V00133a

Figure 57 ServiceMaxx™ startup screen – vehicle connected

4. Verify the following vehicle information matches • Rated Power

the displayed information in ServiceMaxx™
• Total Miles
software and record on Diagnostics Form:
• Engine On Time
• Software Identification
NOTE: The engine serial number is located
• Vehicle Identification Number (VIN)
on the front left side of the crankcase, below
• Engine Serial Number (ESN) the cylinder head. It is also on the engine
emission label on the valve cover.
• Transmission Type

126
 5 HARD START AND NO START DIAGNOSTICS
5. Record the following Key ON, Engine OFF
(KOEO) temperature sensor values on
Diagnostics Form:
NOTE: If possible, allow the engine to cold
soak for at least 8 hours before recording
results.
NOTE: The engine requires a starting aid when
temperatures are below 11° C (52° F). If this
is an inlet air heater problem, verify Inlet Air
Heater is working before continuing. See Inlet
Air Heater System Test (page 140).
• Inlet Air Temperature (IAT)
• Engine Coolant Temperature 1 (ECT1)
• Engine Coolant Temperature 2 (ECT2)
• Engine Oil Temperature (EOT)
6. Record the following KOEO pressure sensor
values on Diagnostics Form:
• Fuel Rail Pressure (FRP)
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• TC1 Turbine Outlet Pressure (TC1TOP)
• Fuel Delivery Pressure (FDP)
• Intake Manifold Pressure (IMP)
• Barometric Pressure (BARO)
• DPF Differential Pressure (DPFDP)
123
7. Look for sensor values that are out of
specification. A sensor out of specification could
cause abnormal operating behavior, incorrect
fueling, and injection timing problems.
• If sensor is out of specification, go to the
suspect sensor in “ELECTRONIC CONTROL
SYSTEMS DIAGNOSTICS.”
• If sensors are within specification, continue to
next step.
8. Use ServiceMaxx™ software to run Actuator Test.
9. Record EGR Valve Position and Engine Throttle
Position values at 5% (closed) and 95% (open)
on Diagnostics Form.
• If either signal is not within specification, go
to the suspect actuator in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.”
10. Look for sensor values that are not within
specification. A sensor out of specification could
cause air management problems.
11. Make sure vehicle air tanks are full before
proceeding to next step.
12. Use ServiceMaxx™ software to run Actuator Test.
13. Visually monitor movement of Exhaust Back
Pressure Valve (EBPV). Record results on
Diagnostics Form.
NOTE: ServiceMaxx™ software does not have
an EBPV feedback position signal.
• If EBPV does not move, go to Exhaust
Back Pressure Valve (page 163) in
“PERFORMANCE DIAGNOSTICS.”
14. Use ServiceMaxx™ software to monitor DPF
status. Record results on Diagnostics Form.
• If DPF status is Regen needed - critical
level, disconnect exhaust system upstream
of Pre-Diesel Oxidation Catalyst (PDOC) and
attempt to start engine. If engine starts, go
to AFT System (page 217) in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.” If
engine does not start, continue with Hard
Start and No Start diagnostics.
127
 124 5 HARD START AND NO START DIAGNOSTICS

4. Check for Diagnostic Trouble Codes (DTCs) 2. Connect EST to vehicle's Diagnostic Connector.
NOTE: 2010 model year vehicles no longer utilize 3. Start ServiceMaxx™ software.
DTC identification by number. DTCs are now
identified using the SPN and FMI identifiers only.
These two identifiers, known as the Suspect
Parameter Number (SPN) and the Failure Mode
Indicator (FMI) are displayed in the DTC Window.
• Suspect Parameter Number (SPN) – The SPN
V00134a
identifies the individual component causing
the DTC. Figure 58 DTC window
• Failure Mode Indicator (FMI) – The FMI 1. Suspect Parameter Number (SPN)
identifies the fault or condition affecting the 2. Failure Mode Indicator (FMI)
individual component. 3. Fault Code Type
• Pending DTCs are possible emission faults 4. Permanent Diagnostic Trouble Codes tab
that were detected on first drive cycle. 5. Freeze Frame
6. Clear DTCs button
• Active DTC are faults that are present now 7. Refresh DTC/Vehicle Events button
or emission faults that were detected on two
consecutive drive cycles.
• Previously Active or Healing DTCs are 4. Record DTCs and Freeze Frame Data on

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historical faults. These faults may have Diagnostics Form.
been cause by an intermittent or operating • Correct any active DTCs. See
condition which is not currently present. “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
Purpose
• Investigate any previously active, pending,
Identify DTCs. or healing DTCs for possible intermittent
operating conditions in which the DTC was
Tools set.
• Electronic Service Tool (EST) with ServiceMaxx™ NOTE: Freeze Frame Data is a snapshot of all
software influencing signals at the time the DTC was set.
• J1939 and J1708 RP1210B Compliant Device This can help diagnose hard to duplicate failures.
Freeze Frame Data is cleared as soon as the DTC
Procedure is cleared.

1. Turn ignition switch to ON, engine OFF.

128
 5 HARD START AND NO START DIAGNOSTICS
5. Engine Cranking
Purpose
Determine which system is causing the hard start or
no start condition.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• Digital Multimeter (DMM)
Procedure
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select Hard Start - No Start session.
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Sq\als I Vols I
T I Name
Enoine Speed
- Value
164.50 RPM
Fuel Delivery Pressure
Fuel Pressure Control Valve
Fuel Rail Pressure 14,572 . 89 J>Si
Fuel Rail Pressure Desired 14,572.89 psi
Switched Batcerv
TCl Turbine Outlet Pressure
Figure 59 Hard Start - No Start session signals
NOTE: ServiceMaxx™ software displays Fuel
Delivery Pressure (FDP) signal 15 psi below actual
gauge pressure. See Appendix A (page 953) for
specifications.
5. Monitor the following signals:
• Switched Battery (SWBAT)
• Engine Speed (RPM)
• Fuel Delivery Pressure (FDP)
• Fuel Rail Pressure (FRP)
• TC1 Turbine Output Pressure (TC1TOP)
125
CAUTION: To prevent damage to the starter, if engine
fails to start within 10 seconds, release ignition switch
and wait 2 to 3 minutes to allow starter motor to cool.
6. Press the record button and crank engine for a
maximum of 20 seconds.
7. Review engine cranking results and record on
Diagnostics Form.
• If FDP takes a long time to build during engine
crank, but engine starts after starting pressure
is met, check fuel supply line for fuel draining
back to the remote-mounted primary fuel filter.
• If SWBAT voltage drops below specification,
continue to step 8.
• If Engine Speed remains at 0.00 rpm
with engine rotating, see CMP Sensor
(page 393) and CKP Sensor (page 382)
in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
• If Engine Speed is below specification, check
batteries and starting system.
lklits
• If FDP is below specification, go
Low-pressure Fuel System (page 127).
to
130 J>Si
SO.OS 's • If FDP is within specification, but FRP is below
specification, go to Fuel Rail Pressure (FRP)
11. oo v
Circuit Test (page 135).
14. 79 psi
• If TC1TOP is above specification, disconnect
exhaust just before Pre-Diesel Oxidation
V00135 Catalyst (PDOC) and try to start engine. If
engine starts, see AFT System (page 217)
in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
NOTE: If all values are within specification
and the engine is normally subjected to
temperatures below 10° C (50° F), go to Inlet
Air Heater System Test (page 140).
8. Connect DMM to battery and monitor voltage
during engine cranking.
• If voltage stays within specification, go to
ECM Power (page 589) in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.”
• If voltage drops below specification, check
batteries and starting system. Connect
battery charger and repeat test.
129
 126 5 HARD START AND NO START DIAGNOSTICS

Special Test Procedures

Fuel System

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V00087

Figure 60 Fuel system

1. Injector (6) 6. Fuel supply to DSI unit 11. Fuel strainer
2. Fuel Rail 7. Fuel return line 12. LP fuel pump
3. Fuel rail pressure limiting valve 8. Fuel filter assembly 13. HP fuel pump
4. Fuel return from cylinder head 9. Drain screw 14. Fuel Rail Pressure (FRP) sensor
5. Engine fuel return connection (to 10. Fuel Delivery Pressure (FDP) 15. Fuel primer pump
chassis filter) sensor

130
 5 HARD START AND NO START DIAGNOSTICS 127

Low-pressure Fuel System

26

24 23

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Figure 61 Low-pressure (LP) fuel system
1. HP fuel pump 9. Fuel supply to DSI unit 18. Fuel return from engine
2. Fuel Pressure Control Valve 10. Chassis mounted primary fuel 19. Fuel supply to engine
(FPCV) filter access 20. Engine mounted fuel module
3. Fuel primer pump assembly w/ 11. Fuel supply to engine 21. Inlet air heater port
fuel strainer element 12. Fuel return from engine 22. Low pressure fuel supply line
4. Fuel pressure test port 13. Fuel supply from tank 23. LP fuel pump outlet
5. Engine fuel supply connection 14. Chassis mounted fuel filter/water 24. LP fuel pump inlet
6. FDP sensor separator 25. HP fuel pump inlet
7. Engine mounted secondary fuel 15. Fuel Heater 26. HP fuel pump return
filter access 16. Water In Fuel (WIF) sensor
8. Engine fuel return connection 17. Fuel return to tank

131
 128 5 HARD START AND NO START DIAGNOSTICS

Fuel System Priming Procedure

1. Verify there is fuel in fuel tank.
.......
iiiiii GOVERNMENT REGULATION: Engine
•==•
fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.

WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or

death, do not smoke and keep fuel away from

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flames and sparks.

WARNING: To prevent personal injury or

death, store diesel fuel properly in an approved
container designed for and clearly marked DIESEL
FUEL.
Figure 62 Fuel primer pump
Purpose
Prime the fuel system.
2. Pump fuel primer pump until fuel fills the system.
Tools • If fuel does not pull from fuel tank, go to Fuel
None Restriction Test (page 133).

132
 5 HARD START AND NO START DIAGNOSTICS 129

Fuel Delivery Pressure (FDP) Test 3. Connect Clean Fuel Source Tool 15–637–01 to
low-pressure fuel pump inlet.
NOTE: Perform this test if directed here from
Engine Cranking test (page 125). 4. Crank engine to remove air from fuel lines.
5. Turn ignition switch to ON, engine OFF.
Purpose
6. Connect EST to vehicle's Diagnostic Connector.
Verify there is sufficient fuel pressure in low-pressure
fuel system to start engine. 7. Start ServiceMaxx™ software.
Tools 8. Select Hard Start - No Start session.
• Electronic Service Tool (EST) with ServiceMaxx™
Si\J)als I Vols I
software
• J1939 and J1708 RP1210B Compliant Device T I Name
Encrine S0eed
- Value lklits
164.50 iRPM
• 15-637-01 – Clean Fuel Source Tool Fuel Delivery Px:essux:e 130 ~Si
Fuel Px:essux:e Control Valve SO. OS '<
• ZTSE4891 – Air Cap, Fuel Cap, and Plug Kit Fuel Rail Px:essux:e 14,572.89 ~Si
Fuel Rail Px:essux:e Desix:ed 14,572.89 psi
Switched Battex:v 11.00V
Procedure TCl Turbine Outlet Px:essux:e 14. 79 psi

CAUTION: To prevent damage to engine, plug

component connections immediately after each fuel V00135
line is removed using clean fuel system caps.

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NOTE: Ensure fuel lines are clear of heavy debris
before breaking fuel line connections.
1. With the engine OFF, disconnect fuel supply line
at low-pressure fuel pump inlet.
2. Use Air Cap, Fuel Cap, and Plug Kit ZTSE4891 to
cap disconnected fuel supply line.
Figure 64 Hard Start - No Start session signals
9. Crank engine for 20 seconds while monitoring
Fuel Delivery Pressure (FDP) signal. Record
results on Diagnostics Form.
NOTE: ServiceMaxx™ software displays Fuel
Delivery Pressure (FDP) signal 15 psi below
actual gauge pressure. See Appendix A (page
953) for specifications.
• If FDP is below specification, go to Fuel Dead
Head Test.
• If FDP builds above specification, go to Fuel
Aeration Test (page 131).

Figure 63 Clean Fuel Source Tool connected to

low-pressure fuel pump inlet

133
 130 5 HARD START AND NO START DIAGNOSTICS
Fuel Dead Head Test
Purpose
Isolate fuel pump to determine if it is able to build
proper pressure.
Tools
• ZTSE4526 - Compucheck Fitting
• 15-637-01 – Clean Fuel Source Tool
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4905 – Fuel Block Off Tool
Procedure
1. Retain connection between Clean Fuel Source
Tool 15–637–01 and low-pressure fuel pump inlet
from previous test.
2. Disconnect fuel line from low-pressure fuel pump
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outlet.
Figure 65 Fuel Inlet Restriction / Aeration Tool
ZTSE4886 connected to low-pressure fuel pump
outlet.
3. Connect Fuel Inlet Restriction / Aeration Tool
ZTSE4886 to low-pressure fuel pump outlet.
4. Use ZTSE4526 - Compucheck Fitting to connect
Fuel Pressure Gauge to Fuel Inlet Restriction /
Aeration Tool ZTSE4886.
5. Connect Fuel Block Off Tool to Fuel Restriction /
Aeration Tool ZTSE4886.
6. Crank engine to remove air from fuel lines.
7. Crank engine until fuel pressure stabilizes or up
to a maximum of 20 seconds.
8. Record gauge pressure on Diagnostics Form.
• If pressure is within specification, inspect
secondary fuel filter, stand pipe, and housing
for defects or damage. If no defect or damage
is found, go to Fuel Rail Pressure (FRP)
Return Flow Test.
• If pressure is below specification, replace
fuel pump following procedures in the Engine
Service Manual. To prevent damage to a
newly installed fuel pump and to verify high
back pressure did not cause fuel pump to fail,
perform HP Pump Fuel Return Pressure Test
(page 139) any time fuel pump is replaced.
NOTE: Before installing a new fuel pump,
ensure new fuel pump is the correct
replacement part.
134
 5 HARD START AND NO START DIAGNOSTICS 131

Fuel Aeration Test

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Figure 66 Fuel aeration test diagram
1. Strainer / primer pump 4. Fuel supply from primary fuel 6. Fuel Inlet Restriction / Aeration
2. Aeration test point 2 filter Tool ZTSE4886
3. Secondary fuel filter 5. Low-pressure fuel pump 7. Aeration test point 1

135
 132 5 HARD START AND NO START DIAGNOSTICS

Purpose 4. Crank engine while visually monitoring for

fuel aeration (air bubbles passing through the
Check for fuel aeration.
clean line). Record results on Diagnostics
Tools Form.
• 15-637-01 – Clean Fuel Source Tool • If fuel is not aerated, go to Fuel Restriction
Test.
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• If fuel is aerated, go to Aeration Test Point
• ZTSE4905 – Fuel Block Off Tool
2.
• ZTSE4906 – Fuel Line Coupler
Aeration Test Point 2
Procedure
1. Connect Clean Fuel Source Tool 15-637-01 to
primer pump inlet.
Aeration Test Point 1
2. Prime fuel system by pumping primer pump.
1. Remove Clean Fuel Source Tool 15-637-01
from low-pressure fuel pump inlet. 3. Crank engine while visually monitoring for
fuel aeration (air bubbles passing through the
2. Use Fuel Line Coupler ZTSE4906 to
clean line). Record results on Diagnostics
connect Fuel Inlet Restriction / Aeration
Form.
Tool ZTSE4886 between fuel supply line to
secondary fuel filter and low-pressure fuel • If fuel is not aerated, repair open in fuel
pump outlet. supply line between fuel primer pump and

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fuel tank.
3. Prime fuel system by pumping primer pump.
• If fuel is aerated, repair open in
low-pressure fuel pump supply line or
fuel primer pump.

136
 5 HARD START AND NO START DIAGNOSTICS 133

Fuel Restriction Test

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Figure 67 Fuel restriction test diagram
1. Fuel restriction test point 1 6. Primary fuel filter 9. Fuel Inlet Restriction / Aeration
2. Strainer / primer pump 7. Low-pressure fuel pump Tool ZTSE4886
3. Fuel restriction test point 2 8. Pressure Test Kit ZTSE4409
4. Fuel supply from tank (vacuum gauge)
5. Fuel restriction test point 3

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 134 5 HARD START AND NO START DIAGNOSTICS

Purpose Restriction Test Point 2

Check for fuel supply restriction.
Tools
• ZTSE4526 - Compucheck Fitting
• 15-637-01 – Clean Fuel Source Tool
• ZTSE4409 – Pressure Test Kit
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4906 – Fuel Line Coupler
Procedure
Restriction Test Point 1
Restriction Test Point 3
1. Use Fuel Line Coupler ZTSE4906 to connect
Fuel Inlet Restriction / Aeration Tool ZTSE4886
between low-pressure fuel pump supply line and
low-pressure fuel pump inlet.
2. Connect Pressure Test Kit ZTSE4409 vacuum
1. Connect Clean Fuel Source Tool 15-637-01 to
primer pump inlet.
2. Prime fuel system by pumping primer pump.
3. Crank engine while monitoring Pressure Test
Kit ZTSE4409 vacuum gauge. Record results
on Diagnostics Form.
• If restriction is within specification, go to
Restriction Test Point 3.
• If restriction is above specification, repair
or replace fuel strainer and primer pump
assembly, and check fuel lines.
1. Connect Clean Fuel Source Tool 15-637-01 to
primary fuel filter inlet.
2. Prime fuel system by pumping primer pump.
3. Crank engine while monitoring Pressure Test

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gauge to Fuel Inlet Restriction / Aeration Tool
Kit ZTSE4409 vacuum gauge. Record results
ZTSE4886.
on Diagnostics Form.
3. Prime fuel system by pumping primer pump.
• If restriction is within specification, repair
4. Crank engine while monitoring Pressure Test Kit restriction between primary fuel filter and
ZTSE4409 vacuum gauge. Record results on fuel tank.
Diagnostics Form.
• If restriction is above specification,
• If restriction is within specification, verify replace primary fuel filter, clean fuel
Fuel Delivery Pressure (FDP) sensor reading strainer, and check fuel lines.
with gauge. If FDP gauge reading is within
specification, go to High-pressure Fuel
System (page 135).
• If restriction is above specification, go to
Restriction Test Point 2.

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 5 HARD START AND NO START DIAGNOSTICS 135

High-pressure Fuel System

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Figure 68 High-pressure (HP) fuel system

1. Injector (6) 4. Fuel Pressure Control Valve 6. HP fuel pump return
2. Fuel rail pressure limiting valve (FPCV) 7. HP fuel pump
3. Fuel Rail 5. HP fuel pump inlet 8. Fuel Rail Pressure (FRP) sensor

Fuel Rail Pressure (FRP) Circuit Test Procedure

1. Disconnect the FRP sensor electrical connector
Purpose
and attempt to start engine.
Verify whether FRP sensor is biased.
• If engine starts, diagnose FRP sensor
circuits. See FRP Sensor (page 683)
Tools
in “ELECTRONIC CONTROL SYSTEMS
None DIAGNOSTICS.”
• If the engine does not start, reconnect FRP
sensor and go to High-pressure Pump Inlet
Pressure Test.

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 136 5 HARD START AND NO START DIAGNOSTICS

High-pressure Pump Inlet Pressure Test
Purpose
Verify high-pressure fuel pump is receiving fuel.
Tools
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4905 – Fuel Block Off Tool
• ZTSE4906 – Fuel Line Coupler
Procedure
1. Disconnect fuel supply to Down Stream Injection
(DSI) valve assembly.
2. Use Fuel Line Coupler ZTSE4906 to connect Fuel
Inlet Restriction / Aeration Tool ZTSE4886 to DSI
fuel supply line.
3. Connect Fuel Block Off Tool ZTSE4905 to Fuel
Inlet Restriction / Aeration Tool ZTSE4886.
4. Connect Fuel Pressure Gauge ZTSE4681 to Fuel
Inlet Restriction / Aeration Tool ZTSE4886.
5. Crank engine while monitoring Fuel Pressure
Gauge ZTSE4681. Record results on Diagnostics
Form.
• If gauge pressure is within specification, go to
High-pressure Fuel Return Flow Test.
• If gauge pressure is below specification,
replace secondary fuel filter and go to HP
Pump Return Flow Test (page 139).

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V21011a

Figure 69 Fuel Pressure Gauge connected to

DSI fuel supply line
1. DSI Fuel Supply Line
2. Fuel Line Coupler ZTSE4906
3. Fuel Inlet Restriction / Aeration Tool ZTSE4886
4. Fuel Pressure Gauge ZTSE4681
5. Fuel Block Off Tool ZTSE4905

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 5 HARD START AND NO START DIAGNOSTICS
Fuel Rail Pressure (FRP) Return Flow Test
Purpose
Verify return flow is within specifications.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• Diesel fuel container
• ZTSE4887 – High Pressure Return Line Tester
Fuel Rail Pressure (FRP) Return Flow Test Part 1
NOTE: Before running this test, ensure
low-pressure fuel system is operating correctly.
1. Disconnect fuel drain tube assembly at rear of
cylinder head.
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Figure 70 High Pressure Return Line Tester
ZTSE4887 connected to cylinder head
137
2. Connect High Pressure Return Line Tester
ZTSE4887-2 using 2 banjo ring seals to cylinder
head fuel drain tube fitting. Thread ZTSE4887-3
to ZTSE4887-2 and route the end into a diesel
fuel container.
3. Crank engine for 20 seconds while monitoring
fuel return from High Pressure Return Line Tester
ZTSE4887.
• If fuel is returning, go to Fuel Rail Pressure
(FRP) Leak Isolation.
• If no fuel is returning, continue to next step.
Fuel Rail Pressure (FRP) Return Flow Test Part 2
NOTE: Before running this test, ensure
low-pressure fuel system is operating correctly.
4. Reconnect fuel drain tube assembly disconnected
in step 1.
5. Disconnect fuel rail return line at fuel rail.
6. Connect High Pressure Return Line Tester
ZTSE4887-2 using 2 banjo ring seals to fuel rail
return port. Thread ZTSE4887-3 to ZTSE4887-2
and route the end into a diesel fuel container.
7. Crank engine and monitor fuel return from High
Pressure Return Line Tester ZTSE4887.
• If fuel flows from High Pressure Return Line
Tester ZTSE4887, replace fuel rail pressure
relief valve.
• If fuel does not flow from High Pressure
Return Line Tester ZTSE4887, go to HP
Pump Return Flow Test.
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 138 5 HARD START AND NO START DIAGNOSTICS

Fuel Rail Pressure (FRP) Leak Isolation

Purpose
Isolate pressure loss in high-pressure fuel system.
Tools
• Diesel fuel container
• ZTSE4887 – High Pressure Rail Return Line
Tester
• ZTSE6098 – High Pressure Rail Plugs

Procedure

WARNING: The high-pressure fuel system

may have extremely high pressure. Verify
pressure is below 500 psi before cracking a
line. Every time the engine is shut down and the
key is in the OFF position, the ECM commands
a blank shot injection process that drains the
high-pressure fuel rail.
Figure 71 High Pressure Rail Plug installed on
injector six
2. Disconnect number six injector fuel line and cap
off rail with High Pressure Rail Plug ZTSE6098.

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NOTE: Perform this procedure only if engine does
NOT START because of low or nonexistent Fuel
Rail Pressure (FRP).
1. Retain High Pressure Return Line Tester
ZTSE4887 connection to cylinder head from
previous test.
3. Crank engine while monitoring fuel leaking out of
High Pressure Return Line Tester ZTSE4887.
• If fuel is leaking out of High Pressure Return
Line Tester ZTSE4887, leave High Pressure
Rail Plug ZTSE6098 connected. Continue
capping off one injector supply port at a time
until fuel rail builds starting pressure. Once
starting pressure is met, replace the removed
injector tubes with new parts. Verify engine
will start.
• If fuel is not leaking out of High Pressure
Return Line Tester ZTSE4887 and fuel rail
builds starting pressure, replace number six
injector tube and fuel pipe.

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 5 HARD START AND NO START DIAGNOSTICS 139

HP Pump Fuel Return Pressure Test 5. Start engine and run high idle while monitoring
Fuel Pressure Gauge ZTSE4681.
Purpose
• If pressure is above specification, inspect fuel
Verify return flow is within specifications. return line between high-pressure fuel pump
and fuel tank for restriction.
Tools
• If pressure is below specification, no further
• ZTSE4526 - Compucheck Fitting
action is required.
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
HP Pump Return Flow Test
• ZTSE4906 – Fuel Line Coupler
Purpose
Procedure
Verify fuel is flowing from high-pressure return.
NOTE: Prior to performing this test, ensure new
Tools
fuel pump is the correct replacement part.
• 15-637-01 - Clean Fuel Source Tool
1. Restore fuel system to normal operating
condition. • ZTSE4905 – Fuel Block Off Tool
2. Disconnect high-pressure fuel pump return line.
Procedure

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1. Disconnect high-pressure fuel pump return line,
and connect Fuel Block Off Tool ZTSE4905 to the
line.
2. Connect 15-637-01 Clean fuel source tool to the
HP fuel pump fuel return port. Verify the shutoff
valve is Open.
3. Crank engine for 20 seconds while monitoring
fuel return from High Pressure Return Line Tester
ZTSE4887.
• If fuel is flowing from the return port into
15-637-01 Clean fuel source tool, replace
Piston Overflow Valve (KUEV) valve.
• If fuel does not flow from the return port into
Figure 72 High-pressure fuel pump return line 15-637-01 Clean fuel source tool, replace fuel
connected to Fuel Pressure Gauge ZTSE4681 pump. Refer to the Engine Service Manual
for replacement procedure and perform HP
Pump Fuel Return Pressure Test to verify high
3. Use Fuel Line Coupler ZTSE4906 to connect back pressure did not cause fuel pump failure.
high-pressure fuel pump return line to Fuel Inlet
Restriction / Aeration Tool ZTSE4886.
4. Use ZTSE4526 - Compucheck Fitting to connect
Fuel Inlet Restriction / Aeration Tool ZTSE4886 to
Fuel Pressure Gauge ZTSE4681.

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 140 5 HARD START AND NO START DIAGNOSTICS
Inlet Air Heater System
WARNING: To prevent personal injury or
death, do not smoke or park vehicle near open
flames or sparks when taking a fuel sample.
WARNING: To prevent personal injury or
death, make sure the parking brake is set, the
transmission is in neutral or park, and the wheels
are blocked when running the engine in the
service bay.
Inlet Air Heater System Test
Purpose
Verify inlet air heater system is working correctly at
any temperature.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
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• J1939 and J1708 RP1210B Compliant Device
Procedure
NOTE: Inlet Air Heater is commanded ON when
Engine Coolant Temperature 1 (ECT1) is below 10
°C (50 °F).
Post production, ServiceMaxx™ software will
have the ability to run Inlet Air Heater at higher
temperatures.
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select Hard Start - No Start session.
5. Monitor Engine Coolant Temperature 1 (ECT1).
• If ECT1 is above 10 °C (50 °F), use
ServiceMaxx™ software to run Inlet Air
Heater procedure.
• If ECT1 is below 10 °C (50 °F), continue to
next step.
NOTE: The ECM may take 15 seconds or
longer to reset between ignition switch cycles.
6. Cycle ignition switch and monitor Wait to Start
lamp in vehicle's dashboard.
7. When Wait to Start lamp begins flashing,
crank engine while monitoring Intake Manifold
Temperature (IMT) and Fuel Delivery Pressure
(FDP). Record results on Diagnostics Form.
• If IMT does not rise approximately 5.5 °C (10
°F) during engine crank, go to Inlet Air Heater
Fuel Igniter (IAHFI) Test.
• If IMT rises 5.5 °C (10 °F) during engine
crank, the Inlet Air Heater system is working
correctly.
• If FDP is below specification, go to
Low-pressure Fuel System (page 127).
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 5 HARD START AND NO START DIAGNOSTICS
Inlet Air Heater Fuel Igniter (IAHFI) Test
Purpose
Verify IAHFI is working properly.
Tools
• Digital Multimeter (DMM)
• EXP-1000 HD by Midtronics
Procedure
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select 2010 BB Actuator session from the
Sessions drop-down menu.
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Figure 73 Current clamp on IAHFI
141
5. Connect EXP-1000 HD by Midtronics current
clamp around IAHFI power circuit.
6. Select Inlet Air Heater Igniter from Actuator
drop-down menu.
7. Press the Start Test button while monitoring
current draw. Record results on Diagnostics
Form.
• If current draw is below specification, go to
Inlet Air Heater Fuel Igniter (IAHFI) (page 411)
in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
• If current draw is above specification, IAHFI is
working correctly. Continue to Fuel Supply at
Inlet Air Heater Fuel Solenoid (IAHFS) Test.
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 142 5 HARD START AND NO START DIAGNOSTICS

Fuel Supply at Inlet Air Heater Fuel Solenoid

(IAHFS) Test

Purpose
Verify sufficient fuel pressure is being supplied to the
IAHFS.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE6059 – Inlet Air Heater Solenoid Test
Adapter Kit Figure 74 Fuel Pressure Gauge ZTSE4681
connected to IAHFS fuel supply line
Procedure
1. Turn ignition switch to ON, engine OFF.
7. Use Inlet Air Heater Solenoid Test Adapter Kit
2. Connect EST to vehicle's Diagnostic Connector. ZTSE6059 to connect Fuel Pressure Gauge

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3. Start ServiceMaxx™ software.
4. Select Hard Start - No Start session.
5. Crank engine while monitoring Fuel Delivery
Pressure (FDP).
• If FDP is below specification, go to Fuel
Delivery Pressure Test (page 129).
• If FDP is within specification, continue to next
step.
6. Disconnect fuel supply to IAHFS.
ZTSE4681 to IAHFS fuel supply line.
8. Crank engine while monitoring Fuel Pressure
Gauge ZTSE4681. Record results on Diagnostics
Form.
• If pressure is below specification, inspect
IAHFS fuel supply line for restriction. If IAHFS
fuel supply line is not restricted, replace fuel
regulator in fuel filter housing.
• If pressure is within specification, go to Fuel
Supply at Inlet Air Heater Fuel Igniter (IAHFI)
Test.

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 5 HARD START AND NO START DIAGNOSTICS 143

Fuel Supply at Inlet Air Heater Fuel Igniter (IAHFI)

Test

Purpose
Verify sufficient fuel pressure is being supplied to the
IAHFI.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE6059 – Inlet Air Heater Solenoid Test
Adapter Kit

Procedure
NOTE: This test can only be run if ECT1 is below
10 °C (50 °F) or ServiceMaxx™ software can run
the Inlet Air Heater procedure.

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NOTE: Post production, ServiceMaxx™ software
will have the ability to run Inlet Air Heater at higher
temperatures.
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select Hard Start - No Start session.
5. Reinstall fuel supply line to Inlet Air Heater Fuel
Solenoid (IAHFS) disconnected in previous test.
6. Disconnect fuel supply to IAHFI.
Figure 75 Fuel Pressure Gauge ZTSE4681
connected to IAHFI fuel supply line
7. Use Inlet Air Heater Solenoid Test Adapter Kit
ZTSE6059 to connect Fuel Pressure Gauge
ZTSE4681 to IAHFI fuel supply line.
8. Monitor Wait to Start lamp in vehicle's dashboard.
9. When Wait to Start lamp begins flashing, crank
engine while monitoring Fuel Pressure Gauge
ZTSE4681. Record results on Diagnostics Form.
• If pressure is below specification, inspect
IAHFI fuel supply line for restriction. If
IAHFI fuel supply line is not restricted, see
Inlet Air Heater Fuel Solenoid (page 411)
in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
• If pressure is within specification, replace
IAHFI.

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 144 5 HARD START AND NO START DIAGNOSTICS

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 6 PERFORMANCE DIAGNOSTICS 145

Table of Contents

Diagnostics Form EGED-530. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Diagnostics Form Vehicle Information and Complaint Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Required Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

1. Initial Key ON Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
2. Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Engine Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Intake Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Charge Air Cooler (CAC) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Vehicle Air Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Fuel Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Primary Fuel Filter Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Fuel Quality Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

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3. Electronic Service Tool (EST) Connection and Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
4. Check for Diagnostic Trouble Codes (DTCs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
5. Engine Low Idle to High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
6. KOER Air Management Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
7. Road Test (Full load to highway speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Special Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

Air Control Valve (ACV) Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Exhaust Back Pressure Valve (EBPV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Turbocharger 2 Wastegate Control (TC2WC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Low-pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Fuel Delivery Pressure (FDP) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Fuel Dead Head Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Fuel Aeration and Restriction Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Aeration Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Restriction Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
High-pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
High-pressure Pump Inlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Fuel Rail Pressure (FRP) Return Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Fuel Rail Pressure (FRP) Leak Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
HP Pump Fuel Return Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Crankcase Oil Breather Separator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Crankcase Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Cylinder Performance Test – Step 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Cylinder Performance Test – Step 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Injector Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Fuel Pressure Control Valve (FPCV) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Charge Air Cooler (CAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

149
 146 6 PERFORMANCE DIAGNOSTICS

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150
 6 PERFORMANCE DIAGNOSTICS 147

Diagnostics Form EGED-530

........ TMll"rocedurM
o.__.. ................... ~·-----"---
--
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....._...,.. _____
V00169b

Figure 76 Diagnostics Form EGED-530 (Performance Diagnostics)

The Performance Diagnostics Form directs
technicians to systematically troubleshoot a
performance condition and avoid unnecessary
repairs.
This Diagnostic Manual section shows detailed
instructions of the tests on the form. The manual
should be used with the form and referenced for
supplemental test information. Use the form as a
worksheet to record test results.
Do all tests in sequence, unless otherwise stated.
Doing a test out of sequence can cause incorrect
results. If a problem was found and corrected, it is
not necessary to complete the remaining tests.
See appropriate section for Diagnostic Trouble Codes
(DTCs) and engine specifications.
To order technical service literature, contact your
International dealer.

151
 148 6 PERFORMANCE DIAGNOSTICS

Diagnostics Form Vehicle Information and

Complaint Page

Note: This form must be completed before calling for technical assistance.
Technician: Date: Rated Power:

Software Identification: Total Miles:

Vehicle Identification Number:

Engine Serial Number:

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EDC Customer Unit Number:

Transmission Type (select one) :

• Automatic

Complaint:

0000047998

152
 6 PERFORMANCE DIAGNOSTICS 149

1. Fill in the following information: • EDC Customer Unit Number

• Technician • Complaint (driver interview)
• Date NOTE: Remaining information will be filled in later
using information from the Electronic Service Tool
• Vehicle Identification Number (VIN)
(EST) with ServiceMaxx™ software.

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153
 150 6 PERFORMANCE DIAGNOSTICS

Required Test Procedures INFORMATION (TSI)” to obtain required specification

information:
........ NOTE: Performance specifications may be
iiiiii GOVERNMENT REGULATION: Engine
periodically published in a Technical Service
•=•
fluids (oil, fuel, and coolant) may be a hazard
Information (TSI) format to support new model
year products. Check service bulletin repository
to human health and the environment.
on Navistar® Service Portal for appropriate model
Handle all fluids and other contaminated
year application.
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle 1. Initial Key ON Check
or dispose of engine fluids, filters, and
other contaminated materials according to Purpose
applicable regulations.
Determine if Engine Control Module (ECM) is powered
up and if water is in fuel supply.

WARNING: To prevent personal injury or Tools

death, read all safety instructions in the “Safety
Information” section of this manual. None

WARNING: To prevent personal injury or Procedure

death, do not let engine fluids stay on your skin. 1. Turn ignition switch to ON, engine OFF. Observe

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Clean skin and nails using hand cleaner and wash the following:
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids. • Wait to Start lamp
• WATER IN FUEL indicator (Integral Digital
WARNING: To prevent personal injury or Display)
death, shift transmission to park or neutral, set
2. Record results on Diagnostics Form.
parking brake, and block wheels before doing
diagnostic or service procedures. • If WATER IN FUEL indicator stays ON, go to
Fuel Quality Check (page 154).
WARNING: To prevent personal injury or
death, do not smoke and keep fuel away from
flames and sparks. 2. Visual Inspection

Purpose
WARNING: To prevent personal injury or
death, provide proper ventilation when operating Check all fluid levels and inspect engine systems
an engine in a closed area. Inhalation of exhaust for problems such as leaks, open connections, and
gas can be fatal. harness chaffing.
Performance Specification Information See
Tools
“APPENDIX A: PERFORMANCE SPECIFICATIONS”
or “APPENDIX C: TECHNICAL SERVICE None

154
 6 PERFORMANCE DIAGNOSTICS
Engine Oil
1. Park vehicle on level ground and check oil level.
NOTE: Engine should be at normal operating
temperature. Turn engine OFF. Wait 15
minutes for level to stabilize.
NOTE: API CJ-4 oils are recommended for
high speed diesel engines with advanced
exhaust aftertreatment systems that meet
2007 and beyond on-highway exhaust
emission standards.
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Figure 78 Lube oil requirements label
2. Use oil level gauge (dipstick) to verify engine oil
level.
NOTE: If oil is diluted or contaminated, oil and
filter must be replaced.
3. Record results on Diagnostics Form.
• If level is below specification, inspect for
leaks, oil consumption, or improper servicing.
If engine oil level is low, fill to specification.
151
• If level is above specification, inspect for
fuel dilution, coolant contamination, or
improper servicing. If engine oil level is
above specification, drain to proper level and
diagnose contamination.
Engine Coolant Level
1. Park vehicle on level ground.
NOTE: Turn engine OFF and allow to cool.
Ensure coolant temperature has stabilized to safe
temperature and pressure.
2. Check coolant level as indicated on deaeration
tank level window.
NOTE: Coolant in the exhaust could damage the
DPF. Inspect DPF for damage. See AFT System
(page 217) in “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS” for inspection of the DPF.
3. Record results on Diagnostics Form.
• If level is above or below deaeration tank fill
level, inspect for leaks, coolant in oil, coolant
in combustion exhaust, or improper servicing.
• If coolant is contaminated, replace coolant.
Electrical System
1. Inspect batteries and electrical system (engine
and vehicle) for poor or loose connections,
corroded terminals, or broken and damaged
wires.
2. Record results on Diagnostics Form.
• If electrical system problem is found, make
necessary repairs.
155
 152 6 PERFORMANCE DIAGNOSTICS
Intake Air
NOTE: Intake air restriction should be less than
172.3 kPa (51 in Hg) at full load, rated speed.
1. Inspect air filter gauge, located on air filter housing
or dashboard.
2. Record results on Diagnostics Form.
• If gauge indicates air filter requires
replacement, verify there are no other
restrictions in the air inlet or filter housing
before replacing air filter.
Charge Air Cooler (CAC) System
1. Inspect CAC, interstage cooler, and all piping for
leaks.
2. Inspect all CAC connections and clamps.
• If CAC system problem is found,
make necessary repairs. See Coolant
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Over-Temperature Conditions Inspection
(page 87) in “ENGINE SYMPTOMS
DIAGNOSTICS”.
Exhaust System
1. Inspect exhaust system (engine and vehicle) for
restrictions, leaks, or damage.
2. Record results on Diagnostics Form.
• If exhaust system problem is found, make
necessary repairs.
Vehicle Air Tanks
1. Inspect vehicle air tanks for water.
• If water is detected in air tanks, drain all water
from air tanks.
Fuel Level
A WARNING: To prevent personal injury or
death, do not smoke and keep fuel away from
flames and sparks.
1. Park vehicle on level ground.
2. Check instrument panel fuel gauge and look into
fuel tank to verify fuel level.
3. Record results on Diagnostics Form.
• If fuel gauge reads above empty, but tank is
empty, diagnose instrument panel fuel gauge.
Verify sufficient fuel level before diagnosing a
pressure problem.
• If fuel tank is empty, add fuel and prime fuel
system. See Fuel System Priming (page
128) in “HARD START AND NO START
DIAGNOSTICS.”
Primary Fuel Filter Inspection
Visually inspect primary fuel filter condition following
the inspection table on next page.
156
 6 PERFORMANCE DIAGNOSTICS 153

Fuel Level Visual Indication Possible Solution

Fuel level below top of fuel Normal - no repair necessary.

C
filter.

V1502 1

Fuel level above top of fuel Change primary fuel filter element.

Q V150 13
filter. May cause loss of
power complaint.

Fuel level is to top of fuel 1. Change primary fuel filter element

filter and looks to be full of
2. Run engine for a minimum of 25 minutes at idle. Do not
wax.
run at high idle.

V 150 14

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Bubbles are seen flowing 1. Check all fittings and lines from between fuel tank and
ff] within fuel. chassis fuel filter assembly.
2. Check upper and lower connector O-rings.

M V 15015

Loss of power complaint. 1. Check for missing grommet at lower end of filter.

Q V150 16
Fuel level is below fuel filter
housing collar.
2. Check for missing or broken spring at top of primary fuel
filter element.

Water is seen (noticeable 1. Inspect fuel tank(s) for water contamination.

Q V150 17
separation) in fuel filter
assembly.
2. Drain a full cup of fuel from chassis fuel filter assembly.
NOTE: Do not drain with engine running.
3. Restart engine. Shut off engine and drain chassis fuel filter
assembly.
4. Repeat step 3 until ALL water is removed.
Fuel drains back to fuel tank 1. Remove and inspect check valve assembly.
when changing fuel filter or
2. Repair (clean) or replace as necessary, and retest.
draining water separator.

157
 154 6 PERFORMANCE DIAGNOSTICS

Fuel Quality Check

Purpose
Check for poor fuel quality or contaminants.
Tools
• Clear diesel fuel container
• Clear plastic hose

Procedure
NOTE: Ultra Low Sulfur Diesel (ULSD) fuel is
®
required for MaxxForce 11 and 13 diesel engines
used with advanced aftertreatment systems.

ULTRA-LOW SULFUR
HIGHWAY DIESEL FUEL
(1 S ppm Sulfur Maximum) Figure 80 Fuel sample
Required for use in all model year

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2007 and later highway diesel
vehicles and engines. 1. Install clear plastic hose on fuel drain valve.
Recommended for use in all diesel
vehicles and engines.
2. Route clear plastic hose into clear diesel fuel
container.
K35145
3. Open fuel drain valve to fill container.
Figure 79 Fuel requirements label NOTE: If fuel does not flow, crank engine.

NOTE: WATER IN FUEL indicator illuminates ON,

then OFF, on the Integral Digital Display if there
is no water in the system. If WATER IN FUEL
indicator stays ON, water is detected.

158
 6 PERFORMANCE DIAGNOSTICS 155

4. Check for water, waxing, icing, sediment, 3. Electronic Service Tool (EST) Connection and
gasoline, Diesel Exhaust Fluid (DEF) or kerosene Data Recording
by shaking fuel sample container and letting
contents settle. Record results on Diagnostics Purpose
Form.
Check Engine Control Module (ECM) software,
• Sediments will fall to bottom of fuel sample sensor signals and DTCs, and to record additional
container. vehicle information on Diagnostics Form.
• Gasoline and kerosene will separate from
Tools
diesel fuel.
• Electronic Service Tool (EST) with ServiceMaxx™
• Waxing or icing will prevent diesel fuel from
software
flowing out of fuel drain valve.
• J1939 and J1708 RP1210B Compliant Device
• If fuel quality is questionable, repair as
necessary. Take another sample to verify fuel
Procedure
quality is satisfactory.
1. Turn ignition switch to ON, engine OFF.
• If fuel quality is satisfactory, continue to
Electronic Service Tool (EST) Connection 2. Connect EST to vehicle's Diagnostic Connector.
and Data Recording test.
3. Start ServiceMaxx™ software.
NOTE: Do not continue diagnostic procedures
• If unable to communicate with the ECM, see
if fuel is contaminated.

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the ServiceMaxx™ Users Guide.
5. Inspect fuel strainer for debris. The fuel strainer
• If unable to communicate with the ECM
is located in the fuel primer pump assembly.
and no problems are found using the
ServiceMaxx™ Users Guide, go to J1939
Data Link (page 804) in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.”

159
 156 6 PERFORMANCE DIAGNOSTICS

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l'Wl II.ell fttNQtt lH.4 'Dal
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V00133a

Figure 81 ServiceMaxx™ startup screen – vehicle connected

4. Verify the following vehicle information matches • Rated Power

the displayed information in ServiceMaxx™
• Total Miles
software and record on Diagnostics Form.
• Engine On Time
• Software Identification
NOTE: The engine serial number is located
• Vehicle Identification Number (VIN)
on the front left side of the crankcase, below
• Engine Serial Number (ESN) the cylinder head. It is also on the engine
emission label on the valve cover.
• Transmission Type

160
 6 PERFORMANCE DIAGNOSTICS
5. Record the following Key ON, Engine OFF
(KOEO) temperature sensor values on
Diagnostics Form:
NOTE: If possible, allow the engine to cold
soak for at least 8 hours before recording
results.
• Inlet Air Temperature (IAT)
• Engine Coolant Temperature 1 (ECT1)
• Engine Coolant Temperature 2 (ECT2)
• Engine Oil Temperature (EOT)
6. Record the following KOEO pressure sensor
values on Diagnostics Form:
• Fuel Rail Pressure (FRP)
• Fuel Delivery Pressure (FDP)
• TC1 Turbine Outlet Pressure (TC1TOP)
• Intake Manifold Pressure (IMP)
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• Barometric Pressure (BARO)
• DPF Differential Pressure (DPFDP)
157
7. Look for sensor values that are out of
specification. A sensor out of specification could
cause abnormal operating behavior, incorrect
fueling, and injection timing problems.
• If sensor is out of specification, go to the
suspect sensor in “ELECTRONIC CONTROL
SYSTEMS DIAGNOSTICS.”
8. Use ServiceMaxx™ software to run Actuator Test.
9. Record EGR Valve Position and Engine Throttle
Position values at 5% (open) and 95% (closed)
on Diagnostics Form.
• If either signal is not within specification, go
to the suspect actuator in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS.”
10. Look for sensor values that are not within
specification. A sensor out of specification could
cause air management problems.
11. Use ServiceMaxx™ software to run Actuator Test.
12. Visually monitor movement of Exhaust Back
Pressure Valve (EBPV). Record results on
Diagnostics Form.
NOTE: ServiceMaxx™ software does not have
an EBPV feedback position signal.
• If EBPV does not move, go to Exhaust Back
Pressure Valve (page 163).
13. Use ServiceMaxx™ software to monitor DPF
status. Record results on Diagnostics Form.
• If DPF status is “Regen needed - critical
level”, run an Onboard Filter Cleanliness
Test.
161
 158 6 PERFORMANCE DIAGNOSTICS

4. Check for Diagnostic Trouble Codes (DTCs) 2. Connect EST to vehicle's Diagnostic Connector.
NOTE: 2010 model year vehicles no longer utilize 3. Start ServiceMaxx™ software.
DTC identification by number. DTCs are now
identified using the SPN and FMI identifiers only.
These two identifiers, known as the Suspect
Parameter Number (SPN) and the Failure Mode
Indicator (FMI), are displayed in the DTC Window.
• Suspect Parameter Number (SPN) – The SPN
V00134a
identifies the individual component causing
the DTC. Figure 82 DTC window
• Failure Mode Indicator (FMI) – The FMI 1. Suspect Parameter Number (SPN)
identifies the fault or condition affecting the 2. Failure Mode Indicator (FMI)
individual component. 3. Fault Code Type
• Pending DTCs are possible emission faults 4. Permanent Diagnostic Trouble Codes tab
that were detected on first drive cycle. 5. Freeze Frame
6. Clear DTCs button
• Active DTC are faults that are present now 7. Refresh DTC/Vehicle Events button
or emission faults that were detected on two
consecutive drive cycles.
• Previously Active or Healing DTCs are 4. Record DTCs and Freeze Frame Data on

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historical faults. These faults may have Diagnostics Form.
been caused by an intermittent or operating • Correct any active DTCs. See
condition which is not currently present. “ELECTRONIC CONTROL SYSTEMS
DIAGNOSTICS.”
Purpose
• Investigate any previously active, healing
Identify DTCs. or pending DTCs for possible intermittent
operating conditions in which the DTC was
Tools set.
• EST with ServiceMaxx™ software NOTE: Freeze Frame Data is a snapshot of all
• J1939 and J1708 RP1210B Compliant Device influencing signals at the time the DTC was set.
This can help diagnose hard to duplicate failures.
Procedure Freeze Frame Data is cleared as soon as the DTC
is cleared.
1. Turn ignition switch to ON, engine OFF.

162
 6 PERFORMANCE DIAGNOSTICS 159

5. Engine Low Idle to High Idle Signals ~

Purpose TI Name
Engine Load
-
Vakle
99 . 00
Units
.
Validate engine performance throughout rpm range. Engine Speed 1 , 885.50 RPM
Fuel Delivety Ptessute 114 . 29 psi
Tools Fuel Rail Ptessute 31 , 162.72 psi
Fuel Rail Ptessute Desited 31 , 959 . 29 psi
• EST with ServiceMaxx™ software Inte.ke Me.n.i fold Ptessute 2 . 90 psi
Intake Manifold Ptessute Desited 34 . 52 psi
• J1939 and J1708 RP1210B Compliant Device TCl Tutbine Outlet Ptessute 15 . 37 psi
TCl Tutbine Outlet Ptessute Des .. . 0.00 psi
TC2 Comp . Inlet Ptessute -0 . 04 fp:,i
Procedure
1. Turn ignition switch to ON, engine OFF. Signals I Volts I

2. Connect EST to vehicle's Diagnostic Connector. V00136

3. Start ServiceMaxx™ software. Figure 83 Performance session signals

4. Select Performance session.
5. Monitor Accel Pedal Position 1 (APP1) signal and 6. Monitor the following signals:
depress accelerator pedal to floor. Record results
on Diagnostics Form. NOTE: ServiceMaxx™ software displays
Fuel Delivery Pressure (FDP) signal 15
• If APP1 signal does not go from 0% to

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psi below actual gauge pressure. When
99.6%, see APP Sensor (page 363) in monitoring FDP with ServiceMaxx™ software,
“ELECTRONIC CONTROL SYSTEMS the specification listed below is correct.
DIAGNOSTICS.”
• Fuel Delivery Pressure (FDP)
• If APP1 signal does go from 0% to 99.6%,
continue to next step. • Fuel Rail Pressure (FRP)
• Fuel Rail Pressure Desired (FRPD)
• Engine Speed
• Intake Manifold Pressure (IMP)
• TC1 Turbine Outlet Pressure (TC1TOP)

163
 160 6 PERFORMANCE DIAGNOSTICS

7. Press the record button and start engine.
8. Allow engine to idle for 5 seconds. Depress
accelerator pedal to floor and hold for 20 seconds,
then return to low idle.
9. Review results with accelerator pedal at 99.6%
and record on Diagnostics Form.
• If FDP is below specification, go to Fuel
Delivery Pressure Test (page 167) in the
Low-pressure Fuel System section.
• If FDP is above specification, go to
High-pressure Pump Inlet Pressure Test
(page 175).
• If engine does not accelerate smoothly,
or feels unbalanced, (not running on all
cylinders), perform Cylinder Performance
Test (page 181) and Fuel Pressure Control
Valve (FPCV) Test (page 184).
• If TC1TOP is above specification, verify
Exhaust Back Pressure Valve (EBPV) is not
the cause of the performance loss. See
Exhaust Back Pressure Valve (EBPV) (page
163). If EBPV is operating correctly, inspect
Pre-Diesel Oxidation Catalyst (PDOC) and
Diesel Oxidation Catalyst (DOC) for face
plugging.
• If IMP is below specifications, visually inspect
for:
• Charge Air Cooler (CAC) and tubing leaks
• Intake restriction
• Turbocharger damage
• Remove and inspect IMP sensor for soot build
up. Clean sensor, reinstall, and continue.

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164
 6 PERFORMANCE DIAGNOSTICS 161

6. KOER Air Management Test
NOTE: Truck air tank must be full before running
this test.
Purpose
To verify air management valves are working correctly.
Tools
• EST with ServiceMaxx™ software
• J1939 and J1708 RP1210B Compliant Device
Procedure
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Start engine.
5. Select KOER Air Management Test from the Tests
drop-down menu. Begin recording snapshot and
7. Road Test (Full load to highway speed)
Purpose
Check for unacceptable engine performance at full
load and rated speeds by means of maximum boost,
minimum fuel pressure, and minimum Fuel Rail
Pressure (FRP).
Tools
• EST with ServiceMaxx™ software
• J1939 and J1708 RP1210B Compliant Device
Procedure
WARNING: To prevent personal injury or
death, read all safety instructions in the “Safety
Information” section of this manual.
NOTE: If truck has progressive shift or gear down
protection enabled, disable these features prior to
performing the road test.

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follow instructions in ServiceMaxx™ software.
Record results on Diagnostics Form.
NOTE: Record whether Intake Manifold
Pressure (IMP) increases or decreases with
actuator change.
NOTE: Perform test while bobtailing (not pulling a
trailer).
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.

NOTE: Turbocharger 1 Wastegate Control 3. Start ServiceMaxx™ software.

(TC1WC) does not affect engine performance 4. Select Performance session.
and is removed from later-built engines.
5. Start engine.
• If IMP does not decrease during EGR Valve
and TC2 Wastegate CTL movement, or IMP Signals~
increases during Exhaust Back Pressure
Valve movement, go to the appropriate
actuator in Air Control Valve (ACV) Tests
TI Name
Engine Load
-
Vakle
99 . 00
Units
.
Engine Speed 1 , 885.50 RPM
(page 163) to diagnose suspect actuator. 114 . 29 psi
Fuel Delivety Ptessute
Fuel Rail Ptessute 31 , 162.72 psi
Fuel Rail Ptessute Desited 31 , 959 . 29 psi
Inte.ke Me.n.i fold Ptessute 2 . 90 psi
Intake Manifold Ptessute Desited 34 . 52 psi
TCl Tutbine Outlet Ptessute 15 . 37 psi
TCl Tutbine Outlet Ptessute Des .. . 0.00 psi
TC2 Comp . Inlet Ptessute -0 . 04 fp:,i

T
SiQnals Voltsl

V00136

Figure 84 Performance session signals

165
 162 6 PERFORMANCE DIAGNOSTICS
6. Monitor the following signals:
• Fuel Rail Pressure (FRP)
• Fuel Delivery Pressure (FDP)
• Fuel Rail Pressure Desired (FRPD)
• Intake Manifold Pressure (IMP)
• TC1 Turbine Outlet Pressure (TC1TOP)
7. Find an open stretch of road. Begin recording.
When driving conditions are safe, select a suitable
gear, press accelerator pedal fully to the floor, and
accelerate to rated speed at 100% load.
8. When road test is complete, stop recording.
9. Review recorded results when engine was at
100% engine load and engine speed was at
the rated speed specified in “APPENDIX A:
PERFORMANCE SPECIFICATIONS." Record
results on Diagnostics Form.
• If FDP is below specification, go to Fuel
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Delivery Pressure Test (page 167) in the
Low-pressure Fuel System section.
• If FDP is above specification, go to
High-pressure Pump Inlet Pressure Test
(page 175).
• If engine does not accelerate smoothly,
or feels unbalanced, (not running on all
cylinders), perform Cylinder Performance
Test (page 181)and Fuel Pressure Control
Valve (FPCV) Test (page 184).
• If TC1TOP is above specification, verify
Exhaust Back Pressure Valve (EBPV) is not
the cause of the performance loss. See
Exhaust Back Pressure Valve (EBPV) (page
163). If EBPV is operating correctly, inspect
Pre-Diesel Oxidation Catalyst (PDOC) and
Diesel Oxidation Catalyst (DOC) for face
plugging.
• If IMP is below specifications, check for
Charge Air Cooler (CAC) and tubing leaks.
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 6 PERFORMANCE DIAGNOSTICS 163

Special Test Procedures
Air Control Valve (ACV) Tests
NOTE: Truck air tank must be full before running
these tests.
Purpose
Verify air management valves are working correctly.
Tools
• EST with ServiceMaxx™ software
• J1939 and J1708 RP1210B Compliant Device
Exhaust Back Pressure Valve (EBPV)
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select 2010 BB Actuator session.
6. Press the Start button and measure actuator rod
movement. Record results on Diagnostics Form.
NOTE: Measurement is taken between the
bottom of the housing and the jam nut.
• If actuator rod moves full travel, no action is
required.
• If actuator rod does not move full travel,
continue to next step.
7. Remove air supply line from actuator and repeat
actuator test.
• If air cannot be heard leaving the open air
supply line when running the test, inspect
supply line for blockage or damage. If supply
line is not blocked or damaged, see EBPV
(page 578), in “ELECTRONIC CONTROL
SYSTEMS DIAGNOSTICS.”
• If air can be heard leaving the open air supply
line, continue to next step.

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8. Remove actuator rod from valve arm. Check if the
5. Select EBPV from Actuator drop-down menu and valve arm moves freely.
set to 95%.
• If valve arm moves freely, replace air actuator.
NOTE: Test will command the actuator ON for 5
• If valve arm does not move freely, replace
seconds, then will return it to the default closed
valve.
position.

Figure 85 EBPV closed

1. EBPV
2. Jam nut
3. Bottom of housing

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 164 6 PERFORMANCE DIAGNOSTICS

Turbocharger 2 Wastegate Control (TC2WC) • If actuator rod does not move full travel,
continue to next step.
1. Turn ignition switch to ON, engine OFF.
7. Remove air supply line from actuator and repeat
2. Connect EST to vehicle's Diagnostic Connector.
actuator test.
3. Start ServiceMaxx™ software.
• If air cannot be heard leaving the open
4. Select 2010 BB Actuator session. air supply line when running the test, see
TC2WC (page 838), in “ELECTRONIC
NOTE: On a cold engine, the TC2 Wastegate
CONTROL SYSTEMS DIAGNOSTICS.”
Control defaults to open (100.00%) to prevent
turbocharger damage. • If air can be heard leaving the open air supply
line, continue to next step.
5. Select TC2 Wastegate Control from Actuator
drop-down menu and set to ON (95% Duty Cycle). 8. Remove actuator rod from valve arm. Check if the
valve arm moves freely.
NOTE: If TC2 Wastegate CTL displays a value
of 100.00% before test is started, duty cycle • If valve arm moves freely, replace air actuator.
must be set to Off (5% duty cycle) for actuator
• If valve arm does not move freely, replace
rod to move.
valve.
NOTE: Test will command actuator ON for 5
seconds, then actuator will return to default
position.

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V07001

Figure 86 TC2 wastegate valve in closed

position

6. Press the Start button and measure actuator rod

movement. Record results on Diagnostics Form.
• If actuator rod moves full travel, no action is
required.

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 6 PERFORMANCE DIAGNOSTICS 165

Fuel System

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Figure 87 Fuel system

1. Injector (6) 6. Fuel supply to DSI unit 11. Fuel strainer
2. Fuel Rail 7. Fuel return line 12. Low-pressure (LP) fuel pump
3. Fuel rail pressure limiting valve 8. Secondary fuel filter assembly 13. HP fuel pump
4. Fuel return from cylinder head 9. Drain screw 14. Fuel Rail Pressure (FRP) sensor
5. Engine fuel return connection (to 10. Fuel Delivery Pressure (FDP) 15. Fuel primer pump
chassis filter) sensor

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 166 6 PERFORMANCE DIAGNOSTICS

Low-pressure Fuel System

26

24 23

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Figure 88 Low-pressure (LP) fuel system
1. HP fuel pump 9. Fuel supply to DSI unit 18. Fuel return from engine
2. Fuel Pressure Control Valve 10. Chassis mounted primary fuel 19. Fuel supply to engine
(FPCV) filter access 20. Engine mounted fuel module
3. Fuel primer pump assembly w/ 11. Fuel supply to engine 21. Inlet air heater port
fuel strainer element 12. Fuel return from engine 22. Fuel supply from primary fuel
4. Fuel pressure test port 13. Fuel supply from tank filter
5. Engine fuel supply connection 14. Chassis mounted fuel filter/water 23. LP fuel pump outlet
6. FDP sensor separator 24. LP fuel pump inlet
7. Engine mounted secondary fuel 15. Fuel Heater 25. HP fuel pump inlet
filter access 16. Water In Fuel (WIF) sensor 26. HP fuel pump return
8. Engine fuel return connection 17. Fuel return to tank

170
 6 PERFORMANCE DIAGNOSTICS 167

• J1939 and J1708 RP1210B Compliant Device

.......
iiiiii GOVERNMENT REGULATION: Engine • Diesel fuel container
•==•
fluids (oil, fuel, and coolant) may be a hazard • 15-637-01 – Clean Fuel Source Tool
to human health and the environment.
Handle all fluids and other contaminated • ZTSE4891 – Air Cap, Fuel Cap, and Plug Kit
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle Procedure
or dispose of engine fluids, filters, and CAUTION: To prevent damage to engine, use clean
other contaminated materials according to fuel system caps to plug component connections
applicable regulations. immediately after each fuel line is removed.
NOTE: Ensure fuel lines are clean from heavy
debris before breaking fuel line connections.
WARNING: To prevent personal injury or
death, read all safety instructions in the “Safety 1. With the engine OFF, disconnect fuel supply line
Information” section of this manual. at low-pressure fuel pump inlet and cap it off using
Air Cap, Fuel Cap, and Plug Kit ZTSE4891.
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing

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and rags contaminated with engine fluids.

WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, do not smoke and keep fuel away from
flames and sparks.

WARNING: To prevent personal injury or

death, provide proper ventilation when operating
an engine in a closed area. Inhalation of exhaust Figure 89 Clean Fuel Source Tool connected to
gas can be fatal. low-pressure fuel pump inlet

Fuel Delivery Pressure (FDP) Test

NOTE: Perform this test if led here from the Low
Idle to High Idle Test or Road Test.
Purpose
Verify low-pressure fuel pump has the ability to
build sufficient fuel pressure for proper engine
performance.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
2. Connect Clean Fuel Source Tool 15-637-01 to
low-pressure fuel pump inlet.
3. Use Clean Fuel Source Tool 15-637-01 to prime
fuel system.
a. Close the ball valve on the Clean Fuel
Source Tool 15-637-01 fuel supply line.
b. Fully squeeze the primer bulb on the
Clean Fuel Source Tool 15-637-01.
Repeat until fuel system is primed (no air
visible in clear lines of Clean Fuel Source
Tool).

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 168 6 PERFORMANCE DIAGNOSTICS

c. After fuel system is primed, open Fuel Dead Head Test

ball valve on Clean Fuel Source Tool
15-637-01 fuel supply line. Purpose
4. Turn ignition switch to ON, engine OFF. Isolate fuel pump to determine if it is able to build
proper pressure.
5. Connect EST to vehicle's Diagnostic Connector.
Tools
6. Start ServiceMaxx™ software.
• ZTSE4526 - Compucheck Fitting
7. Select Performance session.
• 15-637-01 – Clean Fuel Source Tool
Signals TVoltsl
• ZTSE4681 – Fuel Pressure Gauge
TI Name
Engine Load
- Vakle
99 . 00 ,Units
. • ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
Engine Soeed 1 , 885.50 RPM • ZTSE4905 – Fuel Block Off Tool
Fuel Delivety Ptessute 114 . 29 psi
Fuel Rail Ptessute 31 , 162.72 psi
fuel Rail Ptessute Desited 31 , 959 . 29 psi Procedure
Intake M!!nifold Ptessute 2.90 iDSi
Intake H!!nifold Ptessute Desited 34 . 52 psi 1. Retain connection between Clean Fuel Source
TCl Tutbine Outlet Ptessute 15 . 37 psi Tool 15-637-01 and low-pressure fuel pump inlet
TCl Tutbine Outlet Ptessute Des • . • 0.00 psi from previous test.
TC2 Comp . Inlet Ptessute -0 . 04 ipsi
2. Disconnect fuel line from low-pressure fuel pump

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r l
SiQnals Volts outlet.
V00136

Figure 90 Performance session signals

8. Start engine while monitoring Fuel Delivery

Pressure (FDP). Depress accelerator pedal to
floor for 20 seconds and return to low idle. Record
results on Diagnostics Form.
NOTE: ServiceMaxx™ software displays
Fuel Delivery Pressure (FDP) signal 15
psi below actual gauge pressure. When
monitoring FDP with ServiceMaxx™ software,
the specification listed on the Diagnostics
Form is correct.
• If FDP is below specification, go to Fuel Dead Figure 91 Fuel Inlet Restriction / Aeration Tool
Head Test. connected to low-pressure fuel pump outlet.
• If FDP is within specification, go to Fuel
Aeration and Restriction Tests (page 170). 3. Connect Fuel Inlet Restriction / Aeration Tool
• If FDP builds above specification, go to High ZTSE4886 to low-pressure fuel pump outlet.
Pressure Pump Inlet Pressure Test (page 4. Use ZTSE4526 - Compucheck Fitting to connect
184). Fuel Pressure Gauge ZTSE4681 to Fuel Inlet
Restriction / Aeration Tool ZTSE4886.
5. Connect Fuel Block Off Tool ZTSE4905 to Fuel
Restriction/Aeration Tool ZTSE4886.
6. Crank engine to remove air from fuel lines.

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 6 PERFORMANCE DIAGNOSTICS
7. Crank engine until fuel pressure stabilizes or up
to a maximum of 20 seconds.
8. Record gauge pressure on Diagnostics Form.
• If pressure is within specification, inspect
secondary fuel filter, stand pipe, and housing
for defects or damage. If no defect or damage
is found, go to Fuel Rail Pressure Return
Flow Test (page 176).
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169
• If pressure is below specification, replace
fuel pump following procedures in the Engine
Service Manual. To prevent damage to a
newly installed fuel pump and to verify high
back pressure did not cause fuel pump to fail,
perform HP Pump Fuel Return Pressure Test
(page 139) any time fuel pump is replaced.
NOTE: Before installing a new fuel pump,
ensure new fuel pump is the correct
replacement part.
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 170 6 PERFORMANCE DIAGNOSTICS

Fuel Aeration and Restriction Tests

Aeration Test

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Figure 92 Fuel Aeration Test
1. Strainer / primer pump 4. Fuel supply from primary fuel 6. Fuel Inlet Restriction / Aeration
2. Test point 2 filter Tool
3. Secondary fuel filter 5. Low-pressure fuel pump 7. Test point 1

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 6 PERFORMANCE DIAGNOSTICS 171

Purpose 3. Prime fuel system by pumping primer pump.

Check for fuel aeration. 4. Start engine while visually monitoring for fuel
aeration (air bubbles passing through the clean
Tools
line). Record results on Diagnostics Form.
• 15-637-01 – Clean Fuel Source Tool
• If fuel is not aerated, go to Restriction Test.
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• If fuel is aerated, continue to step 5.
• ZTSE4905 – Fuel Block Off Tool
Aeration Test Point 2
• ZTSE4906 – Fuel Line Coupler
5. Connect Clean Fuel Source Tool 15-637-01 to
Aeration Test Point 1 primer pump inlet.
6. Prime fuel system by pumping primer pump.
Procedure
7. Start engine while visually monitoring for fuel
1. Remove Clean Fuel Source Tool 15-637-01 from
aeration (air bubbles passing through the clean
low-pressure fuel pump inlet and restore vehicle
line). Record results on Diagnostics Form.
fuel supply line.
• If fuel is not aerated, repair fuel supply line
2. Use Fuel Line Coupler ZTSE4906 to connect
between fuel primer pump and fuel tank.
Fuel Inlet Restriction / Aeration Tool ZTSE4886
between fuel supply line to secondary fuel filter • If fuel is aerated, repair low-pressure fuel
and low-pressure fuel pump outlet. pump supply line or fuel primer pump.

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 172 6 PERFORMANCE DIAGNOSTICS

Restriction Test

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\ 5

V21010

Figure 93 Fuel Restriction Test

1. Test point 1 6. Primary fuel filter 9. Fuel Inlet Restriction / Aeration
2. Strainer / primer pump 7. Low-pressure fuel pump Tool
3. Test point 2 8. Pressure Test Kit (vacuum
4. Fuel supply from tank gauge)
5. Test point 3

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 6 PERFORMANCE DIAGNOSTICS
Purpose
Check for fuel supply restriction.
Tools
• ZTSE4526 - Compucheck Fitting
• 15-637-01 – Clean Fuel Source Tool
• ZTSE4409 – Pressure Test Kit
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4906 – Fuel Line Coupler
Procedure
Test Point 1
1. Use Fuel Line Coupler ZTSE4906 to connect
Fuel Inlet Restriction / Aeration Tool ZTSE4886
between low-pressure fuel pump supply line and
low-pressure fuel pump inlet.
2. Connect Pressure Test Kit ZTSE4409 vacuum
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gauge to Fuel Inlet Restriction / Aeration Tool
ZTSE4886.
3. Prime fuel system by pumping primer pump.
4. Start engine while monitoring Pressure Test Kit
vacuum gauge. Record results on Diagnostics
Form.
• If restriction is above specification, go to
Restriction Test Point 2.
173
Test Point 2
1. Connect Clean Fuel Source Tool 15-637-01 to
primer pump inlet.
2. Prime fuel system by pumping primer pump.
3. Start engine while monitoring Pressure Test
Kit ZTSE4409 vacuum gauge. Record results
on Diagnostics Form.
• If restriction is within specification, go to
Restriction Test Point 3.
• If restriction is above specification, repair
or replace fuel strainer and primer pump
assembly, and check fuel lines.
Test Point 3
1. Connect Clean Fuel Source Tool 15-637-01 to
primary filter inlet.
2. Prime fuel system by pumping primer pump.
3. Start engine while monitoring Pressure Test
Kit ZTSE4409 vacuum gauge. Record results
on Diagnostics Form.
• If restriction is within specification, repair
restriction between primary fuel filter and
fuel tank.
• If restriction is above specification,
replace primary fuel filter, clean fuel
strainer, and check fuel lines.
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 174 6 PERFORMANCE DIAGNOSTICS

High-pressure Fuel System

BetterManuals.net 6 V00089

Figure 94 High-pressure (HP) fuel system

1. Injector (6) 4. Fuel Pressure Control Valve 6. HP fuel pump return
2. Fuel rail pressure limiting valve (FPCV) 7. HP fuel pump
3. Fuel Rail 5. HP fuel pump inlet 8. Fuel Rail Pressure (FRP) sensor

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 6 PERFORMANCE DIAGNOSTICS 175

High-pressure Pump Inlet Pressure Test

Purpose
Verify high-pressure fuel pump is receiving fuel.
Tools
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4905 – Fuel Block Off Tool
• ZTSE4906 – Fuel Line Coupler
V21011a
Procedure
Figure 95 Pressure Test Kit connected to DSI
1. Disconnect fuel supply to Down Stream Injection fuel supply line
(DSI) valve assembly.
1. DSI Fuel Supply Line
2. Use Fuel Line Coupler ZTSE4906 to connect Fuel 2. Fuel Line Coupler
Inlet Restriction / Aeration Tool ZTSE4886 to DSI 3. Fuel Inlet Restriction / Aeration Tool
fuel supply line. 4. Fuel Pressure Gauge
5. Fuel Block Off Tool

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3. Connect Fuel Block Off Tool ZTSE4905 to Fuel
Inlet Restriction / Aeration Tool ZTSE4886.
4. Connect ZTSE4681 Fuel Pressure Gauge to Fuel
Inlet Restriction / Aeration Tool ZTSE4886.
5. Start engine and run at high idle for 20
seconds, while monitoring Fuel Pressure Gauge
ZTSE4681. Record results on Diagnostics Form.
• If gauge pressure is within specification, go
to Fuel Rail Pressure (FRP) Return Flow Test
(page 176).
• If gauge pressure is below specification,
replace secondary fuel filter.

179
 176 6 PERFORMANCE DIAGNOSTICS
Fuel Rail Pressure (FRP) Return Flow Test
Purpose
Verify return flow is within specifications.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• Diesel fuel container
• ZTSE4887 – High Pressure Return Line Tester
Fuel Rail Pressure (FRP) Return Flow Test Part 1
NOTE: Before running this test, ensure
low-pressure fuel system is operating correctly.
1. Disconnect fuel drain tube assembly at rear of
cylinder head.
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Figure 96 High Pressure Return Line Tester
ZTSE4887 connected to cylinder head
2. Connect High Pressure Return Line Tester
ZTSE4887-2 using 2 banjo ring seals to cylinder
head fuel drain tube fitting. Thread ZTSE4887-3
to ZTSE4887-2 and route the end into a diesel
fuel container.
3. Crank engine for 20 seconds while monitoring
fuel return from High Pressure Return Line Tester
ZTSE4887.
• If fuel is returning, go to Fuel Rail Pressure
(FRP) Leak Isolation.
• If no fuel is returning, continue to next step.
Fuel Rail Pressure (FRP) Return Flow Test Part 2
NOTE: Before running this test, ensure
low-pressure fuel system is operating correctly.
4. Reconnect fuel drain tube assembly disconnected
in step 1.
5. Disconnect fuel rail return line at fuel rail.
6. Connect High Pressure Return Line Tester
ZTSE4887-2 using 2 banjo ring seals to fuel rail
return port. Thread ZTSE4887-3 to ZTSE4887-2
and route the end into a diesel fuel container.
7. Crank engine and monitor fuel return from High
Pressure Return Line Tester ZTSE4887.
• If fuel flows from High Pressure Return Line
Tester ZTSE4887, replace fuel rail pressure
relief valve.
• If fuel does not flow from High Pressure
Return Line Tester ZTSE4887, go to HP
Pump Return Flow Test.
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 6 PERFORMANCE DIAGNOSTICS
Fuel Rail Pressure (FRP) Leak Isolation
Normal fuel return flow with number of connected injectors
All 6 INJs 5 INJs 4 INJs
20 - 22 ml 16 - 18 ml 12 – 16 ml
NOTE: This table displays typical fuel return
volume specifications for a good running engine.
Results much higher than specification indicate
an excessive leak.
Purpose
Isolate pressure loss in high-pressure fuel system.
Tools
• Diesel fuel container measuring in milliliters
• ZTSE4887 – High Pressure Rail Return Line
Tester
• ZTSE6098 – High Pressure Rail Plugs
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Procedure
WARNING: The high-pressure fuel system
may have extremely high pressure. Verify
pressure is below 500 psi before cracking a
line. Every time the engine is shut down and the
key is in the OFF position, the ECM commands
a blank shot injection process that drains the
high-pressure fuel rail.
NOTE: Only run this test if engine fails High
Pressure Pump test.
1. Retain High Pressure Return Line Tester
ZTSE4887 connection to cylinder head from
previous test.
177
3 INJs 2 INJs
8 - 12 ml 8 - 10 ml
Figure 97 High Pressure Rail Plug installed on
injector six
2. Disconnect number six injector fuel line and cap
off rail with High Pressure Rail Plug ZTSE6098.
3. Start engine and run at low idle. When fuel
flow is steady and fuel volume reaches a good
starting measurement point, start timer, and begin
measurement. Measure fuel return volume for 1
minute. Record results on Diagnostics Form.
• If fuel volume is above specification, leave
High Pressure Rail Plug ZTSE6098 installed
and continue to next step.
• If fuel volume is within specification, replace
injector tube and high-pressure connector
body following procedures in the Engine
Service Manual. Retest volume of fuel being
returned with all six injectors connected to
verify repair.
4. Disconnect number five injector fuel line and cap
off rail with High Pressure Rail Plug ZTSE6098.
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 178 6 PERFORMANCE DIAGNOSTICS

5. Start engine and run at low idle. When fuel

flow is steady and fuel volume reaches a good
starting measurement point, start timer and begin
measurement. Measure fuel return volume for 1
minute. Record results on Diagnostics Form.
• If fuel volume is above specification,
leave High Pressure Rail Plug ZTSE6098
connected and continue capping off one
injector supply port at a time until excessive
leak is isolated. Once the excessive leak is
isolated, replace the removed injector tubes
with new parts.

HP Pump Fuel Return Pressure Test

Figure 98 High-pressure fuel pump return line
Purpose connected to Fuel Pressure Gauge
Verify return flow is within specifications.
Tools 3. Use Fuel Line Coupler ZTSE4906 to connect
high-pressure fuel pump return line to Fuel Inlet
• ZTSE4526 - Compucheck Fitting

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Restriction / Aeration Tool ZTSE4886.
• ZTSE4681 – Fuel Pressure Gauge 4. Use ZTSE4526 - Compucheck Fitting to connect
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool Fuel Inlet Restriction / Aeration Tool ZTSE4886 to
Fuel Pressure Gauge ZTSE4681.
• ZTSE4906 – Fuel Line Coupler
5. Start engine and run high idle while monitoring
Procedure Fuel Pressure Gauge.
NOTE: Prior to performing this test, ensure new • If pressure is above specification, inspect
fuel pump is the correct replacement part. fuel return line for restriction between
high-pressure fuel pump and fuel tank.
1. Restore fuel system to normal operating
condition. • If pressure is below specification, no further
action is required.
2. Disconnect high-pressure fuel pump return line.

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 6 PERFORMANCE DIAGNOSTICS
Crankcase Oil Breather Separator Test
Purpose
Check if centrifuge breather is functioning properly.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4800 – Ultrasonic Ear
Procedure
WARNING: To prevent personal injury or
death, read all safety instructions in the “Safety
Information” section of this manual.
WARNING: To prevent personal injury or
death, make sure the parking brake is set, the
transmission is in neutral or park, and the wheels
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are blocked when running the engine in the
service bay.
WARNING: To prevent personal injury or
death, avoid rotating parts (belts and fan) and hot
engine surfaces.
NOTE: Before performing this test, ensure engine
operating temperature is 82 to 88˚ C (180 to 190˚ F)
and oil level and pressure are within specification.
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle's Diagnostic Connector.
3. Start ServiceMaxx™ software.
4. Select Performance session.
5. Start engine. Ensure engine operating
temperature is 82 to 88˚ C (180 - 190˚ F).
NOTE: The Crankcase Oil Separator Speed
(CCOSS) sensor does not have circuit fault
codes. A Diagnostic Trouble Code (DTC)
will only be set if the Engine Control Module
(ECM) does not see an rpm signal with the
engine running.
179
6. Monitor CC Oil Separator (CCOS) signal with
engine at low and high idle. Record results on
Diagnostics Form.
• If CCOS is within specification, crankcase
breather system is operating correctly.
• If CCOS is reading 0 rpm with engine running,
continue to next step.
7. With engine running, place Ultrasonic Ear
ZTSE4800 near CCOSS sensor.
8. Turn engine OFF and quickly monitor for
centrifugal noise.
NOTE: The centrifuge will continue spinning
for 15 seconds after engine is shut off.
• If centrifuge noise is not heard, go to Engine
Service Manual for removal and replacement
procedures.
• If centrifuge noise can be heard, go to
Crankcase Oil Separator Speed (CCOSS)
Sensor (page 376) in “ELECTRONIC
CONTROL SYSTEMS DIAGNOSTICS."
Crankcase Pressure Test
Purpose
Verify if engine is in need for a possible overhaul
or repair due to cylinder or valve wear or damage.
Verify operation of air compressor or turbochargers
for possible worn or damaged parts.
Tools
• Digital manometer
• ZTSE2217A – Water Manometer
• ZTSE4039 – Crankcase Pressure Test Tool
• ZTSE4891 – Air Cap, Fuel Cap and Plug Kit
Procedure
NOTE: Before performing this test, ensure engine
is at normal operating temperature of 70˚ C (158˚ F)
and oil level and pressure are within specification.
1. Verify crankcase oil breather separator is
functioning properly before running this test. See
Crankcase Oil Breather Separator Test.
2. Disconnect breather outlet tube from top of oil
separator.
183
 180 6 PERFORMANCE DIAGNOSTICS

3. Connect Crankcase Pressure Test
ZTSE4039 to 90 degree breather elbow.
Tool 7. Shut engine OFF. Drain vehicle air tanks until
pressure is removed from air system.
8. Remove air line from remote-mounted centrifugal
filter and cap using Air Cap, Fuel Cap, and Plug
Kit ZTSE4891.
9. Start engine and run at high idle. Allow
manometer reading to stabilize before recording
pressure reading.
10. Record crankcase pressure on Diagnostics Form.
• If pressure is within specification, repair or
replace centrifugal filter assembly.
• If pressure is above specification, continue to
next step.

Figure 99 Digital manometer connected to

Crankcase Pressure Tool
1. Crankcase Pressure Test Tool

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2. Digital manometer

4. Connect manometer to Crankcase Pressure Test

Tool ZTSE4039.

WARNING: To prevent personal injury or

death, when routing test line, do not crimp line,
run line too close to moving parts, or let line touch
hot engine. Secure the gauge and test line to not
obstruct vehicle operation.

WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
5. Start engine and run at high idle. Allow
manometer reading to stabilize before recording
pressure reading.
6. Record crankcase pressure on Diagnostics Form.
• If pressure is within specification, no repair is
required.
• If pressure is above specification, continue to
next step.
Figure 100 Air compressor discharge port
11. If engine has an air compressor, remove
discharge line and test again. Allow manometer
reading to stabilize before recording pressure
reading.
12. Record crankcase pressure on Diagnostics Form.
• If pressure is above specification, go to
Relative Compression Test to pinpoint
suspect cylinder.
• If pressure is at or below specification,
compressed air is leaking into crankcase.
Repair or replace air compressor.

184
 6 PERFORMANCE DIAGNOSTICS 181

Cylinder Performance Test – Step 1 5. Follow on-screen instructions.

6. Record results on Diagnostics Form.
Relative Compression Test
• If the speed difference for one cylinder
Purpose is significantly lower than the others, that
cylinder is suspect for compression loss.
Verify all cylinders have good compression.
NOTE: The Relative Compression Test will ,..,_,_.""",._.,..,... ....,
r o• _°"'.,.l'--1..,.1 ~ a -~a-..__
validate cylinder balance. If an unbalanced ~

--·-~--~"-----------------...,,-L-
cylinder is found, it is caused by a mechanical R.elltM<:ompren:ton euo.
-
....,.......
problem, not an injector fault.

Tools ···-:1
M l . ~. .
--
,....
,.....~T.s!JftCtliln
~

l)SlirtO..-:T•lhaT•-
J)W..S_...,.Wc!-,cn,1q:..,.
J)~-.WIIIM-•c...,r&
4)~T•,_,,..
Mt.~•
NOTt.Oa- ......••-tfAl)'•ft>C'J'Cll
,_w..,sa,
a.tti, ..

• Electronic Service Tool (EST) with ServiceMaxx™ _ ,_

software
• J1939 and J1708 RP1210B Compliant Device

Procedure 0..-""""C-~
TfOIC[,_,... (!J:!"'

WARNING: To prevent personal injury or

10..0ICl11-0IC/lllf'IIOt-1 • ..... - -
..w--.1tllll6 ....... ' - ' - , - • ..... , - ~ ~ ..
death, read all safety instructions in the “Safety V21005

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Information” section of this manual.
Figure 101 Relative Compression test
NOTE: Use a battery charger when performing this
test. It is important that cranking rpm remains
consistent throughout test. Possible Causes
NOTE: Run Relative Compression Test a minimum • Valve train damage
of three times.
• Valves out of adjustment
1. Turn ignition switch to ON, engine OFF.
• Worn or broken piston rings
2. Connect EST to vehicle's Diagnostic Connector.
• Excessive cylinder wall wear
3. Start ServiceMaxx™ software.
• Damaged piston
4. Select Relative Compression test.

185
 182 6 PERFORMANCE DIAGNOSTICS

Cylinder Performance Test – Step 2 5. Select Cylinder Cutout Test.

6. Follow on-screen instructions.
Cylinder Cutout Test
NOTE: This test is only meant to isolate a low
Purpose contributing cylinder due to an injector or injector
circuit failure.
Determine cause of rough engine idle.
~ - - 1->I• ~~ , ~ l;,t,
Tools ~ ro• -..,Do1u11><r-.. l~I ~ a -. a,,_,_
Injector Disable 0l0d<
• Electronic Service Tool (EST) with ServiceMaxx™ Forbfflresull1: Coolan\Temperaturelhowdbe
above\60degrmF

software l)Runengine111't>lormaJ."forl0second.l.
Recordlhea~"'tn&ineLoall"andFuelRate'"

• J1939 and J1708 RP1210B Compliant Device 2)Disable(#)irljector forl01econds

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• Open or shorted injector wiring

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cytindenareevt:Njbalante.

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• Power cylinder problem o,
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Procedure
NOTE: Steps taken before running this test:

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Figure 102 ServiceMaxx™ Cylinder Cutout Test
• Run Relative Compression Test.
• Verify fuel system pressure is not below
specification and fuel is not aerated. 7. Record results on Diagnostics Form.
1. Turn ignition switch to ON, engine OFF. • If Cylinder Cutout Test does not identify a suspect
cylinder, no action is required.
2. Connect EST to vehicle's Diagnostic Connector.
• If Cylinder Cutout Test identifies a suspect
3. Start ServiceMaxx™ software.
cylinder and Relative Compression Test does not,
4. Start engine. replace failed Injector. See Injector Replacement.

186
 6 PERFORMANCE DIAGNOSTICS 183

Injector Replacement

Purpose
Calibrate Engine Control Module (ECM) for newly
installed injectors.
NOTE: Each injector is encrypted with an Injection
Quantity Adjustment (IQA) code that must be
programmed into the ECM anytime an injector
has been replaced.

Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
V21001
• J1939 and J1708 RP1210B Compliant Device
Figure 104 Picture of IQA code location
Procedure
IQA injects the correct amount of fuel for each
individual injector throughout the operating range of 5. Type in new IQA code (stamped on top portion of
the engine. Injector mechanical tolerances, high flow, injector) into proper cylinder location.

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and low flow can be evenly balanced with the ECM
calibration. Injection Qwntly Adjustment 7
1. Turn ignition switch to ON, engine OFF.
2. Connect EST to vehicle’s Diagnostic Connector.
Front
3. Start ServiceMaxx™ software.
I
Injection Quantity Adjustment

" Se rviceMaxx • Default

Fie View Sessoons Tests Procedures
0 ltaAtallOAtilltiA
I
j •~ r @ • Sess
Engine Off Procedures
02 5ensor Caibrotion
• I njection-
•
0 IA.*AAAWH!J II lx1do
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Aftertreotment Procedures Quant~y Adjustment
; IAAAA.QAAAAA
I
Figure 103 Injector Quantity Adjustment
-
0 IAAAA.QAAAAC
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procedure
0 IAAAA.QAAAAA
I

4. Select Injection Quantity Adjustment from

0 IAAAAQAAAAA
I
Procedures drop-down menu.
I Program ErlQine ...
I

V00146

Figure 105 Injector Quantity Adjustment

187
 184 6 PERFORMANCE DIAGNOSTICS
NOTE: When the Undo button appears, the
Program Engine button becomes active.
6. Press the Program Engine button.
7. Replace failed injector following procedures in the
Engine Service Manual.
Fuel Pressure Control Valve (FPCV) Test
Purpose
Verify FPCV is not sticking.
Tools
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
Procedure
1. Verify fuel system is operating
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specifications and is not aerated.
2. Start engine and run until Engine Coolant
Temperature is above 65 °C (150 °F)
3. Use ServiceMaxx™ software to run the Fuel
Pressure Control Valve Test. Follow on-screen
instructions.
4. Record results on Diagnostics Form.
NOTE: A minor ripple in the FRP signal
graph display is acceptable. A shark-tooth
fluctuation indicates FPCV is sticking.
• If FRP signal fluctuates in a shark-tooth
pattern, replace FPCV following procedures
in the Engine Service Manual.
• If FRP signal does not fluctuate in a
shark-tooth pattern, no further action is
required.
Charge Air Cooler (CAC) Pressure Test
Procedure
1. Attach Charge Air Cooler Test Kit ZTSE6042 to
the CAC using three-inch couplers and clamps
(obtain locally).
2. Attach pressure test gauge and gradually
pressurize CAC to 30 psi (207 kPa). Turn off air
within
supply when pressure reaches 30 psi (207 kPa).
3. If pressure drops, spray a soapy water solution on
the CAC. Look for leaks from hose connections,
CAC, and test components. Locate and mark
leaks.
4. If a leak is detected on the CAC or the test gauge
pressure drops, replace the CAC.
188
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 185

Table of Contents

Diagnostic Trouble Codes (DTCs) and Sub-section Diagnostics Page Locations. . . . . . . . . . . . . . . . . . . . . . . . .187

Diagnostics Form 0000002941 Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

HD-OBD System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

Diagnostic Procedure Process With Examples. . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .201

Circuit Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207

AAT Sensor (Ambient Air Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
AFT (Aftertreatment) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Aftertreatment System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
AFTFD (Aftertreatment Fuel Doser). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
AFTFIS (Aftertreatment Fuel Inlet Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
AFTFP2 (Aftertreatment Fuel Pressure 2 Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346
AFTFSV (Aftertreatment Fuel Shutoff Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349

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AMS (Air Management System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
APP Sensor (Accelerator Pedal Position). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
CACOT Sensor (Charge Air Cooler Outlet Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
CCOSS Sensor (Crankcase Oil Separator Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
CCS (Cruise Control System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378
CFV (Coolant Flow Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
CKP Sensor (Crankshaft Position). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382
CMP Sensor (Camshaft Position). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393
CMV (Coolant Mixer Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
IAHFI (Inlet Air Heater Fuel Igniter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
IAHFS (Inlet Air Heater Fuel Solenoid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Cylinder Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487
DOCOT Sensor (Diesel Oxidation Catalyst Outlet Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503
DPFDP Sensor (Diesel Particulate Filter Differential Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526
DPF System (Diesel Particulate Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
EBPV (Exhaust Back Pressure Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578
ECB1 (Engine Compression Brake 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581
ECB2 (Engine Compression Brake 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
ECL Switch (Engine Coolant Level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587
ECM Power (Engine Control Module). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
ECM Power Output (Engine Control Module). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591
ECM (Engine Control Module) Self-Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596
ECS (Engine Coolant System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .599
ECT1 Sensor (Engine Coolant Temperature 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605
ECT2 Sensor (Engine Coolant Temperature 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
EFC (Engine Fan Control) – Two Speed and Variable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615
EGRT Sensor (Exhaust Gas Recirculation Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
EGR (Exhaust Gas Recirculation) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .621

189
 186 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Exhaust Gas Recirculation (EGR) System Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625

EOL Sensor (Engine Oil Level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .632
EOP Sensor (Engine Oil Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635
EOT Sensor (Engine Oil Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638
ETV (Engine Throttle Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640
EWPS (Engine Warning Protection System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .647
FDP Sensor (Fuel Delivery Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674
FPCV (Fuel Pressure Control Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681
FRP Sensor (Fuel Rail Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683
FRP (Fuel Rail Pressure) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693
Hard Brake Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .709
HS (Humidity Sensor) / IAT (Inlet Air Temperature Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710
IMP (Intake Manifold Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .715
IMT Sensor (Intake Manifold Temperature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725
INJ (Injector) Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728
IST (Idle Shutdown Timer) System (Clean Low Idle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .802
IST (Idle Shutdown Timer) System (Federal - Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .803
J1939 Data Link Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .804
MAF Sensor (Mass Air Flow). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .807
MIL (Malfunction Indicator Lamp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .808
O2S (Oxygen Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .810
RAPP (Remote Accelerator Pedal Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .826

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Service Interval Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .828
SART (Stand Alone Real Time) Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829
TC1TOP Sensor (Turbocharger 1 Turbine Outlet Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .831
TC1WC (Turbocharger 1 Wastegate Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .835
TC2WC (Turbocharger 2 Wastegate Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .838
TC2CIS (Turbocharger 2 Compressor Inlet Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .841
TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor. . . . . . . . . . . . . . . .861
VREF (Voltage Reference). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .881
WIF Sensor (Water In Fuel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .888
WIFL (Water In Fuel Lamp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891
WTSL (Wait to Start Lamp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897

Sensor and Actuator Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .904

190
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 187

Diagnostic Trouble Codes (DTCs) and

Sub-section Diagnostics Page Locations

SPN FMI Sub-section Condition Description

27 0 EGR (page 621) EGRP fault: over temperature
27 3 EGR (page 621) EGRP signal Out of Range HIGH
27 4 EGR (page 621) EGRP signal Out of Range LOW
27 7 EGR (page 621) EGRP does not agree with commanded position
51 0 ETV (page 640) ETP fault: over temperature
51 3 ETV (page 640) ETP signal Out of Range HIGH
51 4 ETV (page 640) ETP signal Out of Range LOW
51 7 ETV (page 640) ETP does not agree with commanded position
84 2 VS (page 861) Vehicle speed anti-tampering fault
91 2 APP (page 363) APP1 and APP2 signal conflict
91 3 APP (page 363) APP1 signal Out of Range HIGH
91 4 APP (page 363) APP1 signal Out of Range LOW

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94 0 FDP (page 674) Fuel Delivery Pressure above maximum
94 3 FDP (page 674) FDP signal Out of Range HIGH
94 4 FDP (page 674) FDP signal Out of Range LOW
97 3 WIFL (page 891) WIFL short to PWR
97 4 WIFL (page 891) WIFL short to GND
97 5 WIFL (page 891) WIFL open load/circuit
98 3 EOL (page 632) EOL signal Out-of-Range HIGH
98 4 EOL (page 632) EOL signal Out-of-Range LOW
100 1 EWPS (page 647) Engine Oil System below Critical Pressure
100 3 EOP (page 635) EOP signal Out of Range HIGH
100 4 EOP (page 635) EOP signal Out of Range LOW
100 11 EWPS (page 647) Engine oil pressure below dealer programmed engine
RPM value
100 17 EWPS (page 647) Low Oil Pressure vehicle event fault
100 18 EWPS (page 647) Engine Oil System below Warning Pressure
102 2 IMP (page 715) IMP signal does not agree with BARO
102 3 IMP (page 715) IMP signal Out of Range HIGH
102 4 IMP (page 715) IMP signal Out of Range LOW
102 10 IMP (page 715) IMP Boost slow response
102 16 AMS (page 356) Intake Manifold Pressure Overboost
102 18 AMS (page 356) Intake Manifold Pressure Underboost

191
 188 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN FMI Sub-section Condition Description

105 2 IMT (page 725) IMT signal does not agree with other sensors
105 3 IMT (page 725) IMT signal Out of Range HIGH
105 4 IMT (page 725) IMT signal Out of Range LOW
105 18 IMT (page 725) IMT signal not responding as expected
108 3 ECM Self (page 596) BARO signal Out of Range HIGH
108 4 ECM Self (page 596) BARO signal Out of Range LOW
110 0 EWPS (page 647) Engine Coolant System above Critical Temperature
110 3 ECT1 (page 605) ECT1 signal Out of Range HIGH
110 4 ECT1 (page 605) ECT1 signal Out of Range LOW
110 11 EWPS (page 647) Event logger, coolant temperature hot, extreme
110 15 EWPS (page 647) Engine Coolant System above Warning temperature
110 16 EWPS (page 647) Engine Coolant System above OBD maximum
temperature
110 17 ECS (page 599) Engine Coolant System below OBD monitoring
temperature

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110 18 ECS (page 599) Engine coolant system below closed loop minimum
temperature
111 1 EWPS (page 647) Low Engine Coolant Level
ECL (page 587)
157 0 FRP (page 693) FRP relief valve opening fault
157 3 FRP (page 683) FRP signal Out of Range HIGH
157 4 FRP (page 683) FRP signal Out of Range LOW
157 14 FRP (page 693) FRP Relief Valve failure
157 20 FRP (page 683) FRP signal Drifted HIGH
157 21 FRP (page 683) FRP signal Drifted LOW
158 15 ECM PWR (page 589) ECM Switched voltage too HIGH
158 17 ECM PWR (page 589) ECM Switched voltage too LOW
171 2 AAT (page 207) AAT signal does not agree with other sensors
171 3 AAT (page 207) AAT signal Out of Range HIGH (Body mounted sensor)
171 4 AAT (page 207) AAT signal Out of Range LOW (Body mounted sensor)
172 2 IAT (page 710) IAT signal does not agree with other sensors
172 3 IAT (page 710) IAT signal Out of Range HIGH
172 4 IAT (page 710) IAT signal Out of Range LOW
175 0 EWPS (page 647) Engine Oil System above Critical Temperature
175 3 EOT (page 638) EOT signal Out of Range HIGH

192
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 189

SPN FMI Sub-section Condition Description

175 4 EOT (page 638) EOT signal Out of Range LOW
175 11 EWPS (page 647) Oil Temperature Exceeds limit by large amount
175 15 EWPS (page 647) Engine Oil System above warning temperature
188 0 EWPS (page 647) Engine unable to achieve desired idle speed (too high)
188 1 EWPS (page 647) Engine unable to achieve desired idle speed (too low)
190 0 EWPS (page 647) Engine overspeed most severe level
190 11 EWPS (page 647) Engine overspeed vehicle event fault
190 15 EWPS (page 647) Engine overspeed detected
191 1 TOSS (page 861) TOSS not detected with vehicle moving
191 2 TOSS (page 861) TOSS signal erratic, intermittent or incorrect
191 3 TOSS (page 861) TOSS signal Out of Range HIGH
191 4 TOSS (page 861) TOSS signal Out of Range LOW
191 16 TOSS (page 861) Hard wired vehicle speed reading higher than limit
251 19 SART (page 829) ECM not detecting SART module J1939

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354 3 HS (page 710) Relative Humidity signal Out of Range HIGH
354 4 HS (page 710) Relative Humidity signal Out of Range LOW
412 1 EGRT (page 618) EGRT signal stuck low, not warming up
412 2 EGRT (page 618) EGRT signal does not agree with other sensors
412 3 EGRT (page 618) EGRT signal Out of Range HIGH
412 4 EGRT (page 618) EGRT signal Out of Range LOW
560 19 J1939 (page 804) Transmission Driveline Engaged not detected on J1939
626 3 IAHFS (page 421) IAHFS short to PWR
626 4 IAHFS (page 421) IAHFS short to GND
626 5 IAHFS (page 421) IAHFS open load/circuit
626 18 IAHFS (page 421) Inlet Air Heater fault: Lack of heat in the Intake Manifold
IAHFI (page 411)
628 12 ECM Self (page 596) ECM Memory Error
629 2 ECM Self (page 596) ECM Error – Level 2 Monitoring
629 8 ECM Self (page 596) Engine Off timer fault
629 12 ECM Self (page 596) ECM Internal chip Error
629 14 ECM Self (page 596) ECM Internal component
633 3 FPCV (page 681) FPCV short to PWR
633 4 FPCV (page 681) FPCV short to GND
633 5 FPCV (page 681) FPCV open load/circuit

193
 190 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN FMI Sub-section Condition Description

636 2 CMP (page 393) CMP and CKP Synchronization Error
636 8 CMP (page 393) CMP signal noise
636 10 CMP (page 393) CMP signal missing
637 8 CKP (page 382) CKP signal noise
637 10 CKP (page 382) CKP signal inactive
639 14 J1939 (page 804) J1939 Data Link Error (ECM unable to transmit)
639 19 J1939 (page 804) J1939 Data Link Error (ECM unable to transmit or
receive)
647 3 EFC (page 615) EFC short to PWR
647 4 EFC (page 615) EFC short to GND
647 5 EFC (page 615) EFC open load/circuit
651 4 INJ (page 728) INJ short circuit
651 5 INJ (page 728) INJ open circuit
651 13 CYL Balance (page 424) Injector 1 programmable parameter error

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651 16 CYL Balance (page 424) Injector 1 Fuel quantity/timing high error
651 18 CYL Balance (page 424) Injector 1 Fuel quantity/timing low error
652 4 INJ (page 728) Injector 2 short circuit
652 5 INJ (page 728) Injector 2 open circuit
652 13 CYL Balance (page 424) Injector 2 programmable parameter error
652 16 CYL Balance (page 424) Injector 2 Fuel quantity/timing high error
652 18 CYL Balance (page 424) Injector 2 Fuel quantity/timing low error
653 4 INJ (page 728) Injector 3 short circuit
653 5 INJ (page 728) Injector 3 open circuit
653 13 CYL Balance (page 424) Injector 3 programmable parameter error
653 16 CYL Balance (page 424) Injector 3 Fuel quantity/timing high error
653 18 CYL Balance (page 424) Injector 3 Fuel quantity/timing low error
654 4 INJ (page 728) Injector 4 short circuit
654 5 INJ (page 728) Injector 4 open circuit
654 13 CYL Balance (page 424) Injector 4 programmable parameter error
654 16 CYL Balance (page 424) Injector 4 Fuel quantity/timing high error
654 18 CYL Balance (page 424) Injector 4 Fuel quantity/timing low error
655 4 INJ (page 728) Injector 5 short circuit
655 5 INJ (page 728) Injector 5 open circuit
655 13 CYL Balance (page 424) Injector 5 programmable parameter error
655 16 CYL Balance (page 424) Injector 5 Fuel quantity/timing high error

194
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 191

SPN FMI Sub-section Condition Description

655 18 CYL Balance (page 424) Injector 5 Fuel quantity/timing low error
656 4 INJ (page 728) Injector 6 short circuit
656 5 INJ (page 728) Injector 6 open circuit
656 13 CYL Balance (page 424) Injector 6 programmable parameter error
656 16 CYL Balance (page 424) Injector 6 Fuel quantity/timing high error
656 18 CYL Balance (page 424) Injector 6 Fuel quantity/timing low error
2
724 2 O S (page 810) O2S Slow response detecting fueling to non-fueling
2
724 3 O S (page 810) O2S Circuit Fault: Open or short to PWR
2
724 4 O S (page 810) O2S Circuit Fault: Short to GND
2
724 5 O S (page 810) O2S Circuit Fault: Open circuit
2
724 20 O S (page 810) O2S adaptation above maximum limit
2
724 21 O S (page 810) O2S adaptation below minimum limit
837 14 SPEEDO Speedometer Drive Output Error
Refer to the Chassis Electrical Circuit Diagram Manual

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974 3 RAPP (page 826) Remote APP signal Out of Range HIGH
974 4 RAPP (page 826) Remote APP signal Out of Range LOW
1072 3 ECB1 (page 581) ECB1 Control short to PWR
1072 4 ECB1 (page 581) ECB1 Control short to GND
1072 5 ECB1 (page 581) ECB1 Control open load/circuit
1073 3 ECB2 (page 584) ECB2 Control short to PWR
1073 4 ECB2 (page 584) ECB2 Control short to GND
1073 5 ECB2 (page 584) ECB2 Control open load/circuit
1081 3 WTSL (page 897) WTSL short to PWR
1081 4 WTSL (page 897) WTSL short to GND
1081 5 WTSL (page 897) WTSL open load/circuit
1110 31 ECM Self (page 596) ECM detects fueling without demand
1135 3 EOL (page 632) EOT2 signal Out of Range HIGH
1135 4 EOL (page 632) EOT2 signal Out of Range LOW
1173 2 TC2CIS (page 841) TC2CIT signal does not agree with other sensors
1173 3 TC2CIS (page 841) TC2CIT signal Out of Range HIGH
1173 4 TC2CIS (page 841) TC2CIT signal Out of Range LOW
1173 16 AMS (page 356) TC2CIT signal above desired (interstage CAC under
cooling)
1177 2 TC2CIS (page 841) TC2CIT signal erratic, intermittent, or incorrect
1177 3 TC2CIS (page 841) TC2CIP signal Out of Range HIGH

195
 192 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN FMI Sub-section Condition Description

1177 4 TC2CIS (page 841) TC2CIP signal Out of Range LOW
1188 3 TC1WC (page 835) TC1WC short to PWR
1188 4 TC1WC (page 835) TC1WC short to GND
1189 3 TC2WC (page 838) TC2WC short to PWR
1189 4 TC2WC (page 838) TC2WC short to GND
1189 5 TC2WC (page 838) TC2WC open load/circuit
1213 3 MIL (page 808) MIL circuit short to PWR
1213 4 MIL (page 808) MIL circuit short to GND
1213 5 MIL (page 808) MIL open load/circuit
1322 31 CYL Balance (page 424) Misfire - Multiple Cylinders
1323 31 CYL Balance (page 424) Misfire - Cylinder 1
1324 31 CYL Balance (page 424) Misfire - Cylinder 2
1325 31 CYL Balance (page 424) Misfire - Cylinder 3
1326 31 CYL Balance (page 424) Misfire - Cylinder 4

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1327 31 CYL Balance (page 424) Misfire - Cylinder 5
1328 31 CYL Balance (page 424) Misfire - Cylinder 6
1378 31 Service (page 828) Change Engine Oil Service Interval
1590 19 Adaptive Cruise Control (page Adaptive Cruise Control not detected on J1939
804)
1659 20 ECS (page 599) ECT1 below expected: Check Thermostat
1810 0 Hard Brake Monitor (page 709) Hard Brake monitor, event log, extreme
1810 15 Hard Brake Monitor (page 709) Hard Brake monitor, event log, non-extreme
2588 0 EWPS(page 647) Vehicle overspeed 1, event log, extreme
2588 15 EWPS (page 647) Vehicle overspeed 1, event log, non-extreme
2589 0 EWPS (page 647) Vehicle overspeed 2, event log, extreme
2589 15 EWPS (page 647) Vehicle overspeed 2, event log, non-extreme
2623 3 APP (page 363) APP2 signal Out of Range HIGH
2623 4 APP (page 363) APP2 signal Out of Range LOW
2630 2 CACOT (page 368) CACOT signal does not agree with other sensors
2630 3 CACOT (page 368) CACOT signal Out of Range HIGH
2630 4 CACOT (page 368) CACOT signal Out of Range LOW
2630 16 CACOT (page 368) CACOT undercooling
2659 20 AMS (page 356) EGR High Flow Rate detected
2659 21 AMS (page 356) EGR Low Flow Rate detected
2791 3 EGR (page 621) EGRC short to PWR

196
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 193

SPN FMI Sub-section Condition Description

2791 5 EGR (page 621) EGRC open load/circuit
2791 8 EGR (page 621) EGR valve not receiving ECM PWM signal
2797 11 INJ (page 728) Injector Control Group 1 short circuit (INJ 1, 3, 5)
2798 11 INJ (page 728) Injector Control Group 2 short circuit (INJ 2, 4, 6)
3055 0 FRPS (page 693) FRP exceeded maximum
3055 1 FRPS (page 693) No start due to low rail fuel pressure
3055 15 FRPS (page 693) FRP below minimum with maximum command
3055 17 FRPS (page 693) FRP above maximum with minimum command
3058 0 EGR System Monitor (page EGR did not go into Open loop EGR control when
625) expected
3058 10 EGR System Monitor (page EGR did not go into Closed loop EGR control when
625) expected
3223 0 O2S (page 810) O2S heater temperature above maximum
3223 1 O2S (page 810) O2S heater temperature below minimum
3223 3 O2S (page 810) O2S heater short to PWR

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3223 4 O2S (page 810) O2S heater short to GND
3223 5 O2S (page 810) O2S heater open load/circuit
3223 17 O2S (page 810) O2S heater temperature below minimum at low battery
PWR
3246 2 DPFOT (page 526) DPFOT signal does not agree with other exhaust sensors
3246 3 DPFOT (page 526) DPFOT signal Out of Range HIGH
3246 4 DPFOT (page 526) DPFOT signal Out of Range LOW
3246 20 DPFOT (page 526) DPFOT signal drifted HIGH
3246 21 DPFOT (page 526) DPFOT signal drifted LOW
3251 0 AFT System (page 217) DPFDP excessively HIGH (restricted filter)
3251 2 DPFDP (page 514) DPFDP above or below desired level
3251 3 DPFDP (page 514) DPFDP signal Out of Range HIGH
3251 4 DPFDP (page 514) DPFDP signal Out of Range LOW
3251 14 AFT System (page 217) DPFDP sensor pressure hoses reversed
3251 21 AFT System (page 217) DPFDP excessively LOW (Sensor/circuit fault or missing
DPF)
3464 3 ETV (page 640) ETC short to PWR
3464 5 ETV (page 640) ETC open load/circuit
3464 8 ETV (page 640) ETC not receiving command from ECM
3471 1 AFT System (page 217) Fuel Pressure 1 below desired (Low system pressure)
3471 7 AFT System (page 217) Fuel Doser Valve not responding as expected

197
 194 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN FMI Sub-section Condition Description

3479 3 AFTFD (page 330) AFTFD Fuel Doser Valve short to PWR
3479 5 AFTFD (page 330) AFT Fuel Doser Valve open/load circuit
3479 6 AFTFD (page 330) AFT Fuel Doser Valve High Side Short circuit
3480 0 AFT System (page 217) AFTFP1 too high while dosing
3480 1 AFT System (page 217) AFTFP1 too low while dosing
3480 2 AFTFIS (page 333) AFTFP1 sensor plausibility error
3480 3 AFTFIS (page 333) AFTFP1 signal Out of Range HIGH
3480 4 AFTFIS (page 333) AFTFP1 signal Out of Range LOW
3481 7 AFT System (page 217) Incorrect dosing pressure, multiple events
3482 3 AFTFSV (page 349) AFT Fuel Shutoff Valve short to PWR
3482 4 AFTFSV (page 349) AFT Fuel Shutoff Valve short to GND
3509 14 VREF (page 881) VREF1 voltage deviation ECM pins: C1-36
3510 14 VREF (page 881) VREF2 voltage deviation ECM pins: E1-85 and E1-86
3511 14 VREF (page 881) VREF3 voltage deviation ECM pins: E1-89

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3512 14 VREF (page 881) VREF4 voltage deviation ECM pins: C1-37, C1-49,
C2-08 and E1-58
3513 14 VREF (page 881) VREF5 voltage deviation ECM pins: C1-50, E1-81, and
E1-82.
3514 14 VREF (page 881) VREF6 voltage deviation ECM pin: E1-88
3556 0 AFT System (page 217) AFT fuel pressure 2 excessively high
3556 1 AFT System (page 217) AFT fuel pressure 2 below desired
3556 7 AFT System (page 217) AFT fuel injector not responding as expected
3597 4 ECM PWR Output (page 591) ECM Power Output 1 below normal ECM Pins: C1-31,
C1-33, C1-54, C2-51, E1-01 and E1-51
3598 4 ECM PWR Output (page 591) ECM Power Output 2 below normal ECM Pins: C1-42,
C2-06, E1-05, E1-28, E1-29 and E1-54
3599 4 ECM PWR Output (page 591) ECM Power Output 3 below normal ECM Pins: C1-30,
C2-03, E1-24, E1-26 and E1-27
3719 0 DPF System (page 549) DPF Soot Load - Highest (level 3/3)
3719 15 DPF System (page 549) DPF Soot Load - Lowest (level 1/3)
3719 16 DPF System (page 549) DPF Soot Load - Moderate (level 2/3)
3720 0 DPF System (page 549) DPF Ash load at maximum limit (Remove DPF for
cleaning)
3750 31 AFT System (page 217) DPF Regen inhibited due to low exhaust temperatures
3936 10 DPF System (page 549) DPF Thermal management mode failed to raise DOC-In
Temp as expected
3936 20 DPF System (page 549) High Regen Frequency

198
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 195

SPN FMI Sub-section Condition Description

4076 0 EWPS (page 647) ECT2 above Critical (EWPS programmable limit)
4076 2 ECT2 (page 607) ECT2 signal erratic, intermittent, or incorrect
4076 3 ECT2 (page 607) ECT2 signal Out of Range HIGH
4076 4 ECT2 (page 607) ECT2 signal Out of Range LOW
4076 15 EWPS (page 647) ECT2 above Warning (EWPS programmable limit)
4076 16 ECT2 (page 607) ECT2 signal does not agree with other sensors (Cold
soak)
4076 17 ECT2 (page 607) ECT2 signal stuck low, not warming up
4077 0 AFT System (page 217) AFTFP2 too high while dosing
4077 1 AFT System (page 217) AFTFP2 too low while dosing
4077 3 AFTFP2 (page 346) AFTFP2 signal out of Range HIGH
4077 4 AFTFP2 (page 346) AFTFP2 signal out of Range LOW
4077 14 AFTFP2 (page 346) AFTFP2 Sensor plausibility error
4192 3 WIF (page 888) WIF signal Out of Range HIGH

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4192 4 WIF (page 888) WIF signal Out of Range LOW
4227 7 CCOSS (page 376) CC Oil Separator Speed: Not spinning
4752 4 ECS (page 599) EGR Cooler Efficiency: EGR outlet Temperature above
expected
4765 2 DOCIT (page 487) DOCIT signal does not agree with other exhaust sensors
4765 3 DOCIT (page 487) DOCIT signal Out of Range HIGH
4765 4 DOCIT (page 487) DOCIT signal Out of Range LOW
4765 20 DOCIT (page 487) DOCIT signal drifted HIGH
4765 21 DOCIT (page 487) DOCIT signal drifted LOW
4766 2 DOCOT (page 503) DOCOT signal does not agree with other exhaust
sensors
4766 3 DOCOT (page 503) DOCOT signal Out of Range HIGH
4766 4 DOCOT (page 503) DOCOT signal Out of Range LOW
4766 10 AFT System (page 217) DPF Regeneration feedback fault
4766 20 AFT System (page 217) DOC Outlet Temp above maximum desired
4766 21 AFT System (page 217) DOC Outlet Temp below minimum desired
5298 2 AFT System (page 217) Reduced DOC Efficiency – De-Rate
5319 31 AFT System (page 217) DPF incomplete Regeneration
5395 0 EWPS (page 647) Engine idle fuel quantity too high
5395 1 EWPS (page 647) Engine idle fuel quantity too high
5456 3 AFTFIS (page 333) AFTFT signal Out of Range HIGH

199
 196 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN FMI Sub-section Condition Description

5456 4 AFTFIS (page 333) AFTFT signal Out of Range LOW
5541 2 TC1TOP (page 831) TC1TOP does not agree with BARO
5541 3 TC1TOP (page 831) TC1TOP signal Out of Range HIGH
5541 4 TC1TOP (page 831) TC1TOP signal Out of Range LOW
5542 15 EBPV (page 578) TC1TOP above desired
5542 17 EBPV (page 578) TC1TOP below desired
5543 3 EBPV (page 578) EBPC short to PWR
5543 4 EBPV (page 578) EBPC short to GND
5543 5 EBPV (page 578) EBPC open load/circuit
5546 3 CMV (page 409) CMV short to PWR
5546 4 CMV (page 409) CMV short to GND
5546 5 CMV (page 409) CMV open load/circuit
5547 3 CFV (page 380) CFV short to PWR
5547 4 CFV (page 380) CFV short to GND

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5547 5 CFV (page 380)
5548 3 IAHFI (page 411)
5548 4 IAHFI (page 411)
5548 5 IAHFI (page 411)
5548 7 IAHFI (page 411)
CFV open load/circuit
IAHFI short to PWR
IAHFI short to GND
IAHFI open load/circuit
Inlet Air Heater Relay return (relay, or igniter, or circuit
failure)

200
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 197

Diagnostics Form 0000002941 Usage

Diagnostics Form Example

ELECTRONIC CONTROL SYSTEM DIAGNOSTICS AwARNING

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Figure 106 Diagnostics form (front side)

Engine diagnostics form 0000002941 assists description of vehicle circuits, circuit numbers, or
®
technicians in troubleshooting MaxxForce diesel connector and fuse locations, see truck Chassis
engines. Diagnostic schematics and signal values Electrical Circuit Diagram Manual and Electrical
help technicians find problems to avoid unnecessary System Troubleshooting Guide. The back side of the
repairs. form consists of signal values.
The Electronic Control System Diagnostics form Diagnostics Form 0000002941 is available in 50 sheet
consists of a circuit diagram for electrical components pads. To order technical service literature, contact
mounted on the engine and vehicle. For a detailed your International dealer.

201
 198 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

HD-OBD System Description

Heavy Duty – Onboard Diagnostic System
HD-OBD System is comprised mainly of software
designed into the engine’s onboard computer to
detect emission control system malfunctions as they
occur by monitoring virtually every component and
system that can cause an increase in emissions.
Diagnostic Trouble Codes (DTCs)

110 - - - - ~ -
aow,<edNUOt
_,,_ lll - Dou nnUc Ultcralitcnt ..

V00134a

Figure 107 Electronic Service Tool DTC Screen Shot

1. Suspect Parameter Number 4. Permanent Diagnostic Trouble 7. Refresh DTC/Vehicle Events
(SPN) Codes tab button
2. Failure Mode Indicator (FMI) 5. Freeze Frame

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3. Fault Code Type 6. Clear DTCs button

DTC Faults • If the same fault is detected on the second drive

® cycle, the fault becomes Active and turns on the
NOTE: 2010 MaxxForce engines are now
Malfunction Indicator Lamp (MIL).
complying with Society of Automotive Engineers
(SAE) naming conventions. Many components Active DTC (MIL on)
will have different names than the 2008-2009
® Active faults or HD-OBD faults are faults that were
MaxxForce 11 and 13 engines.
detected on two consecutive drive cycles and are
Suspect Parameter Number (SPN) currently active right now.
The SPN identifies the individual component causing Healing DTC (MIL on)
the DTC.
A Healing DTC is an Active fault that was detected on
Failure Mode Indicator (FMI) a previous drive cycle, but was not detected on the
second drive cycle.
The FMI identifies the type of failure of the individual
component. • If the same fault is not detected on the next three
consecutive drive cycles, then the fault becomes
Pending DTC (MIL off)
Previously Active and the Malfunction Indicator
Pending faults are possible faults that were detected Lamp (MIL) is turned off.
on the first drive cycle and do not turn on the
• If the same fault is detected within the next three
Malfunction Indicator Lamp (MIL). Only a Heavy Duty
consecutive drive cycles, then the fault returns to
Onboard Diagnostic (HD-OBD) fault can be set as
Active and the MIL stays on.
pending.
• If the same fault was not detected on the second
drive cycle, that same fault is cleared on the third
drive cycle.

202
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Previously Active DTC (MIL off)
Previously active faults, are historical faults that were
detected in a previous drive cycle, but were not
detected on then next 3 consecutive Healing drive
cycles.
• If the same fault is not detected again on three
consecutive drive cycles, the fault becomes
Previously Active and Malfunction Indicator Lamp
(MIL) is turned off.
• If the same fault is detected within three
consecutive drive cycles, then the fault returns
Active and the MIL turns on.
Freeze Frame
Freeze Frame data is a snapshot of the engine's
operating condition at the time the fault was detected.
• Freeze Frame data is updated each drive cycle in
which a fault is detected
• Freeze Frame data is cleared when the DTC is
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cleared.
Permanent Diagnostic Trouble Codes
Permanent DTCs are historic faults that should not be
treated as a current problem with the control system.
When an active HD-OBD DTC is set, a permanent
DTC is also set. A permanent DTC is cleared when
the monitor that set the active DTC passes on three
consecutive drive cycles.
Clearing DTCs
DTCs can be cleared by pressing the Clear DTCs
button with the ignition Key ON, Engine OFF (KOEO).
DTCs cannot be cleared with the engine running.
Cycle the ignition key to verify DTCs have been
cleared from the ECM.
HD-OBD Fault Detection
The HD-OBD system monitors the control system
much like a non-OBD system, but with much tighter
tolerances. HD-OBD allows two occurrences of a
fault before the MIL is turned on. This provides
more confidence that the fault really exists. If a
fault condition is detected, a pending fault is set
with Freeze Frame data and will remain pending
through the rest of the drive cycle. If the fault occurs
again before the end of the next drive cycle, then it
199
becomes an active fault, and the MIL is illuminated
with updated Freeze Frame data. If the fault does not
occur again before the end of the next drive cycle,
then the pending fault is cleared along with the Freeze
Frame data, and the MIL is not illuminated.
Not all faults require two occurrences to become
active. Most sensor and actuator circuit faults will
skip the pending status and make the fault active on
the first occurrence.
After faults become active, the monitor will continue to
check the fault condition. If the fault test continues to
fail, it will be reported as active. If the fault test passes,
it will start the process of clearing the fault. After three
consecutive drive cycles, where the fault condition is
tested and passed, the MIL will turn off, the code will
go previous active for the next 40 warm-up cycles,
and the MIL is not illuminated. After those warm-up
cycles, the code is cleared without using the Electronic
Service Tool (EST).
Readiness Monitors
Readiness indicates the status of the HD-OBD
monitors, whether they can be run on this drive cycle
and whether they have been run. It is not related
to whether a fault is pending, active, or previously
active.
Readiness is required to assist in HD-OBD
inspections. If a vehicle is due for HD-OBD inspection
and would fail because a fault code exists, it is
possible for the driver to clear the code by using the
Electronic Service Tool (EST) or by disconnecting
the battery. However, either of these will reset the
readiness status. The inspector will see that there
are no codes, but also see that some of the HD-OBD
monitors have not been run, so will refuse to allow the
vehicle to pass inspection until all the monitors have
a Run Status and no codes are present.
All monitors will run at some point during normal
operation of the vehicle. However, to satisfy all the
different trip monitors, the vehicle must be driven
under a variety of conditions.
ServiceMaxx™ HD-OBD Monitor Session
HD-OBD monitors can be viewed using
ServiceMaxx™ software with the HD-OBD Monitor
session file.
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 200 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Monitor Results • The HD-OBD Compliant level of the system.

Monitor Results display the results of each monitors
actual value with pass or fail thresholds. A technician
can use this information to validate if a repair was
successful.
• A monitor will pass if the value is within the
minimum and maximum allowed value for a
certain amount of time.
• A monitor will fail if the value is outside of the
minimum and maximum allowed value for a
certain amount of time. A failed monitor will set a
DTC with Freeze Frame data.
• If a monitor has not run, the drive cycle conditions
have not been met.
NOTE: Press the Refresh DTC/Vehicle Event
button to view monitors. Press the Clear DTCs
button to clear monitors.
Readiness Report Tab
• The status of groups of HD-OBD monitors:
whether or not the monitors in each group
are supported on this vehicle, whether or not
the monitors in each group have finished, and
whether or not a condition has occurred that
would prevent the execution of the monitors in
each group on the current drive cycle.
After faults have been cleared, the technician could
use this information to find out if monitors have been
run or not.
Not-To-Exceed Operation Status Tab
This tab displays information about whether the
engine is operating in a geographical region to
control NOx and particulate matter emissions that
cannot exceed specified limits. For both NOx and
particulate matter emissions, the information includes
whether or not the engine is operating in the defined
Not-To-Exceed area, whether or not the engine is
operating in an area of limited Not-To-Exceed testing

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This tab displays the results from the last execution of
(the carve-out area), and whether or not the engine
HD-OBD monitors. The results include the minimum
is operating in an area where a Not-To-Exceed
and maximum allowed value (if applicable) and the
deficiency has been received.
actual test result value. If the test result is within the
minimum and maximum allowed value, the monitor Calibration Identification Tab
passed successfully and no failure was detected.
This tab displays information about the calibration in
This information can be used by a technician to check the engine control module. This information includes
the test results after repairs were performed. the calibration identifier and a verification number that
is computed for each calibration.
Diagnostic Readiness Tab
This tab displays general information about the state
of the HD-OBD system. This includes:
• The number of active and previous active fault
codes.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 201

Diagnostic Procedure Process With Pin-grip Inspection

Examples
Description
The test procedures in this section are based on the
assumption there is a Diagnostic Trouble Code (DTC)
or problem with the component being tested.
When a DTC is detected, select the appropriate SPN,
FMI, and sub-section page number from DTC list to
locate a specific component or circuit to be tested.
Do checks in sequence unless directed otherwise. If
a test point is out of specification, the comment area
will direct the technician to the possible cause or to
another test point. It is not necessary to complete all
the test points, unless additional assistance is needed
to pinpoint the fault.
Figure 108 Pin grip check

1. Disconnect the harness connector from the

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sensor or actuator.
2. Inspect for corrosion, bent pins, spread pins,
or conditions that could cause a loose or
intermittent connection.
3. Check the pin grip in the female pin by
inserting the correct tool from Terminal Test
Kit.

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 202 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

IMP circuit

IMP IMP
ECM 96-Pin connector sensor
IMP (end view)

a-3
E1 connector
connector
SIG GND
Pin E1 - 43 1
VREF-2
Pin E1 - 86 2
IMP 2
PinE1-18 3

V00040

Figure 109 “Example” IMP sensor circuit diagram

Using Electronic Service Using a Digital Multi-Meter, measure Using a Digital Multi-Meter, measure
Tool , monitor IMP voltage. voltage between pin 2 and battery voltage between pin 1 and 2.
ground .

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1ceMaxx M Software

< 4.5 V, check IMP signal circu it for short to GND. Do

Harness Resistance Check (page 185 ).
DMM - Measur If > 5.5 V, check VR EF2 circuit for short to PWR .
2 to GND If < 4.5 V, check VREF2 circuit for OPEN or short to GND .
Do Harness Resistance Check (page 185).
DMM - Measure If < 4.5 V, check SIG GND for OP EN. Do Harness
voltage Resistance Check (page 185).
1 to 2
EST - Monitor IMPv 0V If > 0.5 V, check IMP signal circu it fo r OPEN or short to
PWR. Do Harness Resistance Check (page 185).
Short across breakout
hames< pins 1 and 3
If checl \ are within specifications, connect senso r and clear DTCs. If active OTC rema ins replace IMP
sensor.

,-- '~---~
Using Electronic Service Tool ,
monitor IMP voltage, while shorting
pin 1 to pin 3.

V00164

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 203

Pin-point Diagnostics (without ServiceMaxx™

software)
1. Connect Breakout Harness to the engine harness.
Leave sensor disconnected.
2. Turn ignition switch ON, engine OFF.
3. Use a DMM to measure voltage on each circuit to
engine ground.

Example
Test Point Specifications Comment – < Less than, > Greater than

C to GND 5.0 V ± 0.5 V If > 5.5 V, check VREF for short to PWR.
If < 4.5 V, check VREF for OPEN or short to GND. Do Harness Resistance
Checks.

• If the circuit is not within specification, the • If the circuit is within specification, continue to the
comment area will list possible cause or direct next test point.
the technician to the next test point. Do Harness

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Resistance Check if additional assistance is
needed in diagnosing fault.

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 204 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Actuator Operational Voltage Check – Output

State Test
This test will allow the technician to take voltage
measurements on actuators commanded high or low.
1. Disconnect actuator. Inspect connector for
damaged pins. Repair as necessary.
2. Connect Breakout Harness between engine
harness and actuator.
3. Connect the EST to the Diagnostic Connector.
4. Turn ignition switch ON, engine OFF.
5. Start ServiceMaxx™ software.
6. Open the Output State session. This session
allows the technician to monitor the state of all engine
actuators.
7. Run the Output State test (high or low) or Glow Plug
/ IAH test.
8. Use a DMM to measure voltage on each circuit to

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engine ground.

Example
Test Point Test Specifications Comment – < Less than, > Greater than
A to GND Key On-Engine Off B+ If < B+, check for OPEN circuit.
(KOEO)
B to GND KOEO B+ If < B+, check actuator coil for OPEN.
B to GND Output State HIGH B+ If < B+, check actuator control circuit for short to
GND.
B to GND Output State LOW 7.5 V If > 7.5 V, check actuator control circuit for OPEN or
short to PWR or failed across coil.

• If any circuit is not within specification, the • If all circuits are within specification, the actuator
comment area will list possible cause or direct the may not be operating mechanically.
technician to the next test point.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 205

Harness Resistance Check

Complete Sensor End Diagnostics or Pin-point
Diagnostics tests before using this procedure.
Resistance cannot be measured on a circuit if
voltage is present. Isolate circuit from voltage before
continuing.
1. Turn ignition switch to OFF or disconnect batteries.
2. Connect 180-Pin Breakout Box and breakout
harness to vehicle or engine harness. Leave ECM
and sensor or actuator disconnected.
3. Use a DMM to measure resistance on each circuit
from point to point, then to engine ground.

A WARNING: To prevent personal injury or

death, always disconnect main negative battery
cable first. Always connect the main negative
battery cable last.

Example

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Test Point Specifications Comment – < Less than, > Greater than
E-66 to 2 <5Ω If > 5 Ω, check EOT control circuit for OPEN.
E-66 to GND > 1k Ω If < 1k Ω, check EOT control circuit for short to GND.

• If the circuit is not within specification, the • If the circuit is within specification, continue to the
comment area will list possible circuit faults. next test point.

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 206 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Operational Voltage Check

This test shows what a normal sensor or actuator
should read at certain operating conditions. This test
is helpful in diagnosing in-range faults or intermittent
problems.
1. Connect 180-Pin Breakout Box or breakout
harness between ECM and the component being
tested.
2. Turn ignition switch to ON.
3. Open Continuous Monitor session or Output State
test session (dependent upon what is being tested)
using the ServiceMaxx™ software.
4. Run the Continuous Monitor test.
5. Verify actual sensor or actuator readings are within
specification.

Example
Test Point Condition DMM Signal Value

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APP Foot off pedal 0.64 V ± 0.5 V 0%
A to GND or Pedal to floor 3.85 V ± 0.5 V 102%
C-48 to GND
APP2 Foot off pedal 0V 0V
D to GND or Pedal to floor B+ B+
C-33 to GND

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 207

Circuit Diagnostics
AAT Sensor (Ambient Air Temperature)

SPN FMI Condition Possible Causes Actions

171 2 AAT signal does not agree with other • Failed AAT sensor Step-Based Diagnostics
sensors (page 209)
• High resistance in
AAT circuit
• High resistance in
SIG GND circuit
171 3 AAT signal Out of Range HIGH (Body • High resistance or Step-Based Diagnostics
mounted sensor) open in SIG GND (page 212)
circuit
• High resistance or
open in AAT circuit
• Short to PWR in AAT
circuit
• Failed AAT sensor

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171 4 AAT signal Out of Range LOW (Body • Short to GND in AAT Step-Based Diagnostics
mounted sensor) circuit (page 215)
• SIG GND circuit
shorted to AAT
circuit
• Failed AAT sensor

AAT circuit

21-Way On/Off
AAT
ECM 96-Pin Engine Harness AAT AAT
E1 connector Interface connector connector connector
AAT (end view)
Pin E1 - 42 >-+-----115+-------t1

Pin C2 - 43 Q --1,....S_I_G_G_N_D_ _ _ _ _ _ _-1 2

ECM 58-Pin
C2 connector
2
V00047

Figure 111 AAT circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 Overview

Engine and Aftertreatment Wiring Schematic
The Ambient Air Temperature (AAT) measures the
Form 0000002941 for additional circuit
outside air temperature where the engine is operating.
information.
AAT represents the air temperature for engine cooling
performance.

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 208 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Tools Required • Digital Multimeter (DMM)

• 180-Pin Breakout Box 00-00956-08 • Electronic Service Tool (EST) with ServiceMaxx™
software
• Breakout Harness 00-01467-00
• Interface cable (RP1210B compliant supporting
• Breakout Harness 00-01468-00
J1939 and J1708)
• 3-Banana Plug Harness ZTSE4498
• Breakout Harness ZTSE4871 (AAT)

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 209

SPN 171 FMI 2 - AAT signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Ambient Air AAT sensor temperature Key ON 1 event
Temperature (AAT) differs from Inlet Air
Engine is cold soaked
does not agree with Temperature (IAT),
other sensors. Engine Coolant Engine speed > 1000 RPM
Temperature 1 (ECT1),
Vehicle speed > 24.85 mph
and Engine Coolant
Temperature 2 (ECT2) > Engine speed and vehicle speed
27°F (15°C). conditions met for > 30 seconds

Fault Overview Associated Faults

Fault code sets when Ambient Air Temperature (AAT) SPN 171 FMI 3 and 4 (AAT)
sensor temperature differs from Inlet Air Temperature
(IAT), Engine Coolant Temperature 1 (ECT1), and Fault Facts
Engine Coolant Temperature 2 (ECT2) by greater
Diagnostic runs at initial Key ON after a minimum of
than 27°F (15°C) after a cold soak.
an 8 hour cold soak.
Malfunction Indicator Lamp (MIL) Reaction

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Drive Cycle to Determine Fault Status
MIL will illuminate when this fault is detected during
Drive Cycle 10 then 5 in 2013 HD-OBD Diagnostic
two consecutive drive cycles.
Reference Manual.

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 210 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AAT circuit

21-Way On/Off
AAT
ECM 96-Pin Engine Harness AAT AAT
E1 connector Interface connector connector connector
AAT (end view)
Pin E1 - 42 >--+-------115+------ 1

Pin C2 - 43 0 __,_S_I_G_G_N_D
_ _ _ _ _ _ __, 2

ECM 58-Pin
C2 connector
2
V00047

Figure 112 AAT circuit diagram

Possible Causes
• Failed AAT sensor
• High resistance in AAT circuit

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• High resistance in SIG GND circuit

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 171 FMI 3 and
No: Repair SPN 171 FMI 3 and
4 (AAT).
4. After repairs are complete,
Is EST DTC list free of SPN 171 FMI 3 and 4? retest for SPN 171 FMI 2.

Step Action Decision

2 Inspect connections at Ambient Air Temperature (AAT) sensor. Yes: Go to step 3.
Key OFF, disconnect AAT sensor connector. Check AAT sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 171 FMI 2.
Are the AAT sensor, connector, harness, and terminals clean and
undamaged?

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 171 FMI 2.
undamaged?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 211

Step Action Decision

4 Check AAT circuit for high resistance. Connect Breakout Harness Yes: Go to step 5.
ZTSE4871 to AAT harness and leave AAT disconnected. Connect
No: Repair high resistance
180-pin Breakout Box with ECM Breakout Harness 00-01468-00
between AAT connector pin-1
to ECM E1 harness, and leave ECM disconnected. Key OFF,
and ECM connector pin E1-42.
use a DMM to measure resistance from Breakout Harness pin-1
After repairs are complete, retest
and Breakout Box pin E1-42.
for SPN 171 FMI 2.
Is resistance less than 5 ohms?

Step Action Decision

5 Check SIG GND circuit for high resistance. Connect Breakout Yes: Replace AAT sensor. After
Harness ZTSE4871 to AAT harness and leave AAT disconnected. repairs are complete, retest for
Connect 180-pin Breakout Box with ECM Breakout Harness SPN 171 FMI 2.
00-01467-00 to Chassis C2 harness, and leave ECM
No: Repair high resistance
disconnected. Key OFF, use a DMM to measure resistance from
between AAT connector pin-2
Breakout Harness pin-2 and Breakout Box pin C2-43.
and ECM connector pin C2-43.
Is resistance less than 5 ohms? After repairs are complete, retest
for SPN 171 FMI 2.

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NOTE: After performing all diagnostic steps, if
SPN 171 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 212 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 171 FMI 3- AAT Signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Ambient Air AAT sensor voltage > 4.5 Key ON 2 seconds
Temperature (AAT) volts.
value greater than
expected.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the Ambient Air Temperature
(AAT) voltage is greater than 4.5 volts for 2 seconds.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference

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Manual.

AAT circuit

21-Way On/Off
AAT
ECM 96-Pin Engine Harness AAT AAT
E1 connector Interface connector connector connector
AAT (end view)
Pin E1 - 42 ------t15------ 1

Pin C2 - 43 Q ---1r-S_IG_G_N_D_ _ _ _ _ _ _-1 2

ECM 58-Pin
C2 connector
2
V00047

Figure 113 AAT circuit diagram

Possible Causes • Short to PWR in AAT circuit

• High resistance or open in SIG GND circuit • Failed AAT sensor
• High resistance or open in AAT circuit

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 213

Step Action Decision

1 Inspect connections at Ambient Air Temperature (AAT) sensor. Yes: Go to step 2.
Key OFF, disconnect AAT sensor connector. Check AAT sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 171 FMI 3.
Are the AAT sensor, connector, harness, and terminals clean and
undamaged?

Step Action Decision

2 Check AAT circuit for short to PWR. Connect Breakout Harness Yes: Go to step 3.
ZTSE4871 to vehicle harness and leave AAT sensor disconnected.
No: Repair short to power in
Key-On Engine-Off (KOEO) measure voltage between Breakout
AAT circuit. After repairs are
Harness pin-1 and a known good ground.
complete, retest for SPN 171
Is voltage within 0.5 volts of 5 volts? FMI 3.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.

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disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 171 FMI 3.
undamaged?

Step Action Decision

4 Check AAT circuit for high resistance or Open. Connect 180-pin Yes: Go to step 5.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair Open or high
harness, and leave ECM disconnected. With Breakout Harness
resistance in AAT circuit
ZTSE4871 connected to vehicle harness and with AAT sensor
between ECM pin E1-42 and
disconnected. Use a DMM to measure resistance from Breakout
AAT sensor pin-1. After repairs
Box pin E1-42 and Breakout Harness pin-1.
are complete, retest for SPN 171
Is resistance less than 5 ohms? FMI 3.

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 214 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

5 Check SIG GND circuit for high resistance or Open. Connect Yes: Replace AAT sensor. After
180-pin Breakout Box with Breakout Harness 00-01467-00 to repairs are complete, retest for
vehicle harness, and leave ECM disconnected. With Breakout SPN 171 FMI 3.
Harness ZTSE4871 connected to vehicle harness and with AAT
No: Repair Open or high
sensor disconnected. Use a DMM to measure resistance from
resistance in SIG GND circuit
Breakout Box pin C2-43 and Breakout Harness pin-2.
between ECM pin C2-43 and
Is resistance less than 5 ohms? AAT sensor pin-2. After repairs
are complete, retest for SPN 171
FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 171 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 215

SPN 171 FMI 4- AAT Signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Ambient Air AAT sensor voltage > Key ON 2 seconds
Temperature (AAT) 0.25 volts.
sensor reading less
than expected.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the Ambient Air Temperature
(AAT) signal voltage is less than expends.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference

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Manual.

AAT circuit

21-Way On/Off
AAT
ECM 96-Pin Engine Harness AAT AAT
E1 connector Interface connector connector connector
AAT (end view)
Pin E1 - 42 --------,15+------1

Pin C2 - 43 Q --1,_S_I_G_G_N_D_ _ _ _ _ _ _-1 2

ECM 58-Pin
C2 connector
2
V00047

Figure 114 AAT circuit diagram

Possible Causes • SIG GND circuit shorted to AAT circuit

• Short to GND in AAT circuit • Failed AAT sensor

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 216 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Ambient Air Temperature (AAT) sensor. Yes: Go to step 2.
Key OFF, disconnect AAT sensor connector. Check AAT sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 171 FMI 4.
Are the AAT sensor, connector, harness, and terminals clean and
undamaged?

Step Action Decision

2 Check AAT circuit for short to GND. Connect Breakout Harness Yes: Go to step 3.
ZTSE4871 to vehicle harness and leave AAT sensor disconnected.
No: Repair short to GND in
Key-On Engine-Off (KOEO) measure voltage between Breakout
AAT circuit. After repairs are
Harness pin-1 and a known good ground.
complete, retest for SPN 171
Is voltage within 0.5 volts of 5 volts? FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.

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disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 171 FMI 4.
undamaged?

Step Action Decision

4 Check for short between AAT and SIG GND circuits. Connect Yes: Replace AAT sensor. After
Breakout Harness ZTSE4871 and leave AAT sensor disconnected. repairs are complete, retest for
Key OFF, disconnect ECM and measure resistance between SPN 171 FMI 4.
Breakout Harness pin-1 and pin-2.
No: Repair short between AAT
Is resistance greater than 1000 ohms? and SIG GND circuits. After
repairs are complete, retest for
SPN 171 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 171 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 217

AFT (Aftertreatment) System

SPN FMI Condition Possible Causes Actions

3251 0 DPFDP excessively HIGH (Restricted • Restricted Step-Based
filter) Diesel Diagnostics
Particulate (page 225)
Filter (DPF)
• Low Fuel
Delivery
Pressure
• Restricted
Aftertreatment
Fuel Injector
(AFI) unit
• Parked Regen
Inhibited
• Exhaust
leak(s)
• Biased Diesel

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Particulate
Filter
Differential
Pressure
(DPFDP)
sensor
• Biased IMP
sensor
• Low boost
pressure
3251 14 DPFDP sensor pressure hoses reversed • DPFDP Pin-Point
sensor Diagnostics
pressure (page 231)
hoses
reversed
• DPFDP
sensor hose
(before filter)
restricted

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 218 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3251 21 DPFDP excessively LOW (Sensor/circuit • Biased Step-Based

fault or missing DPF) DPFDP Diagnostics
sensor or (page 232)
circuit
• Cracked DPF
• DPFDP
sensor
pressure
hoses
reversed
• DPFDP
sensor hose
(before filter)
leaking or
disconnected
3471 1 Fuel Pressure 1 below desired (Low • Aftertreatment Step-Based
system pressure) Fuel Doser Diagnostics
(AFTFD) (page 235)
failure.
Blocked, stuck

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open, or
closed
• Leak in
AFTFD fuel
supply line
• Failed
Aftertreatment
Fuel Pressure
1 (AFTFP1)
sensor
• Aftertreatment
Fuel Shutoff
Valve
(AFTFSV)
stuck closed,
or blocked
3471 7 Fuel Doser Valve not responding as • AFTFD failure. Step-Based
expected Blocked, stuck Diagnostics
open, or (page 240)
closed.
• Stuck AFI or
AFTFSV
• Biased AFT
Fuel Pressure
2 signal

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 219

3480 0 AFTFP1 too high while dosing • Fuel Delivery Step-Based

Pressure Diagnostics
(FDP) above (page 246)
maximum
• Restricted fuel
return line
between filter
housing and
fuel tank
3480 1 AFTFP1 too low while dosing • FDP below Pin-Point
minimum Diagnostics
(page 250)
• Dirty fuel filter
• Stuck closed
AFT Shutoff
valve
• Fuel Leak in
Down Stream
Injection (DSI)
System

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3481 7 Incorrect dosing pressure, multiple events • FDP above Step-Based
maximum Diagnostics
(page 254)
• Restricted fuel
return line
between filter
housing and
fuel tank
3556 0 AFT fuel pressure 2 excessively high • Aftertreatment Step-Based
(Restricted injection) Fuel Injector Diagnostics
(AFI) is (page 258)
restricted or
sticking
3556 1 AFT fuel pressure 2 below desired • Leak in DSI Step-Based
system Diagnostics
(page 262)
• AFT Fuel
Doser sticking
Open
• AFI stuck
Open

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 220 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3556 7 AFT Fuel Injector not responding as • DSI failed Step-Based

expected system Diagnostics
validation (page 266)
cycle
• Biased
AFTFIS or
circuit
• Biased
Aftertreatment
Fuel Pressure
2 (AFTFP2)
sensor or
circuit
• Failed AFTFD
or circuit
• Failed
AFTFSV or
circuit
• Aftertreatment

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Fuel Injector
(AFI) failure
(restricted)
3750 31 DPF Regen inhibited due to low exhaust • Degraded Step-Based
temperatures Diesel Diagnostics
Oxidation (page 271)
Catalyst
(DOC)
• Exhaust leak
• Damaged or
missing Diesel
Particulate
Filter (DPF)
• Failed
DOC / DPF
temperature
sensors
4077 0 AFTFP2 too high while dosing • AFTFD stuck Step-Based
closed Diagnostics
(page 273)
• AFI restricted
4077 1 AFTFP2 too low while dosing • Fuel leak Step-Based
between Diagnostics
AFTFD and (page 277)
AFI
• AFTFSV stuck
closed

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 221

4766 10 DPF Regeneration feedback fault • Diesel Step-Based

Oxidation Diagnostics
Catalyst (page 281)
Outlet
Temperature
(DOCOT)
not heating
up during
exhaust
injection
• Diesel
Oxidation
Catalyst
(DOC) failure
(face plugged)
4766 20 DOC Outlet Temp above maximum • Aftertreatment Step-Based
desired Fuel Injector Diagnostics
(AFI) (page 288)
restricted or
sticking

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• Engine
over-fueling
• DSI leaking
into exhaust
• AFTFD stuck
open
• Fuel leak(s) to
exhaust
• DOCOT
sensor or
circuit failure
4766 21 DOC Outlet Temp below minimum desired • DOC failure Step-Based
Diagnostics
• DSI fault, not
(page 294)
injecting when
commanded
• DSI system
fuel leak
• DOCOT
sensor or
circuit failure

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 222 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

5298 2 Reduced DOC Efficiency — De-Rate • Biased Step-Based

DOCOT Diagnostics
sensor or (page 300)
circuit
• Restricted AFI
or AFI housing
• DSI failure
• DSI system
leak
• DOC failure
• Restricted air
filter
• Exhaust leaks
• Coolant leak
to exhaust
5319 31 DPF incomplete Regeneration • Low engine Step-Based
performance Diagnostics
(page 307)

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• Failed fuel
injector
• Engine
mechanical
• Oil leak to
exhaust
• Failed Diesel
Particulate
Filter
Differential
Pressure
(DPFDP)
• Restricted
DPFDP
sensor
hose(s)
• Damaged or
failed Diesel
Oxidation
Catalyst
(DOC)
• Restricted
DOC (soot
accumulation)
• Failed DSI

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 223

Input Output

AFT regen
Enable
switch

ESC or MSM J1939

module

APP
Park brake Disable
vss Parked regen
DDS
PTO

DOCIT Exhaust sensors

DOCOT
DPFOT
DPFDP

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OSI

DOCOT

DPFDP V00142

Figure 115 Function diagram for AFT System

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 224 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Overview The health of the system and the Regen processes

are monitored by the DOC Inlet Temperature (DOCIT),
The purpose of the Aftertreatment (AFT) System
DOC Outlet Temperature (DOCOT), DPF Outlet
is to catalyze carbon monoxide (CO), Oxides of
Temperature (DPFOT) and the Diesel Particulate
Nitrogen (NOx), and Hydrocarbons (HC). The Diesel
Filter Differential Pressure (DPFDP) sensor. The
Particulate Filter (DPF) will capture soot and other
DPFDP measures the pressure difference across
particulates exiting the exhaust pipe. Typically a good
the DPF. The temperature sensors measure the
running engine will have 99% soot to 1% ash.
temperature differences across the DOC and DPF.
The soot is captured by the Diesel Particulate Filter
The DPF and or the DOC may fail or plug prematurely
(DPF). Although the Diesel Oxidation Catalyst (DOC)
for a number of reasons. It is important to pinpoint the
should not require regular maintenance, the DPF
root cause and repair the failure before replacing the
does require off-board cleaning to remove ash from
DOC or DPF. Failure to do so could result in destroying
the DPF.
a newly replaced component.
Soot is converted to carbon dioxide by a process of
NOTE: Any time the DPF is replaced or removed
regeneration (Regen). The temperature at the face of
for cleaning, record DPF serial number and
the DPF is raised to approximately 1000°F (538°C),
use ServiceMaxx™ software to run the Diesel
for a period of time, depending on the amount of
Particulate Filter Servicing procedure. Follow
soot that accumulated within the DPF. Regen time is
on-screen instructions. See DPF Servicing (page
calculated by the Engine Gas Differential Pressure
66) in "DIAGNOSTIC SOFTWARE OPERATION"
(DPFDP) feedback.
for additional information.
The Regen may take place as the vehicle is in

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Tools Required
operation under a steady state heavy engine loading
condition, or by forcing a Stationary Regen process. • Electronic Service Tool (EST) with ServiceMaxx™
software
During a Stationary Regen, the engine speed is
increased, while the Engine Control Module (ECM) • J1939 and J1708 RP1210B Compliant Device
controls the engine systems; Post-Injection, Exhaust
• ZTSE4526 - Compucheck Fitting
Gas Recirculation (EGR), and Engine Throttle Valve
(ETV) to increase the heat going into the exhaust • ZTSE4681 – Fuel Pressure Gauge
system. The Inlet Air Heater (IAH) will also cycle on
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
and off, not just to increase the Inlet Air Temperature
(IAT), but to add extra load on the engine. • ZTSE4906 – Fuel Line Coupler

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 225

SPN 3251 FMI 0 - DPFDP excessively HIGH (Restricted filter)

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
The Diesel Particulate DPFDP reading does not Time after Key On > 0 seconds 0.5 seconds
Filter Differential equal modeled value
Battery voltage > 10.7 volts
Pressure (DPFDP)
DPFDP > 350 hPa
is excessively high. Battery voltage < 15 volts
DPF surface temp > 392°F
(200°C) and < 752°F (400°C)
Exhaust gas volume flow > 1500
cubic meters/hour and <6553
cubic meters/hour

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

The Diesel Particulate Filter Differential Pressure MIL will illuminate when this fault is detected during
(DPFDP) sensor is a variable-capacitance sensor two drive cycles.
that measures pressure at two locations. The first
location is between the Diesel Oxidation Catalyst Associated Faults
(DOC) and the Diesel Particulate Filter (DPF). The

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SPN’s 27,102, 1189, 2791, 3480, 4077, 5456, and
second location is immediately after the DPF. DPFDP
5541.
provides a feedback signal to the ECM indicating
pressure difference between the inlet and outlet of
Drive Cycle to Determine Fault Status
the DPF.
See 2013 HD-OBD Diagnostic Reference Manual.

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 226 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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0000046718

Figure 116 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
SIG GND connector sensor
Pin C2 _ 41 1
(end view)
2
VREF- 4

e
1~ 3

-
ECM 58-Pin
C1 connector
Pin C1 - 12
DPFDP

connector~t•(end
_ _ _ _ _ _ _ _ _ _ _ _ _ ____.'.~E~x~h~a~u;
n
1: ~ I:
. ~------------
view)
~S~e~n~s;or~ V00022.

Figure 117 DPFDP sensor circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ Yes: Go to step 2.
software, check for other fault codes.
No: Repair other fault code(s).
Is SPN 3251 FMI 0 the only fault code active? After repairs are complete,
retest for SPN 3251 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 227

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 5.
monitor Diesel Particulate Filter Differential Pressure (DPFDP)
No: Go to step 3.
signal with Key-On Engine-Off (KOEO). See "Appendix A (page
953)" for DPFDP specifications.
Is DPFDP within specifications?

Step Action Decision

3 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 4.
Pressure (DPFDP) sensor. Key OFF, disconnect DPFDP sensor
No: Repair connector, harness,
connector. Check DPFDP sensor and connector terminals for:
or terminal damage. After
damaged or pinched wires; corroded terminals; loose, bent, or
repairs are complete, retest for
broken pins; or broken connector housing.
SPN 3251 FMI 0.
Is the DPFDP sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

4 Check for biased DPFDP sensor. Do DPFDP sensor biased Yes: Go to step 5.

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check (page 514).
No: Repair DPFDP sensor
Are DPFDP sensor and circuits within specifications? or circuits. After repairs are
complete, retest for SPN 3251
FMI 0.

Step Action Decision

5 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Go to step 6.
Inspect the DPFDP hoses for kinks, improper hose routing,
No: Repair DPFDP hoses. After
reversed hoses or damage. See DPFDP sensor locator for correct
repairs are complete, retest for
routing of hoses.
SPN 3251 FMI 0.
Are the DPFDP hoses routed correctly and free of damage?

Step Action Decision

6 Using EST with ServiceMaxx software, start an Onboard Filter Yes: Go to Step 7.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort message in ServiceMaxx? Inhibitors (page 319) and restart
OBFCT.

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 228 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 8.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3251 FMI 0.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3251 FMI 0.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3251 FMI 0.
pressure.

Step Action Decision

8 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 9.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3251
FMI 0.

Step Action Decision

9 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 10.
out of specifications. Using EST with ServiceMaxx software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 3251 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 229

Step Action Decision

10 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal changes only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.
After repairs are complete, retest
Does IMP sensor signal change:
for SPN 3251 FMI 0.
• When TC2WC is commanded On?
IMP signal changes only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN
3251 FMI 0.
Neither change IMP signal when
commanded On: Go to step 11.
Both change IMP signal when
commanded On: Go to step 12.

Step Action Decision

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11 Verify IMP sensor and bore are not restricted due to carbon Yes: Go to step 12.
buildup. Remove and inspect IMP sensor and bore for carbon
No: Clean IMP sensor bore of
buildup.
carbon deposits. After repairs
Is IMP sensor and bore free of carbon buildup? are complete, retest for SPN
3251 FMI 0.

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 230 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

12 Do Road Test (Full load to highway speed) (page 161), 100% Both TC1TOP and DPFDP
engine load (when safe to do so). Record a snapshot of the signals are above specification:
following signals: After doing all diagnostic steps,
verify each step was completed
• Diesel Particulate Filter Differential Pressure (DPFDP) = 0.5
correctly and the proper decision
to 0.8 psi
was made. Notify supervisor for
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP) = 2 to 3 psi further action.
• Soot load < 40% Only TC1TOP signal above
specification: Remove Pre
Are DPFDP and TC1TOP signals within specifications?
Diesel Oxidation Catalyst
NOTE: DPFDP and TC1TOP specifications only apply with soot (PREDOC) and Diesel Oxidation
load < 40%. Catalyst (DOC) for inspection
and clean or replace as
necessary. After repairs are
complete, retest for SPN 3251
FMI 0.
Neither signal above
specification: Retest for SPN
3251 FMI 0.

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NOTE: After doing all diagnostic steps, if
SPN 3251 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 231

DPFDP sensor pressure hoses reversed

Pinpoint AFT System Fault

1. Key On, Engine Off, check for biased DPFDP sensor. See Key-On Engine-Off in “APPENDIX A:
PERFORMANCE SPECIFICATIONS.”
• If sensor is not within specification, go to DPFDP Sensor Circuit Check (page 514).
2. Check DPFDP sensor hoses for correct routing and possible restriction.
• If sensor hoses are reversed or restricted, repair condition.
3. Check for restriction. Remove and inspect filter for face plugging.

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 232 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Missing / Cracked DPF Function of exhaust Simulated soot mass < 201 g 40 seconds
gas flow and specific and > 0 g
soot mass corrected for
DPF surface temp < 752°F
transfer lag
(400°C) and > 392°F (200°C)
DPFDP > 12 hPa

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

The Diesel Particulate Filter Differential Pressure MIL will illuminate when this fault is detected during
(DPFDP) sensor is a variable-capacitance sensor that two drive cycles.
measures pressure at two locations. The first location
is between the Diesel Oxidation Catalyst (DOC) Associated Faults
and the Diesel Particulate Filter (DPF). The second
SPN’s 3512.
location is immediately after the DPF. The DPFDP
provides a feedback signal to the ECM indicating
Drive Cycle to Determine Fault Status
pressure difference between the inlet and outlet of
the DPF. See 2013 HD-OBD Diagnostic Reference Manual.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 233

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0000046718

Figure 118 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
SIG GND connector sensor
Pin C2 _ 41 1
(end view)
2
VREF-4

e
Pin C2 _ OB 1~ 3

ECM 58-Pin
C1 connector
Pin C1 - 12
DPFDP n
1: ~ I:
Exhau;t Sensor
connector (end view)
.

Figure 119 DPFDP sensor circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3251 FMI 21 the only fault code active? After repairs are complete, retest
for SPN 3251 FMI 21.

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 234 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

2 Inspect exhaust system for missing Diesel Particulate Filter (DPF), Yes: Go to step 3.
leaks, or physical damage.
No: Replace DPF, repair exhaust
Is DPF in place, and exhaust system free of leaks and physical leaks, or repair physical damage.
damage? After repairs are complete, retest
for SPN 3251 FMI 21.

Step Action Decision

3 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 4.
Pressure (DPFDP) sensor. Key OFF, disconnect DPFDP sensor
No: Repair connector, harness,
connector. Check DPFDP sensor and connector terminals for:
or terminal damage. After
damaged or pinched wires; corroded terminals; loose, bent, or
repairs are complete, retest for
broken pins; or broken connector housing.
SPN 3251 FMI 21.
Is the DPFDP sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

4 Check for biased DPFDP sensor. Do DPFDP sensor biased Yes: Go to step 5.

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check (page 514).
No: Repair DPFDP sensor
Are DPFDP sensor and circuits within specification? or circuits. After repairs are
complete, retest for SPN 3251
FMI 21.

Step Action Decision

5 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Remove DPF and inspect
Inspect the DPFDP hoses for kinks, improper hose routing, the outlet of the DPF filter for
reversed hoses or damage. See DPFDP sensor locator for correct damage and soot leakage (see
routing of hoses. DPF Outlet Leaking Soot (page
327). After repairs are complete,
Are the DPFDP hoses routed correctly and free of damage?
retest for SPN 3251 FMI 21.
No: Repair DPFDP hoses. After
repairs are complete, retest for
SPN 3251 FMI 21.

NOTE: After doing all diagnostic steps, if SPN

3251 FMI 21 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 235

SPN 3471 FMI 1 - Fuel Pressure 1 Below Desired

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel Aftertreatment Fuel System test has run (Occurs 3 event
Pressure 1 (AFTFP1) System test failure before dosing)
signal is reading
(Table D002) Time after Key On > 0 seconds
pressure below desired.
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

The Aftertreatment Fuel Inlet Sensor (AFTFIS) is SPN’s 2659, 3479, 3480, 3482, and 5456.
both a variable-capacitance pressure sensor and
a thermistor sensor used to measure fuel pressure Drive Cycle to Determine Fault Status
and fuel temperature at the inlet of the Down Stream
See 2013 HD-OBD Diagnostic Reference Manual.
Injection (DSI) unit. The ECM measures signals
given by this sensor to supply the Aftertreatment Fuel
Injector (AFI) with the proper amount of fuel.

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Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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 236 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Figure 120 Downstream Injection (DSI) Unit Location

AFTFIS Circuit
0000045745

AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector
- 1
C1-41 ::: SIG GND 1
C1-26.:. AFTFT 2
VREF4 3
C2-08:::
C1-25::: AFTFP1 4
AFTFIS
~

V45003

Figure 121 AFTFIS circuit diagram

240
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 237

Step Action Decision

1 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Yes: Go to step 2.
Key OFF, disconnect AFTFIS. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3471 FMI 1.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for biased AFTFP1 signal. Using EST with ServiceMaxx™ Yes: Go to step 3.
software, with AFTFIS connected, run Continuous Monitor session
No: Do AFTFIS Circuit Checks
and monitor Aftertreatment Fuel Pressure 1 (AFTFP1) signal.
(page 344). After repairs are
Is AFTFP1 between 0.66 and 0.86 volts? (Wiggle test may be complete, retest for SPN 3471
necessary if code is inactive or pending.) FMI 1.
NOTE: AFTFIS is a 4 wire sensor containing Aftertreatment
Fuel Temperature (AFTFT) signal for fuel temperature, and
AFTFP1 signal for fuel pressure.

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Step Action Decision
3 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 4.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3471 FMI 1.

Step Action Decision

4 Prime Aftertreatment Fuel Injector (AFI) by actuating Yes: Go to step 6.
Aftertreatment Fuel Doser (AFTFD) valve and Aftertreatment
No: Go to step 5.
Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration test. Using
EST with ServiceMaxx™ software, go to Procedures > KOER
Aftertreatment Procedures > DSI De-Aeration procedure. Start
engine, actuate AFTFSV while monitoring AFTFP1 signal during
actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

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 238 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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4 3
0000047001

Figure 122 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

5 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Replace DSI unit. After
connectors are connected to the correct location. (AFTFSV and repairs are complete, retest for
AFTFD harness connectors can be swapped.) SPN 3471 FMI 1.
Are AFTFSV and AFTFD harness connectors connected to the No: Connect harness
correct sensors? connectors to correct location.
After repairs are complete, retest
for SPN 3471 FMI 1.

Step Action Decision

6 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 7.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 239

Step Action Decision

7 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 8.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3471 FMI 1.
DOCIT 482°F (250°C) to 572°F If AFTFP2 fuel pressure
(300°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3471 FMI 1.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3471 FMI 1.
pressure.

Step Action Decision

8 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Verify each step was
Pressure (DPFDP) signal measure below 0.5 psi at high idle? completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3471
FMI 1.

NOTE: After doing all diagnostic steps, if

SPN 3471 FMI 1 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 240 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3471 FMI 7 - Fuel Doser Valve not responding as expected

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel Aftertreatment Fuel System test has run (occurs 3 event
Doser Vale (AFTFDV) System test failure before dosing)
is not responding as
(Table D002) Time after Key On > 0 seconds
expected.
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

The Aftertreatment Fuel Doser Valve (AFTFDV) SPN’s 2659, 3479, 3480, 3482, 4077, and 5456.
is used to provide high-pressure fuel flow to the
Aftertreatment Fuel Injector (AFI). The AFTFD is Drive Cycle to Determine Fault Status
sent a pulse Width Modulated (PWM) signal from
See 2013 HD-OBD Diagnostic Reference Manual.
the Engine Control Module (ECM), after inputs from
the Downstream Injection (DSI) unit components are
processed.

BetterManuals.net
Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 241

BetterManuals.net
Figure 123 Downstream Injection (DSI) Unit Location
0000045745

AFTFD Circuit
AFTFD
21-Way On/Off
Engine Harness AFTFD
ECM, Interface Connector AFTFD
E1 Connector Connector
1
1--------i
2

V45002

Figure 124 AFTFD circuit diagram

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 242 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Yes: Go to step 2.
sensor. Key OFF, disconnect AFTFP2 sensor. Check AFTFP2
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 3471 FMI 7.
Are the AFTFP2 sensor connector, harness, and terminals clean
and undamaged?

NOTE: Using EST with ServiceMaxx™ software,

open doser actuator to release pressure in DSI
before checking for biased AFTFP2 sensor.

Step Action Decision

2 Check for biased AFTFP2 sensor. Using EST with ServiceMaxx™ Yes: Go to step 3.
software, with AFTFP2 sensor connected, run Continuous Monitor
No: Do AFTFP2 Circuit Checks
session and monitor Aftertreatment Fuel Pressure 2 (AFTFP2)
(page 348). After repairs are
signal.
complete, retest for SPN 3471
Is AFTFP2 signal value between 0.30 and 0.50 volts? (Wiggle test FMI 7.
may be necessary if code is inactive or pending.)

BetterManuals.net
Step Action Decision
3 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 4.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3471 FMI 7.

Step Action Decision

4 Prime Aftertreatment Fuel Injector (AFI) by actuating Yes: Go to step 6.
Aftertreatment Fuel Doser (AFTFD) valve and Aftertreatment
No: Go to step 5.
Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration test. Using
EST with ServiceMaxx™ software, go to Procedures > KOER
Aftertreatment Procedures > DSI De-Aeration procedure. Start
engine, actuate AFTFSV while monitoring AFTFP1 signal during
actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

246
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 243

1 2

BetterManuals.net
4 3
0000047001

Figure 125 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

5 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Replace DSI unit. After
connectors are connected to the correct location. (AFTFSV and repairs are complete, retest for
AFTFD harness connectors can be swapped.) SPN 3471 FMI 7.
Are AFTFSV and AFTFD harness connectors connected to the No: Connect harness
correct sensors? connectors to correct location.
After repairs are complete, retest
for SPN 3471 FMI 7.

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 244 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 3471 FMI 7.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise then drop when AFI opens:
Go to step 7.
• Does AFTFP2 signal value rise then drop when AFI opens?
AFTFP1 signal value drops
and AFTFP2 rises, then drops
when AFI is opened (correct
operation): Retest for SPN 3471
FMI 7 status.

Step Action Decision

7 Visually inspect AFI supply line for leaks or damage. Yes: Replace AFI supply line.
After repairs are complete, retest
Is the line leaking or damaged?
for SPN 3471 FMI 7.
No: Go to step 8.

BetterManuals.net
Step Action Decision
8 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 9.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

248
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 245

Step Action Decision

9 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 10.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3471 FMI 7.
DOCIT 482°F (250°C) to 572°F If AFTFP2 fuel pressure
(300°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

BetterManuals.net
3471 FMI 7.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3471 FMI 7.
pressure.

Step Action Decision

10 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Verify each step was
Pressure (DPFDP) signal measure below 0.5 psi at high idle? completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3471
FMI 7.

NOTE: After doing all diagnostic steps, if

SPN 3471 FMI 7 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 246 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3480 FMI 0 - AFTFP1 too high while dosing

Fault Overview
The Aftertreatment Fuel Inlet Sensor (AFTFIS) is
both a variable-capacitance pressure sensor and
a thermistor sensor used to measure fuel pressure
and fuel temperature at the inlet of the Down Stream
Injection (DSI) unit. The ECM measures signals
given by this sensor to supply the Aftertreatment Fuel
Injector (AFI) with the proper amount of fuel.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 94 and 5456.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

BetterManuals.net
AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector 1
C1-41 ot_----l,,l.!.l,,:!...l,,:WN!..!.:D~-------1 1
C1-26 2
C2-08 VREF4 3
C1-25 AFTFP1 4
AFTFIS
V45003

Figure 126 AFTFIS circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3480 FMI 0 the only fault code active? After repairs are complete, retest
for SPN 3480 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 247

Step Action Decision

2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Yes: Go to step 3.
Key OFF, disconnect AFTFIS. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3480 FMI 0.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Check for biased AFTFP1 signal. Using EST with ServiceMaxx™ Yes: Go to step 4.
software, with AFTFIS connected, run Continuous Monitor session
No: Do AFTFIS Circuit Checks
and monitor Aftertreatment Fuel Pressure 1 (AFTFP1) signal.
(page 344). After repairs are
Is AFTFP1 between 0.66 and 0.86 volts? (Wiggle test may be complete, retest for SPN 3480
necessary if code is inactive or pending.) FMI 0.
NOTE: AFTFIS is a 4 wire sensor containing Aftertreatment
Fuel Temperature (AFTFT) signal for fuel temperature, and
AFTFP1 signal for fuel pressure.

BetterManuals.net
Step Action Decision
4 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 5.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3480 FMI 0.

251
 248 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

1 2

BetterManuals.net
3 0000047621

Figure 127 Fuel Pressure Test Locations

1. HP fuel pump return 2. HP fuel pump inlet 3. Fuel supply to DSI unit

Step Action Decision

5 Measure fuel return pressure from high-pressure fuel pump. Yes: Go to step 6.
Connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 and fuel
No: Replace DSI unit. After
pressure gauge between high-pressure fuel pump and fuel return
repairs are complete, retest for
line. Measure fuel pressure at high idle, no load, and stabilized
SPN 3480 FMI 0.
engine operating temperature.
Is fuel return pressure greater than 15 psi?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Step Action
6 Inspect fuel return line for fuel cooler.
Is a fuel cooler present?
NOTE: After doing all diagnostic steps, if
SPN 3480 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.
BetterManuals.net
249
Decision
Yes: Remove fuel cooler and
install a fuel line in its place.
After repairs are complete, retest
for SPN 3480 FMI 0.
No: Repair restriction in fuel
return line. After repairs are
complete, retest for SPN 3480
FMI 0.
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 250 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3480 FMI 1- AFTFP1 too low while dosing

Fault Overview
The Aftertreatment Fuel Inlet Sensor (AFTFIS) is
both a variable-capacitance pressure sensor and
a thermistor sensor used to measure fuel pressure
and fuel temperature at the inlet of the Down Stream
Injection (DSI) unit. The ECM measures signals
given by this sensor to supply the Aftertreatment Fuel
Injector (AFI) with the proper amount of fuel.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 94, 3479, 3482, and 5456.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

BetterManuals.net
AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector 1
C1-41 ot_----l,,l.!.l,,:!...l,,:WN!..!.:D~-------1 1
C1-26 2
C2-08 VREF4 3
C1-25 AFTFP1 4
AFTFIS
V45003

Figure 128 AFTFIS circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3480 FMI 1 the only fault code active? After repairs are complete, retest
for SPN 3480 FMI 1.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 251

Step Action Decision

2 Visually inspect Down Stream Injection (DSI) unit supply line for Yes: Go to step 3.
leaks or damage.
No: Replace DSI supply line.
Is the line free of leaks and damage? After repairs are complete, retest
for SPN 3480 FMI 1.

Step Action Decision

3 Inspect fuel filter(s). Check if fuel filter(s) is dirty, restricted, or Yes: Go to step 4.
clogged?
No: Replace fuel filter(s). After
Is fuel filter(s) clean, unrestricted, and unclogged? repairs are complete, retest for
SPN 3480 FMI 1.

Step Action Decision

4 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Yes: Go to step 5.
Key OFF, disconnect AFTFIS. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3480 FMI 1.

BetterManuals.net
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

5 Check for biased AFTFP1 signal. Using EST with ServiceMaxx™ Yes: Go to step 6.
software, with AFTFIS connected, run Continuous Monitor session
No: Do AFTFIS Circuit Checks
and monitor Aftertreatment Fuel Pressure 1 (AFTFP1) signal.
(page 344). After repairs are
Is AFTFP1 between 0.66 and 0.86 volts? (Wiggle test may be complete, retest for SPN 3480
necessary if code is inactive or pending.) FMI 1.
NOTE: AFTFIS is a 4 wire sensor containing Aftertreatment
Fuel Temperature (AFTFT) signal for fuel temperature, and
AFTFP1 signal for fuel pressure.

Step Action Decision

6 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 7.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3480 FMI 1.

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 252 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 Prime Aftertreatment Fuel Injector (AFI) by actuating Yes: Retest for SPN 3480 FMI 1.
Aftertreatment Fuel Doser (AFTFD) valve and Aftertreatment
No: Go to step 8.
Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration test. Using
EST with ServiceMaxx™ software, go to Procedures > KOER
Aftertreatment Procedures > DSI De-Aeration procedure. Start
engine, actuate AFTFSV while monitoring AFTFP1 signal during
actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

BetterManuals.net
4 3
0000047001

Figure 129 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 253

Step Action Decision

8 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Replace DSI unit. After
connectors are connected to the correct location. (AFTFSV and repairs are complete, retest for
AFTFD harness connectors can be swapped.) SPN 3480 FMI 1.
Are AFTFSV and AFTFD harness connectors connected to the No: Connect harness
correct sensors? connectors to correct location.
After repairs are complete, retest
for SPN 3480 FMI 1.

NOTE: After doing all diagnostic steps, if

SPN 3480 FMI 1 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

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 254 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3481 FMI 7 - Incorrect dosing pressure,

multiple events

Fault Overview
The Aftertreatment Fuel Inlet Sensor (AFTFIS) is
both a variable-capacitance pressure sensor and
a thermistor sensor used to measure fuel pressure
and fuel temperature at the inlet of the Down Stream
Injection (DSI) unit. The ECM measures signals
given by this sensor to supply the Aftertreatment Fuel
Injector (AFI) with the proper amount of fuel.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 94, 2659, and 5456.

Drive Cycle to Determine Fault Status

BetterManuals.net
See 2013 HD-OBD Diagnostic Reference Manual.

AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector 1
C1-41 u-r----"=..lod..LlN~D'-----------1 1
C1-26 2
C2-08 VREF4 3
C1-25 AFTFP1 4
AFTFIS
V45003

Figure 130 AFTFIS circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3481 FMI 7 the only fault code active? After repairs are complete, retest
for SPN 3481 FMI 7.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 255

Step Action Decision

2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Yes: Go to step 3.
Key OFF, disconnect AFTFIS. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3481 FMI 7.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Check for biased AFTFP1 signal. Using EST with ServiceMaxx™ Yes: Go to step 4.
software, with AFTFIS connected, Key-On Engine-Off (KOEO),
No: Do AFTFIS Circuit Checks
run Continuous Monitor session and monitor Aftertreatment Fuel
(page 344). After repairs are
Pressure 1 (AFTFP1) signal.
complete, retest for SPN 3481
Is AFTFP1 between 0.66 and 0.86 volts? (Wiggle test may be FMI 7.
necessary if code is inactive or pending.)
NOTE: AFTFIS is a 4 wire sensor containing Aftertreatment
Fuel Temperature (AFTFT) signal for fuel temperature, and
AFTFP1 signal for fuel pressure.

BetterManuals.net
Step Action Decision
4 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 5.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3481 FMI 7.

259
 256 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

1 2

BetterManuals.net
3 0000047621

Figure 131 Fuel Pressure Test Locations

1. HP fuel pump return 2. HP fuel pump inlet 3. Fuel supply to DSI unit

Step Action Decision

5 Measure fuel return pressure from high-pressure fuel pump. Yes: Go to step 6.
Connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 and fuel
No: Replace DSI unit. After
pressure gauge between high-pressure fuel pump and fuel return
repairs are complete, retest for
line. Measure fuel pressure at high idle, no load, and stabilized
SPN 3481 FMI 7.
engine operating temperature.
Is fuel return pressure greater than 15 psi?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Step Action
6 Inspect fuel return line for fuel cooler.
Is a fuel cooler present?
NOTE: After doing all diagnostic steps, if
SPN 3481 FMI 7 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.
BetterManuals.net
257
Decision
Yes: Remove fuel cooler and
install a fuel line in its place.
After repairs are complete, retest
for SPN 3481 FMI 7.
No: Repair restriction in fuel
return line. After repairs are
complete, retest for SPN 3481
FMI 7.
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 258 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel Aftertreatment Fuel System test has run (Occurs 3 event
Pressure 2 (AFTFP2) System test failure before dosing)
signal is reading
(Table D002) Time after Key On > 0 seconds
pressure excessively
high. Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview
The Aftertreatment Fuel Pressure 2 (AFTFP2) sensor
is a variable capacitance sensor that monitors fuel
pressure after the Aftertreatment Fuel Doser (AFTFD)
valve. The Engine Control Module (ECM) uses the
AFTFP2 sensor to monitor fuel delivery pressure to
the Aftertreatment Fuel Injector (AFI).

Malfunction Indicator Lamp (MIL) Reaction

BetterManuals.net
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 27, 94, 102, 1189, 2659, 2791, and 4077.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3556 FMI 0 the only fault code active? After repairs are complete, retest
for SPN 3556 FMI 0.

Step Action Decision

2 Visually inspect Down Stream Injection (DSI) unit supply line for Yes: Go to step 3.
leaks or damage.
No: Replace DSI supply line.
Is the line free of leaks and damage? After repairs are complete, retest
for SPN 3556 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 259

Step Action Decision

3 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 4.
restrictions, air leaks, or physical damage.
No: Repair restrictions, air
Is air intake system, exhaust system, and air filter free of leaks, or physical damage. After
restrictions, leaks, and physical damage? repairs are complete, retest for
SPN 3556 FMI 0.

Step Action Decision

4 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 5.
out of specifications. Using EST with ServiceMaxx software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 3556 FMI 0.

Step Action Decision

5 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal change only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.

BetterManuals.net
After repairs are complete, retest
Does IMP sensor signal change:
for SPN 3556 FMI 0.
• When TC2WC is commanded On?
IMP signal change only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN
3556 FMI 0.
Neither change IMP signal when
commanded On: Go to step 6.
Both change IMP signal when
commanded On: Go to step 7.

Step Action Decision

6 Verify IMP sensor and bore are not restricted due to carbon Yes: Go to step 7.
buildup. Remove and inspect IMP sensor and bore for carbon
No: Clean IMP sensor bore of
buildup.
carbon deposits. After repairs
Is IMP sensor and bore free of carbon buildup? are complete, retest for SPN
3556 FMI 0.

Step Action Decision

7 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 8.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3556 FMI 0.

263
 260 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

1 2

BetterManuals.net
3 0000047621

Figure 132 Fuel Pressure Test Locations

1. HP fuel pump return 2. HP fuel pump inlet 3. Fuel supply to DSI unit

Step Action Decision

8 Measure fuel return pressure from high-pressure fuel pump. Yes: Go to step 10.
Connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 and fuel
No: Go to step 9.
pressure gauge between high-pressure fuel pump and fuel return
line. Measure fuel pressure at high idle, no load, and stabilized
engine operating temperature.
Is fuel return pressure greater than 15 psi?

Step Action Decision

9 Visually inspect Aftertreatment Fuel Injector (AFI) supply line for Yes: Replace AFI supply line.
leaks or damage. After repairs are complete, retest
for fault SPN 3556 FMI 0.
Is the line leaking or damaged?
No: Clean AFI valve, housing,
and bore. After cleaning
procedure is complete, retest for
SPN 3556 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Step Action
10 Inspect fuel return line for fuel cooler.
Is a fuel cooler present?
NOTE: After doing all diagnostic steps, if
SPN 3556 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.
BetterManuals.net
261
Decision
Yes: Remove fuel cooler and
install a fuel line in its place.
After repairs are complete, retest
for SPN 3556 FMI 0.
No: Repair restriction in fuel
return line. After repairs are
complete, retest for SPN 3556
FMI 0.
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 262 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3556 FMI 1- AFT Fuel Pressure 2 below desired

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel Aftertreatment Fuel System test has run (Occurs 3 event
Pressure 2 (AFTFP2) System test failure before dosing)
signal is reading
(Table D002) Time after Key On > 0 seconds
pressure below desired.
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

The Aftertreatment Fuel Pressure 2 (AFTFP2) sensor SPN’s 94, 2659, 3479, 3480, 3482, 4077, and 5456.
is a variable capacitance sensor that monitors fuel
pressure after the Aftertreatment Fuel Doser (AFTFD) Drive Cycle to Determine Fault Status
valve. The Engine Control Module (ECM) uses the
See 2013 HD-OBD Diagnostic Reference Manual.
AFTFP2 sensor to monitor fuel delivery pressure to
the Aftertreatment Fuel Injector (AFI).

Malfunction Indicator Lamp (MIL) Reaction

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MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 263

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Figure 133

Step
Downstream Injection (DSI) Unit Location

Action
0000045745

Decision
1 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 2.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3556 FMI 1.

Step Action Decision

2 Determine if Aftertreatment Fuel Doser (AFTFD) is stuck open. Yes: Go to step 4.
Prime Aftertreatment Fuel Injector (AFI) by actuating AFTFD and
No: Go to step 3.
Aftertreatment Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration
test. Using EST with ServiceMaxx™ software, go to Procedures >
KOER Aftertreatment Procedures > DSI De-Aeration procedure.
Start engine, actuate AFTFSV while monitoring AFTFP1 signal
during actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

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 264 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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4 3
0000047001

Figure 134 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

3 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Replace DSI unit. After
connectors are connected to the correct location. (AFTFSV and repairs are complete, retest for
AFTFD harness connectors can be swapped.) SPN 3556 FMI 1.
Are AFTFSV and AFTFD harness connectors connected to the No: Connect harness
correct sensors? connectors to correct location.
After repairs are complete, retest
for SPN 3556 FMI 1.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 265

Step Action Decision

4 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 3556 FMI 1.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise then drop when AFI opens:
Go to step 5.
• Does AFTFP2 signal value rise then drop when AFI opens?
AFTFP1 signal value drops
and AFTFP2 rises, then drops
when AFI is opened (correct
operation): Retest for SPN 3556
FMI 1 status.

Step Action Decision

5 Visually inspect AFI supply line for leaks or damage. Yes: Replace AFI supply line.
After repairs are complete, retest
Is the line leaking or damaged?
for SPN 3556 FMI 1.
No: Clean AFI, AFI housing, and

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bore. After repairs are complete,
retest for SPN 3556 FMI 1.

NOTE: After doing all diagnostic steps, if

SPN 3556 FMI 1 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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SPN 3556 FMI 7 - AFT Fuel Injector not responding as expected

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel Aftertreatment Fuel System test has run (Occurs 1 event
Injector (AFI) is System test failure before dosing)
not responding as
(Table D002) Time after Key On > 0 seconds
expected.
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

The Aftertreatment Fuel Injector (AFI) receives SPN’s 2659, 3479, 3480, 3482, 4077, and 5456.
pressurized fuel injection pulses from the Down
Stream Injection (DSI) unit. The AFI is a mechanical Drive Cycle to Determine Fault Status
poppet type injector, and will only inject fuel when fuel
See 2013 HD-OBD Diagnostic Reference Manual.
line pressure is increased above a specific pressure.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 267

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Figure 135 Downstream Injection (DSI) Unit Location

AFTFIS Circuit
0000045745

AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C 1 Connector
SIG GND
-1 1
C1-41 o
C1-26,:. AFTFT 2
VREF4
C2-08 c 3
C1-25 o AFTFP1 4
.__ AFTFIS

V45003

Figure 136 AFTFIS circuit diagram

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 268 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Yes: Go to step 2.
Key OFF, disconnect AFTFIS. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3556 FMI 7.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

1 2

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4 3
0000047001

Figure 137 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

2 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 3.
connectors are connected to the correct location. (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 3556 FMI 7.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 269

Step Action Decision

3 Check for biased AFTFP1 signal. Using EST with ServiceMaxx™ Yes: Go to step 4.
software, with AFTFIS connected, Key-On Engine-Off (KOEO),
No: Do AFTFIS Circuit Checks
run Continuous Monitor session and monitor Aftertreatment Fuel
(page 344). After repairs are
Pressure 1 (AFTFP1) signal.
complete, retest for SPN 3556
Is AFTFP1 between 0.66 and 0.86 volts? (Wiggle test may be FMI 7.
necessary if code is inactive or pending.)
NOTE: AFTFIS is a 4 wire sensor containing Aftertreatment
Fuel Temperature (AFTFT) signal for fuel temperature, and
AFTFP1 signal for fuel pressure.

Step Action Decision

4 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Yes: Go to step 5.
sensor. Key OFF, disconnect AFTFP2 sensor. Check AFTFP2
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 3556 FMI 7.
Are the AFTFP2 sensor connector, harness, and terminals clean
and undamaged?

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Step Action Decision
5 Check for biased AFTFP2 sensor. Using EST with ServiceMaxx™ Yes: Go to step 6.
software, with AFTFP2 sensor connected, KOEO, run Continuous
No: Do AFTFP2 Circuit Checks
Monitor session and monitor Aftertreatment Fuel Pressure 2
(page 348). After repairs are
(AFTFP2) signal.
complete, retest for SPN 3556
Is AFTFP2 signal value between 0.30 and 0.50 volts? (Wiggle test FMI 7.
may be necessary if code is inactive or pending.)

Step Action Decision

6 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 7.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 3556 FMI 7.

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Step Action Decision

7 Determine if Aftertreatment Fuel Doser (AFTFD) is stuck open. Yes: Go to step 8.
Prime Aftertreatment Fuel Injector (AFI) by actuating AFTFD and
No: Replace DSI unit. After
Aftertreatment Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration
repairs are complete, retest for
test. Using EST with ServiceMaxx™ software, go to Procedures >
SPN 3556 FMI 7.
KOER Aftertreatment Procedures > DSI De-Aeration procedure.
Start engine, actuate AFTFSV while monitoring AFTFP1 signal
during actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

Step Action Decision

8 Verify correct Down Stream Injection (DSI) unit and Aftertreatment Yes: Go to step 9.
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST)
with ServiceMaxx™ software, KOER, run DSI De-Aeration test.
Actuate AFTFSV, then actuate AFTFD. Monitor AFTFP1 signal No: Replace DSI unit. After
value during actuation. repairs are complete, retest for
Does AFTFP1 signal value drop when AFTFD is actuated? SPN 3556 FMI 7.

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Step Action Decision
9 Verify correct Down Stream Injection (DSI) unit and Aftertreatment Yes: Retest for SPN 3556 FMI 7.
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST)
with ServiceMaxx™ software, KOER, run DSI De-Aeration test.
No: Go to step 10.
Actuate AFTFSV, then actuate AFTFD. Monitor AFTFP2 signal
value during actuation.
Does AFTFP2 signal value rise, then drop when AFI opens?

Step Action Decision

10 Visually inspect AFI supply line for leaks or damage. Yes: Replace AFI supply line.
After repairs are complete, retest
Is the line leaking or damaged?
for SPN 3556 FMI 7.
No: Clean Aftertreatment Fuel
Injector (AFI), AFI housing, and
bore. After repairs are complete,
retest for SPN 3556 FMI 7.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 271

SPN 3750 FMI 31 - DPF Regen inhibited due to low exhaust temperatures
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Unable to begin closed Diesel Oxidation Catalyst Engine speed > 800 RPM for 90 seconds
loop control of active Outlet Temperature 200 seconds
regeneration of Diesel (DOCOT) < 500°F
Barometric Pressure (BARO) ≥
Particulate Filter (DPF) (260°C)
10.9 psi (75 kPa)
due to low DOC
temperature. Ambient Air Temperature (AAT)
≥ -4°F (-20°C)
Active regeneration of DPF has
been requested more than 200
seconds.
Inactive: SPN 3242 FMI 3 and
4; SPN 4765 FMI 3 and 4

Fault Overview Fault Facts

Fault code sets when the Engine Control Module This fault code may indicate exhaust temperature
(ECM) is unable to achieve closed loop control of is not high enough to actively regenerate the

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active regeneration of the aftertreatment system due aftertreatment system. Driving the vehicle
to low Diesel Oxidation Catalyst (DOC) temperature. with long-term increased load may increase
exhaust temperatures and decrease aftertreatment
Malfunction Indicator Lamp (MIL) Reaction regeneration frequency.
This fault does not illuminate the MIL when active. Possible Causes
• Degraded Diesel Oxidation Catalyst (DOC)
Associated Faults
• Exhaust leak
SPN 27 (EGR); SPN 51 (ETV); SPN 2659 (AMS);
SPN 2791 (EGR); SPN 3058 FMI 10 (EGR System • Damaged or missing Diesel Particulate Filter
Monitor); SPN 3246 (DPFOT); SPN 3251 FMI 2, 3, (DPF)
and 4 (DPFDP); and SPN 4766 (DOCOT)
• Failed DOC / DPF temperature sensors
Drive Cycle to Determine Fault Status
Drive Cycle 13 then 3 in 2013 HD-OBD Diagnostic
Reference Manual.

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Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 27 (EGR); SPN
No: Repair SPN 27; SPN 51;
51 (ETV); SPN 2659 (AMS); SPN 2791 (EGR); SPN 3058 FMI 10
SPN 2659; SPN 2791; SPN
(EGR System Monitor); SPN 3246 (DPFOT); SPN 3251 FMI 2, 3,
3058 FMI 10; SPN 3246; SPN
and 4 (DPFDP); and SPN 4766 (DOCOT).
3251 FMI 2, 3, and 4; and
Is EST DTC list free of SPN 27; SPN 51; SPN 2659; SPN 2791; SPN 4766. After repairs are
SPN 3058 FMI 10; SPN 3246; SPN 3251 FMI 2, 3, and 4; and complete, retest for SPN 3750
SPN 4766? FMI 31.

Step Action Decision

2 Inspect exhaust system for leaks and physical damage. Yes: Go to step 3.
Is exhaust system free of leaks and physical damage? No: Repair or replace leaking or
damaged exhaust components.
After repairs are complete, retest
for SPN 3750 FMI 31.

Step Action Decision

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3 Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT), Yes: Go to step 3.
Diesel Oxidation Catalyst Outlet Temperature (DOCOT), and DPF
No: Replace sensors that are
Outlet Temperature (DPFOT) temperatures. Perform Hot Run
not reading as expected. After
Sensor Comparison Test (page 72).
repairs are complete, retest for
Are the DOCIT, DOCOT, and DPFOT temperatures within 77°F SPN 3750 FMI 31.
(25°C) of each other?

Step Action Decision

4 Check the exhaust system for an installed and undamaged Diesel Yes: Inspect DOC for damage
Particulate Filter (DPF). and replace if damaged. After
repairs are complete, retest for
Is a DPF installed in the exhaust system and free damage?
SPN 3750 FMI 31.
No: Install correct DPF. After
repairs are complete, retest for
SPN 3750 FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 3750 FMI 31 remains, verify each step was
completed correctly, and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 273

SPN 4077 FMI 0 - AFTFP2 too high while dosing

Fault Overview
The Aftertreatment Fuel Pressure 2 (AFTFP2) sensor
is a variable capacitance sensor that monitors fuel
pressure after the Aftertreatment Fuel Doser (AFTFD)
valve. The Engine Control Module (ECM) uses the
AFTFP2 sensor to monitor fuel delivery pressure to
the Aftertreatment Fuel Injector (AFI).

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 27, 94, 102, 1189, 2791, and 4077.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

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Step Action Decision
1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4077 FMI 0 the only fault code active? After repairs are complete, retest
for SPN 4077 FMI 0.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage.
No: Repair restrictions, air
Is air intake system, exhaust system, and air filter free of leaks, or physical damage. After
restrictions, leaks, and physical damage? repairs are complete, retest for
SPN 4077 FMI 0.

Step Action Decision

3 Visually inspect Down Stream Injection (DSI) unit supply line for Yes: Go to step 4.
leaks or damage.
No: Replace DSI supply line.
Is the line free of leaks and damage? After repairs are complete, retest
for SPN 4077 FMI 0.

Step Action Decision

4 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 5.
out of specifications. Using EST with ServiceMaxx software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 4077 FMI 0.

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Step Action Decision

5 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal change only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.
After repairs are complete, retest
Does IMP sensor signal change:
for SPN 4077 FMI 0.
• When TC2WC is commanded On?
IMP signal change only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN
4077 FMI 0.
Neither change IMP signal when
commanded On: Go to step 6.
Both change IMP signal when
commanded On: Go to step 7.

Step Action Decision

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6 Verify IMP sensor and bore are not restricted due to carbon Yes: Go to step 7.
buildup. Remove and inspect IMP sensor and bore for carbon
No: Clean IMP sensor bore of
buildup.
carbon deposits. After repairs
Is IMP sensor and bore free of carbon buildup? are complete, retest for SPN
4077 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 275

Step Action Decision

7 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 8.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 4077 FMI 0.

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3 0000047621

Figure 138 Fuel Pressure Test Locations

1. HP fuel pump return 2. HP fuel pump inlet 3. Fuel supply to DSI unit

Step Action Decision

8 Measure fuel return pressure from high-pressure fuel pump. Yes: Go to step 10.
Connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 and fuel
No: Go to step 9.
pressure gauge between high-pressure fuel pump and fuel return
line. Measure fuel pressure at high idle, no load, and stabilized
engine operating temperature.
Is fuel return pressure greater than 15 psi?

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Step Action Decision

9 Visually inspect Aftertreatment Fuel Injector (AFI) supply line for Yes: Replace AFI supply line.
leaks or damage. After repairs are complete, retest
for SPN 4077 FMI 0.
Is the line leaking or damaged?
No: Clean AFI valve, housing,
and bore. After cleaning
procedure is complete, retest for
SPN 4077 FMI 0.

Step Action Decision

10 Inspect fuel return line for fuel cooler. Yes: Remove fuel cooler and
install a fuel line in its place.
Is a fuel cooler present?
After repairs are complete, retest
for SPN 4077 FMI 0.
No: Repair restriction in fuel
return line. After repairs are
complete, retest for SPN 4077
FMI 0.

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NOTE: After doing all diagnostic steps, if
SPN 4077 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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SPN 4077 FMI 1 - AFTFP2 too low while dosing

Fault Overview
The Aftertreatment Fuel Pressure 2 (AFTFP2) sensor
is a variable capacitance sensor that monitors fuel
pressure after the Aftertreatment Fuel Doser (AFTFD)
valve. The Engine Control Module (ECM) uses the
AFTFP2 sensor to monitor fuel delivery pressure to
the Aftertreatment Fuel Injector (AFI).

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN’s 94, 3479, and 3482.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

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AFTFP2 circuit
AFTFP2
connector AFTFP2
(end view)
ECM 58 - Pin C2 AFTFP2
connector (6730) 1
connector (6019)
Pin C2 - 08 o-+---V.:....:R....:.:E=-:F_4:..___ _ _ ____j 1
Pin C2 - 42 SIG GND 2
Pin C2 - 50 AFTFP2 3

0000047760

Step Action Decision

1 Visually inspect Down Stream Injection (DSI) unit supply line for Yes: Go to step 2.
leaks or damage.
No: Replace DSI supply line.
Is the line free of leaks and damage? After repairs are complete, retest
for SPN 4077 FMI 1.

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Step Action Decision

2 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Yes: Go to step 3.
sensor. Key OFF, disconnect AFTFP2 sensor. Check AFTFP2
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 4077 FMI 1.
Are the AFTFP2 sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Check for biased AFTFP2 sensor. Using EST with ServiceMaxx™ Yes: Go to step 4.
software, with AFTFP2 sensor connected, run Continuous Monitor
No: Do AFTFP2 Circuit Checks
session and monitor Aftertreatment Fuel Pressure 2 (AFTFP2)
(page 348). After repairs are
signal.
complete, retest for SPN 4077
Is AFTFP2 signal value between 0.30 and 0.50 volts? (Wiggle test FMI 1.
may be necessary if code is inactive or pending.)

Step Action Decision

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4 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 5.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: See Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
Test (page 167). After repairs
should be at a steady pressure of 90 psi or more.
are complete, retest for SPN
Is FDP between 85 – 120 psi? 4077 FMI 1.

Step Action Decision

5 Prime Aftertreatment Fuel Injector (AFI) by actuating Yes: Go to step 7.
Aftertreatment Fuel Doser (AFTFD) valve and Aftertreatment
No: Go to step 6.
Fuel Shutoff Valve (AFTFSV) with DSI De-Aeration test. Using
EST with ServiceMaxx™ software, go to Procedures > KOER
Aftertreatment Procedures > DSI De-Aeration procedure. Start
engine, actuate AFTFSV while monitoring AFTFP1 signal during
actuation.
Does AFTFP1 rise to 100 psi or more and hold steady for at least
5 seconds?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 279

1 2

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4 3
0000047001

Figure 140 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

6 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Replace DSI unit. After
connectors are connected to the correct location. (AFTFSV and repairs are complete, retest for
AFTFD harness connectors can be swapped.) SPN 4077 FMI 1.
Are AFTFSV and AFTFD harness connectors connected to the No: Connect harness
correct sensors? connectors to correct location.
After repairs are complete, retest
for SPN 4077 FMI 1.

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Step Action Decision

7 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 4077 FMI 1.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise then drop when AFI opens:
Go to step 8.
• Does AFTFP2 signal value rise then drop when AFI opens?
AFTFP1 signal value drops
and AFTFP2 rises, then drops
when AFI is opened (correct
operation): Retest for SPN 4077
FMI 1.

Step Action Decision

8 Visually inspect AFI supply line for leaks or damage. Yes: Replace AFI supply line.
After repairs are complete, retest
Is the line leaking or damaged?
for SPN 4077 FMI 1.
No: Clean AFI valve, housing,

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and bore. After cleaning
procedure is complete, retest for
SPN 4077 FMI 1.

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SPN 4766 FMI 10 - DPF Regeneration feedback fault

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Function of time to reach Regeneration active 1 event
Catalyst Outlet desired DOCOT and
Injection quantity < 1 mg / stroke
Temperature (DOCOT) regeneration desired
and Engine operating status =
did not reach the desired temperature
Running for 30 seconds
operating temperature
(Tables A028, A021,
within the desired time. Open loop dosing active
A040, and C005)
Engine Coolant temperature 1
(ECT1) > 122°F (50°C)
Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) > 392°F
(200°C)
Exhaust gas mass flow > 200 kg
/ hr
Engine operating in monitoring
region: 900-2100 rpm and >
50% load

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Regeneration interruptions
(disable) > 20 events less than
30 seconds in duration
Regeneration interruptions
(disable) > 1 event more than 30
seconds in duration

Fault Overview Associated Faults

Fault code sets when the Diesel Oxidation Catalyst SPN’s 94, 2659, 3251, 3480, 4077, 4765, and 5456.
Outlet Temperature (DOCOT) does not reach desired
temperature within a predetermined time frame during Drive Cycle to Determine Fault Status
exhaust injection.
See 2013 HD-OBD Diagnostic Reference Manual.
Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two drive cycles.

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1 2

0000047042

Figure 141 DOCOT and DOCIT Sensor Locations (Typical)

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1. Diesel Oxidation Catalyst Outlet 2. Diesel Oxidation Catalyst Inlet
Temperature (DOCOT) sensor Temperature (DOCIT) sensor

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4766 FMI 10 the only fault code active? After repairs are complete, retest
for SPN 4766 FMI 10.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks, or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 4766 FMI 10.
of restrictions, leaks, and physical damage?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 283

Step Action Decision

3 Inspect connections at Diesel Oxidation Catalyst Inlet (DOCIT) Yes: Go to step 4.
sensor, and Diesel Oxidation Catalyst Outlet (DOCOT) sensor.
No: Repair damaged connector,
Key OFF, disconnect DOCIT and DOCOT sensor connectors.
harness, or terminal. After
Check sensor and connector terminals for: damaged or pinched
repairs are complete, retest for
wires; corroded terminals; loose, bent, or broken pins; or broken
SPN 4766 FMI 10.
connector housing.
Are DOCIT and DOCOT sensor connectors, harnesses, and
terminals clean and undamaged?

Step Action Decision

4 Check for biased aftertreatment temperature sensor. Do Hot Run Yes: Go to step 5.
Sensor Comparison Test (page 72).
No: Replace sensors that are
Are the DOCIT, DOCOT, and DPFOT temperatures within 77°F not reading as expected. After
(25°C) of each other? repairs are complete, retest for
SPN 4766 FMI 10.

Step Action Decision

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5 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 6.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 4766 FMI 10.

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 284 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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4 3
0000047001

Figure 142 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

6 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 7.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 4766 FMI 10.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 285

Step Action Decision

7 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 4766 FMI 10.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 4766
FMI 10.
AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 4766 FMI 10.
AFTFP1 signal value drops

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and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step 8.

Step Action Decision

8 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 9.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 286 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 While running OBFCT, inspect for exhaust leaks and monitor following
signals during test:
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks
Engine condition
Engine Coolant Temp
(ECT)
DOCIT
DOCOT
Specifications
Smooth, not stumbling
Above 122°F (50°C) per
ServiceMaxx
After 5 - 10 minutes above
500°F (260°C)
After 5 – 10 minutes above
986°F (530°C)
If Parked Regen Checks
are within specification:
Go to step 10.
Pass / Fail
If AFTFP1 is below 110
psi: Do Fuel Delivery
Pressure (FDP) Test (page
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 4766 FMI 10.
If AFTFP2 fuel pressure
is below 40-70 psi at AFI
opening: Clean AFI valve,
housing, and bore. After
cleaning procedure is
complete, retest for SPN

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DPFOT
Aftertreatment Fuel
Pressure 1 (AFTFP1)
Aftertreatment Fuel
Pressure 2 (AFTFP2)
4766 FMI 10.
Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
> 110 psi during test
and AFTFP2 are out
of specifications: Repair
Aftertreatment Fuel Parked Regen Check
Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 4766 FMI 10.
pressure.

Step Action Decision

10 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 11.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 4766
FMI 10.

Step Action Decision

11 Check vehicle repair history for EGR cooler repairs (internal Yes: Go to step 12.
coolant leak), since last Diesel Oxidation Catalyst (DOC)
No: Replace DOC. After repairs
replacement.
are complete, retest for SPN
Is vehicle history free of EGR cooler repairs (internal coolant leak), 4766 FMI 10.
since last DOC replacement?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 287

Step Action Decision

12 Inspect for coolant leak to exhaust. Do Coolant Leak to Exhaust Yes: Verify each step was
(page 82) test and check for coolant leaks. completed correctly and the
proper decision was made.
Is exhaust system free of coolant leaks?
Notify supervisor for further
action.
No: Repair coolant leak into
exhaust system and replace
DOC. After repairs are complete,
retest for SPN 4766 FMI 10.

NOTE: After doing all diagnostic steps, if SPN

4766 FMI 10 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 288 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4766 FMI 20 - DOC Outlet Temp above maximum desired

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Oxidation Catalyst Time after successful regen 10 seconds
Catalyst Outlet downstream temperature complete > 10 minutes
Temperature (DOCOT) > 932°F (500°C)
Timer after Key On > 0 seconds
above desired operating
temperature. Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

Fault code sets when the Diesel Oxidation Catalyst SPN’s 94, 2659, 3251, 3480, 4077, 4765, and 5456.
Outlet Temperature (DOCOT) reaches above 932°F
(500°C) within a predetermined time frame by the Drive Cycle to Determine Fault Status
Engine Control Module (ECM).
See 2013 HD-OBD Diagnostic Reference Manual.
Malfunction Indicator Lamp (MIL) Reaction
When fault is active, MIL will not illuminate.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 289

0000047042

Figure 143 DOCOT Sensor Location

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1. Diesel Oxidation Catalyst Outlet
Temperature (DOCOT) sensor

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4766 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 4766 FMI 20.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 4766 FMI 20.
of restrictions, leaks, and physical damage?

Step Action Decision

3 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 4.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT.
No: Repair connector, harness,
Check DOCOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 4766 FMI 20.
Are the DOCOT sensor connector, harness, and terminals clean
and undamaged?

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Step Action Decision

4 Check for biased aftertreatment temperature sensor. Do Hot Run Yes: Go to step 5.
Sensor Comparison Test (page 72).
No: Replace sensors that are
Are the DOCIT, DOCOT, and DPFOT temperatures within 77°F not reading as expected. After
(25°C) of each other? repairs are complete, retest for
SPN 4766 FMI 20.

Step Action Decision

5 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 6.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 4766 FMI 20.

Step Action Decision

6 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

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SPN 4766 FMI 20.
Does engine have excessive crankcase pressure?
No: Go to step 7.

Step Action Decision

7 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 8.
Cylinder Cutout Test (page 182).
No: Go to step 9.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

8 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 4766 FMI 20.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 4766
FMI 20.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 291

1 2

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4 3
0000047001

Figure 144 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

9 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 10.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 4766 FMI 20.

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 292 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

10 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 4766 FMI 20.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 4766
FMI 20.
AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 4766 FMI 20.
AFTFP1 signal value drops

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and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step
11.

Step Action Decision

11 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 12.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 293

Step Action Decision

12 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification:
Go to step 13.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 4766 FMI 20.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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4766 FMI 20.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 4766 FMI 20.
pressure.

Step Action Decision

13 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Verify each step was
Pressure (DPFDP) signal measure below 0.5 psi at high idle? completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 4766
FMI 20.

NOTE: After doing all diagnostic steps, if SPN

4766 FMI 20 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 294 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4766 FMI 21 - DOC Outlet Temp below minimum desired

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Diesel Oxidation Engine speed > 1400 rpm 10 seconds
Catalyst Outlet Catalyst (DOC) output
Injection quantity > 115 mg /
Temperature (DOCOT) temperature < 392°F
stroke
did not get above 392°F (200°C)
(200°C) for 10 seconds Intake Manifold Pressure (IMP)
with enable conditions > 17.5 psi (120 kPa)
met. (start of regen)
In above conditions > 45
seconds
Time after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

Fault code sets when the Diesel Oxidation Catalyst SPN’s 94, 3251, 3480, 4077, 4765, and 5456.
Outlet Temperature (DOCOT), with enable conditions

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met, does not reach a minimum of 392°F (200°C) Drive Cycle to Determine Fault Status
during exhaust injection.
See 2013 HD-OBD Diagnostic Reference Manual.
Malfunction Indicator Lamp (MIL) Reaction
When fault is active, MIL will not illuminate.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 295

0000047042

Figure 145 DOCOT Sensor Location

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1. Diesel Oxidation Catalyst Outlet 2. Diesel Oxidation Catalyst Inlet
Temperature (DOCOT) sensor Temperature (DOCIT) sensor

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4766 FMI 21 the only fault code active? After repairs are complete, retest
for SPN 4766 FMI 21.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 4766 FMI 21.
of restrictions, leaks, and physical damage?

Step Action Decision

3 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 4.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT.
No: Repair connector, harness,
Check DOCOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 4766 FMI 21.
Are the DOCOT sensor connector, harness, and terminals clean
and undamaged?

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 296 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Check for biased aftertreatment temperature sensor. Do Hot Run Yes: Go to step 5.
Sensor Comparison Test (page 72).
No: Replace sensors that are
Are the DOCIT, DOCOT, and DPFOT temperatures within 77°F not reading as expected. After
(25°C) of each other? repairs are complete, retest for
SPN 4766 FMI 21.

Step Action Decision

5 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 6.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 4766 FMI 21.

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4 3
0000047001

Figure 146 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 297

Step Action Decision

6 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 7.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 4766 FMI 21.

Step Action Decision

7 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 4766 FMI 21.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 4766
FMI 21.

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AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 4766 FMI 21.
AFTFP1 signal value drops
and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step 8.

Step Action Decision

8 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 9.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 298 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 While running OBFCT, inspect for exhaust leaks and monitor following
signals during test:
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks
Engine condition
Engine Coolant Temp
(ECT)
DOCIT
DOCOT
Specifications
Smooth, not stumbling
Above 122°F (50°C) per
ServiceMaxx
After 5 - 10 minutes above
500°F (260°C)
After 5 – 10 minutes above
986°F (530°C)
If Parked Regen Checks
are within specification:
Go to step 10.
Pass / Fail
If AFTFP1 is below 110
psi: Do Fuel Delivery
Pressure (FDP) Test (page
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 4766 FMI 21.
If AFTFP2 fuel pressure
is below 40-70 psi at AFI
opening: Clean AFI valve,
housing, and bore. After
cleaning procedure is
complete, retest for SPN

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DPFOT
Aftertreatment Fuel
Pressure 1 (AFTFP1)
Aftertreatment Fuel
Pressure 2 (AFTFP2)
4766 FMI 21.
Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
> 110 psi during test
and AFTFP2 are out
of specifications: Repair
Aftertreatment Fuel Parked Regen Check
Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 4766 FMI 21.
pressure.

Step Action Decision

10 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 11.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 4766
FMI 21.

Step Action Decision

11 Check vehicle repair history for EGR cooler repairs (internal Yes: Go to step 12.
coolant leak), since last Diesel Oxidation Catalyst (DOC)
No: Replace DOC. After repairs
replacement.
are complete, retest for SPN
Is vehicle history free of EGR cooler repairs (internal coolant leak), 4766 FMI 21.
since last DOC replacement?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 299

Step Action Decision

12 Inspect for coolant leak to exhaust. Do Coolant Leak to Exhaust Yes: Verify each step was
(page 82) test and check for coolant leaks. completed correctly and the
proper decision was made.
Is exhaust system free of coolant leaks?
Notify supervisor for further
action.
No: Repair coolant leak into
exhaust system and replace
DOC. After repairs are complete,
retest for SPN 4766 FMI 21.

NOTE: After doing all diagnostic steps, if SPN

4766 FMI 21 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 300 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 5298 FMI 2 - Reduced DOC Efficiency – De-Rate

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Difference between Demanded aftertreatment 3 event
Catalyst (DOC) modeled DOCOT and dosing quantity > 1000 mg/s
Efficiency low. average DOCOT > 275°F
Time after Key On > 0 seconds
(135°C)
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Injection quantity < 1 mg/stroke
and Engine operating status =
Running for 30 seconds
DOCOT rate of change < 68°F
(20°C)
Modeled DOCOT rate of change
< 122°F (50°C)
Regeneration Active
Exhaust gas volume flow < 750

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cubic meters/hour and > 500
cubic meters/hour
Engine operating in monitoring
region

Fault Overview Associated Faults

Fault code sets when the Engine Control Module SPN’s 94, 3251, 3480, 4077, 4765, 4766, and 5456.
(ECM) determines Diesel Oxidation Catalyst (DOC)
efficiency is low. The ECM calculates Modeled Diesel Drive Cycle to Determine Fault Status
Oxidation Catalyst Outlet Temperature (DOCOT) rate
See 2013 HD-OBD Diagnostic Reference Manual.
of change based on an average of Aftertreament Fuel
2
Injector (AFI) quantity and calculated O quantity, and
compares to average DOCOT.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 301

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Figure 147

Step
Downstream Injection (DSI) Unit Location

Action
0000045745

Decision
1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 5298 FMI 2 the only fault code active? After repairs are complete, retest
for SPN 5298 FMI 2.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 5298 FMI 2.
of restrictions, leaks, and physical damage?

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 302 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 4.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT.
No: Repair connector, harness,
Check DOCOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 5298 FMI 2.
Are the DOCOT sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

4 Check for biased aftertreatment temperature sensor. Do Hot Run Yes: Go to step 5.
Sensor Comparison Test (page 72).
No: Replace sensors that are
Are the DOCIT, DOCOT, and DPFOT temperatures within 77°F not reading as expected. After
(25°C) of each other? repairs are complete, retest for
SPN 4766 FMI 10.

Step Action Decision

5 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 6.

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Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 5298 FMI 2.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 303

1 2

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4 3
0000047001

Figure 148 DSI Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

6 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 7.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 5298 FMI 2.

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 304 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 5298 FMI 2.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 5298
FMI 2.
AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 5298 FMI 2.
AFTFP1 signal value drops

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and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step 8.

Step Action Decision

8 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 9.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 305

Step Action Decision

9 While running OBFCT, inspect for exhaust leaks and monitor following
signals during test:
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks
Engine condition
Engine Coolant Temp
(ECT)
DOCIT
DOCOT
Specifications
Smooth, not stumbling
Above 122°F (50°C) per
ServiceMaxx
After 5 - 10 minutes above
500°F (260°C)
After 5 – 10 minutes above
986°F (530°C)
If Parked Regen Checks
are within specification:
Go to step 10.
Pass / Fail
If AFTFP1 is below 110
psi: Do Fuel Delivery
Pressure (FDP) Test (page
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 5298 FMI 2.
If AFTFP2 fuel pressure
is below 40-70 psi at AFI
opening: Clean AFI valve,
housing, and bore. After
cleaning procedure is
complete, retest for SPN

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DPFOT
Aftertreatment Fuel
Pressure 1 (AFTFP1)
Aftertreatment Fuel
Pressure 2 (AFTFP2)
5298 FMI 2.
Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
> 110 psi during test
and AFTFP2 are out
of specifications: Repair
Aftertreatment Fuel Parked Regen Check
Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 5298 FMI 2.
pressure.

Step Action Decision

10 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 11.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 5298
FMI 2.

Step Action Decision

11 Check vehicle repair history for EGR cooler repairs (internal Yes: Go to step 12.
coolant leak), since last Diesel Oxidation Catalyst (DOC)
No: Replace DOC. After repairs
replacement.
are complete, retest for SPN
Is vehicle history free of EGR cooler repairs (internal coolant leak), 5298 FMI 2.
since last DOC replacement?

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 306 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

12 Inspect for coolant leak to exhaust. Do Coolant Leak to Exhaust Yes: Verify each step was
(page 82) test and check for coolant leaks. completed correctly and the
proper decision was made.
Is exhaust system free of coolant leaks?
Notify supervisor for further
action.
No: Repair coolant leak into
exhaust system and replace
DOC. After repairs are complete,
retest for SPN 5298 FMI 2.

NOTE: After doing all diagnostic steps, if

SPN 5298 FMI 2 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 307

SPN 5319 FMI 31 - DPF Incomplete Regeneration

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incomplete Estimated soot burn < 75 Number of allowable 1 event
regeneration of the grams regeneration attempts since
aftertreatment system the last successful regeneration
has been detected. was completed < 50
Limp Home Mode = Inactive
Diesel Particulate Filter (DPF)
regeneration = Inactive
Engine Coolant Temperature
1 (ECT1) > -44°F (-7°C) <
239°F (115°C) and Ambient
Air Temperature (AAT) > -44°F
(-7°C) < 131°F (55°C)
Barometric pressure (BARO) >
11 psi (75 kPa)
Engine is coasting (Disable)

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Injection quantity < 1 mg/stroke
and Engine operating status =
Running for 30 seconds
Exhaust gas volume flow > 500
cubic meters/hour
Distance since regeneration <
62 miles (100,000) meters
Continuous simulated soot mass
< 20 g
DPF temperature < 788°F
(420°C)
Enable conditions met for > 300
seconds
Fuel injection quantity (disable
condition) < 5 mg/stroke for > 3
seconds

Fault Overview provides a feedback signal to the ECM indicating

pressure difference between the inlet and outlet of
The Diesel Particulate Filter Differential Pressure
the DPF.
(DPFDP) sensor is a variable-capacitance sensor
that measures pressure at two locations. The first
Malfunction Indicator Lamp (MIL) Reaction
location is between the Diesel Oxidation Catalyst
(DOC) and the Diesel Particulate Filter (DPF). The MIL will illuminate when this fault is detected during
second location is immediately after the DPF. DPFDP two drive cycles.

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 308 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Associated Faults Drive Cycle to Determine Fault Status

SPN 27 (EGR), SPN 1173 (TC2CIT), SPN 1177 Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(TC2CIP), SPN 1189 (TC2WC) Manual.
SPN 94 (FDP); SPN 102 (IMP); SPN 157 (FRP); SPN Possible Causes
651-656 (INJ/CYL); SPN 3055 (FRP); SPN 3479
• Low engine performance
(AFTFD) SPN 3480 (AFTFP1); SPN 3481 (AFT);
SPN 3482 (AFTFSV); SPN 4077 (AFTFP2); SPN • Failed fuel injector
5456 (AFTFT); SPN 5541 (TC1TOP)
• Engine mechanical
SPN 3251 FMI 2, 3, and 4 (DPFDP / outlet pressure)
• Oil leak to exhaust
Fault Facts • Failed Diesel Particulate Filter Differential
Pressure (DPFDP)
If aftertreatment system has had excess fuel, oil,
coolant, metal, or other contamination; inspect the • Restricted DPFDP sensor hose(s)
entire aftertreatment system for causal damage
• Damaged or failed Diesel Oxidation Catalyst
before re-installing. Inspect for overheated
(DOC)
aftertreatment components, cracked exhaust system
welds, leaking exhaust system seams, or other • Restricted DOC (soot accumulation)
damage. Excessive ash accumulation in the
• Failed DSI
Diesel Particulate Filter (DPF) will cause frequent
regenerations of the aftertreatment system. If all

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step-based diagnostics have been completed with no
failure found, inspect the ash load of the DPF.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 309

Step Action Decision

1 Using EST, check DTC list for SPN 27 (EGR); SPN 1173 Yes: Go to step 2.
(TC2CIT); SPN 1177 (TC2CIP); and SPN 1189 (TC2WC).
No: Repair SPN 27; SPN 1173;
Is EST DTC list free of SPN 27; SPN 1173; SPN 1177; and SPN SPN 1177; and SPN 1189. After
1189? repairs are complete, retest for
SPN 5319 FMI 31.

Step Action Decision

2 Using EST with ServiceMaxx™ software, check DTC list for SPN Yes: Go to step 3.
94 (FDP); SPN 102 (IMP); SPN 157 (FRP); SPN 651-656 (INJ
No: Repair SPN 94; SPN 102;
/ CYL); SPN 3479 (AFTFD); SPN 3480 (AFTFP1); SPN 3481
SPN 157; SPN 651-656; SPN
(AFT); SPN 3482 (AFTFSV); SPN 4077 (AFTFP2); SPN 5456
3055; SPN 3479; SPN 3480;
(AFTFT); and SPN 5541 (TC1TOP).
SPN 3481; SPN 3482; SPN
Is EST DTC list free of SPN 94; SPN 102; SPN 157; SPN 651-656; 4077; SPN 5456; and SPN 5541.
SPN 3055; SPN 3479; SPN 3480; SPN 3481; SPN 3482; SPN After repairs are complete, retest
4077; SPN 5456; and SPN 5541? for SPN 5319 FMI 31.

Step Action Decision

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3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 3251 FMI 2,
No: Repair SPN 3251 FMI
3, and 4 (DPFDP).
2, 3, and 4. After repairs are
Is EST DTC list free of SPN 3251 FMI 2, 3, and 4? complete, retest for SPN 5319
FMI 31.

Step Action Decision

4 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 5.
Pressure (DPFDP) sensor module. Key OFF, disconnect DPFDP
No: Repair connector, harness,
sensor module. Check DPFDP sensor module and connector
or terminal damage. After
terminals for: damaged or pinched wires; corroded terminals;
repairs are complete, retest for
loose, bent, or broken pins; or broken connector housing.
SPN 5319 FMI 31.
Are the DPFDP sensor module connector, harness, and terminals
clean and undamaged?

Step Action Decision

5 Monitor DPFDP signal following active regeneration of the Yes: Go to step 7.
aftertreatment system. Key-On Engine-Off (KOEO), using EST
No: Go to step 6.
with ServiceMaxx software, load the Signals session and monitor
DPFDP.
Is DPFDP below 0.5 psi?

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 310 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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0000046718

Figure 149 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

6 Check DPFDP / outlet pressure sensor module hoses for correct Yes: Replace DPFDP / outlet
routing and restrictions. Inspect the DPFDP / outlet pressure Pressure sensor. After repairs
sensor module hoses for kinks, improper hose routing, restrictions, are complete, retest for SPN
or damage. 5319 FMI 31.
Are the DPFDP / outlet pressure sensor module hoses routed No: Repair or replace DPFDP /
correctly, free of damage, and unrestricted? outlet pressure sensor hose(s).
After repairs are complete, retest
for SPN 5319 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 5319 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 311

Step Action Decision

8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Go to step 10.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 5319 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 5319
FMI 31.

Step Action Decision

10 Check for lube oil leak to exhaust. Perform Lube Oil Leak to Yes: Go to step 11.

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Exhaust (page 95).
No: Repair lube oil leak to
Was the exhaust free of lube oil contamination? exhaust. After repairs are
complete, retest for SPN 5319
FMI 31.

Step Action Decision

11 Check for fuel leak to exhaust. Perform Fuel Leak to Exhaust Yes: Clean or replace DOC.
(page 103). Refer to fault facts. After repairs
are complete, retest for SPN
Was the exhaust free of fuel contamination?
5319 FMI 31.
No: Repair fuel leak to exhaust.
After repairs are complete, retest
for SPN 5319 FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 5319 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 312 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

.-. )
Aftertreatment System Overview

Types of Regens
Passive - Not initiated by operator or by control
system. Occurs when exhaust gas temperatures are
hot enough to ignite soot particles in the aftertreatment
system.
Active - Initiated by control system. Occurs when
exhaust gas temperatures are too low to ignite soot
particles. The ECM will command the Aftertreatment
Fuel Injector ON causing extra fuel to be injected into
the aftertreatment system increasing exhaust gas
temperatures.
Parked - Initiated by operator. Occurs when soot
levels are too high for Passive or Active regen
methods. During a Parked regen, engine RPM is
raised, fuel is injected into the exhaust, and the
Engine Throttle Valve (ETV) is positioned to restrict
air flow. If equipped with an Exhaust Back Pressure
Valve (EBPV), the valve is positioned to restrict
-··-
.....-..-) )
DPF
T01159
Figure 151 DPF Lamp
DPF lamp on solid. This notifies the operator the
Aftertreatment System is cleaning the DPF.
Operator Action: Drive at highway speed, until lamp
goes out, or perform a Parked Regen.
Technician Action: None
If system is unable to finish the cleaning process due
to driving conditions (Low load, short trip) or if there’s
a problem with the system, the soot level will continue
to build in the DPF and trigger the next soot level DTC.

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exhaust gas flow.
AFT System Indicators SPN 3719 FMI 15 – DPF Soot Load - Lowest (level
1/3)
Fault codes that require a Regen are better
.-.
-··-..-
understood as Alert codes. This is a normal condition
.....
used to alert the operator or technician that soot level
in the DPF has reached a set point and the system is
running or needs to run a DPF Regen. -
)
))
Hot Exhaust Temperature (HET) Lamp DPF
T01159

_f:_)
___ ,, Figure 152 DPF Lamp Flashing

DPF soot level 1, DPF lamp flashing. This notifies

TEMP
T01158
the operator the Aftertreatment System is cleaning the
DPF.
Figure 150 HET Lamp Operator Action: Perform a Parked Regen.
Technician Action: Verify the system is working
Hot Exhaust System Temperature lamp indicates without fault. See below procedure.
exhaust temperature is above
DPF soot level 1, DPF lamp flashing. This notifies the
400 °C (752 °F) and vehicle speed is below 5 mph.
operator the soot level is reaching a much higher level,
Operator Action: Beware of surroundings, the and the system is not completing a Regen through the
exhaust is very hot. operators current drive cycle. If this is ignored, the
soot level will continue to build to setting the next level
Technician Action: None
DTC.

Diesel Particulate Filter (DPF) Lamp

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 313

SPN 3719 FMI 16 – DPF Soot Load - Moderate (level

2/3)
-==-,,v
.....-..-
)
-==-,,v
.....-..-
) DPF T01160

DPF T0 1160
Figure 154
Sounding
DPF Lamp Flashing and Buzzer

Figure 153 DPF Lamp Flashing, Amber Warning

Lamp On Solid
Operator Action: Perform a Parked Regen.
Technician Action: Verify the system is working
without fault. See below procedure.
DPF soot level 2, DPF lamp flashing and the buzzer
sounding. This notifies the operator the soot level has
reached a critical level and the engine now de-rated
engine is de-rated by 15% of normal engine power.
Operator Action: Tow vehicle in for service.
Technician Action: The DPF must be replaced at
soot level 3, when the DPF lamp is flashing and the
buzzer sounding. This notifies the operator the soot
level has reached a critical level and the engine is
engine is de-rated by 85% of normal power.
Regen Inhibitors

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A DPF Regen can be inhibited by disabling switches,
or the entry conditions have not yet been met to start
the regeneration process.
SPN 3719 FMI 0 DPF Soot Load - Highest (level 3/3)
Fault Code Regen Inhibitors
Fault codes that can inhibit a Regen will not allow a
Regen process to take place. The ECM continuously
monitors for system faults. If a fault is detected the
Malfunction Indicator Lamp (MIL) lamp will illuminate
and a DTC will set.

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 314 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Entry Conditions for a Rolling Regen

When the ECM determines the soot level threshold is reached, the system triggers DPF Regen.
NOTE: Short trips or stop and go driving could prevent a successful Regen.
The following conditions are required for a Rolling Regen:
• DPF Status signal displaying: Regen Needed
• Red stop engine lamp not on
• Engine Coolant Temperature is above or at least 75 ºC (170 ºF)
• Inhibiting DTCs must not be active (See Fault Code Regen Inhibitors (page 313)
• Regen Inhibit switch not active (switch must be off)
• PTO not active (switch must be off)
• Exhaust Temperature sensors below safe thresholds:
• DOCIT below 500 °C (932 °F)
• DOCOT below 650 °C (120 °F)
• DPFOT below 750 °C (1382 °F)
If DPF Status displays "Regen needed" and vehicle is unable to perform a Rolling Regen, perform the

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Diagnostic Test Procedure (page 316).

318
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 315

Entry Conditions for a Parked Regen

A Parked Regen can only be performed when the DPF soot level threshold is reached. The DPF lamp will
flash or stay on solid, signaling the need for Regen.
The following conditions are required for a Parked Regen:
• Engine Running
• DPF lamp is on
• Parked Regen switch on
• DPF Status signal displaying: Regen Needed
• Red stop engine lamp not on
• Engine Coolant Temperature is above or at least 75 ºC (170 ºF)
• Vehicle speed not rolling
• Inhibiting DTCs must not be active (See Fault Code Regen Inhibitors (page 313)
• Regen Inhibit switch not active (switch must be off)
• PTO not active (switch must be off)
• Exhaust Temperature sensors below safe thresholds:

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• DOCIT below 500 °C (932 °F)
• DOCOT below 650 °C (1202 °F)
• DPFOT below 750 °C (1382 °F)
Onboard Filter Cleanliness Test. DPF Status displays “Regen needed” and vehicle is unable to perform a
Active Regen, go to appropriate aftertreatment system diagnostics section in this manual.

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 316 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPF Status Test

This test checks the status of the DPF if the Soot level is within a Regen Needed limit. The test will
automatically start a Parked Regen.
NOTE: The KOER Standard Test must be run before performing this test.

This test will perform a complete Parked Regen.

Engine speed is ramped up to increase exhaust flow through the DPF while the DPFDP sensor monitors the
pressure difference across the DPF. The test runs for about 15 minutes. If a Regen is needed, the engine
ramps up for another 15 minutes, but this time to run DPF Regen cycle.
The following conditions are required for a Onboard Filter Cleanliness Test.
• Engine Running
• Engine Coolant Temperature is above or at least 75 ºC (170 ºF)
• Vehicle stationary
• Inhibit DTCs must not be active: Refer to Fault Code Regen Inhibitors (page 313)
• PTO not active (switch must be off)
• Regen inhibit switch not active (switch must be off)

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• Parking brake must be applied
• Brake pedal not depressed
• Accelerator pedal not depressed
• Driveline disengaged
• If the Soot level is within normal range, the test completes and displays “Test Completed Successful.”
No further action is required.
• If the test is aborted, perform the following Diagnostic Test Procedure.

Diagnostic Test Procedure 3. Interview the operator about their drive cycle.
The system may not be able to finish DPF
If engine does not start due to a restricted DPF:
Regen due to driving conditions (Low load,
1. Remove the DPF and inspect for oil or coolant short trip).
in the exhaust. Repair problem found before
4. Install a new DPF and run the Onboard Filter
continuing.
Cleanliness Test.
2. Run all of the below tests but the Parked
Regen Test. Repair any problem found before
continuing.

320
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 317

Sensor Compare Checks

NOTE: This test is not dependent on engine temperature.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open Sessions / Aftertreatment / Temperatures.
3. Turn ignition switch ON, engine ON.
4. Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT), Diesel Oxidation Catalyst Outlet
Temperature (DOCOT), and Diesel Particulate Filter Outlet Temperature (DPFOT) sensors. Sensor
temperatures should be within 15° C (25°) of each other.
• If DOCIT, DOCOT or DPFOT is 15 °C (25 °F) above or below of each other, check for poor
circuitry going to the out of range sensor.
• If circuits are within specification, replace out of range sensor.
• If sensors and circuits are within specifications, continue to Exhaust Restriction Test.

Exhaust Restriction Test

Connect EST, open the Performance session.
NOTE: Run engine at High Idle while monitoring DPF Differential Pressure and TC1 Turbine Outlet

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Pressure.
Checks Specification Comment – < Less than, > Greater than
DPFDP < 1.5 psi If > 1.5 psi, the DPF is restricted, go to Parked Regen.
TC1TOP < 45 psi If TC1TOP is > 45 psi and DPFDP is < 1.5 psi, remove DOC and inspect
for face plugging.
If TC1TOP and DPFDP are within expected range, but the DPF Status reads “Regen Needed”, go to
Parked Regen Checks (page 321).

321
 318 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Regen Inhibitors

lnltnldlons l ~ J IIHlliors It - - • • l -contrckl OownStr--llf ~ >I IMaYI

Aftertreabnent @IOdt Tl"- . YM U't;s

Mmforce s. 7, OT.Pct 10: Vehicle SMt4 o.oo _,.

no StaC4 OCC/D1Nlllttd
• Onbowd Filer Clemlilless Tat d rmip up mgjnc speed ll>Pr Status 11-.-en not. nee"-4
llld 1111:81Ure lbe presllll'C cif'f'ermceacross the OPf. This lat Clutcb Mtcb Releued
does not 1'\111 a Regen. ll ON/ momon Ille £GOP unsor IO a,ue SV1"11 R.eltutd
Cllelllale the OPf soot level Ira Rqui is needed. Ille I.at Will a,uc ,,u.w:c SY1tc11 a,ue Dcd&l ulcue<
cOlllinue inlOa Parked Regen. An Reaen Inbil>1t Status IJ>bil>tu.
An Reaen nilillllt - ,._ua Fault Active • Ot 1nbil>l u.
An R.eaen Inblbtt • Ser:vtce az:uc Active • ot 1nbil>l u.
Mmforce II ct 13: An Reaen IJlbill1t - no Active llot lllbilli U<
• Onbowd Flier Clemlilless Tat d 1'\111 a complete pat1ced 11T Reaen Inbil>it - Inbil>lt Switcb llot 1nbil>itcd
DPFRegai. An Reaen nilillltt - ....,,lM llot IJUM4 Ill> • ot 1nb1!>1•-'
11T Reaal fJ!bUllt - Clutch D1s•--c4 llot Ulbal•-'
IAff Re_,, Inbil>lt - Accduat.o, Ott Idle llot Ulbil>i .....

• AFS Lelle Test will s11u1 the Fud Supply valve. AFT Fud
Pressure should not nise. lnspect system t01flcalcs..
• AFI Flow Test will llowlbeAFT Injector. Injector needs IO
b e ~ Ille exbaust so lbal llow can be mASUted.
• AFT System Leek Tat will opui Ille Flld Supply valve 111d
s11u1 Ille Orlin valve. AFT Fud Pressure wi1 l'lise. lDspect
system for leaks.

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~ Tl'Mlle COdH I ~ Tr.nlc 11'-lf• I OTC1,oal
TIOTC IR IM IT-tPe I~ I~ lc:o.n IMmlOt IMocUt

.. I 0..0TCs II RthdlDTC/WINCII [-es I

V00165

Figure 155 Aftertreatment session screen shot

Overview • Active fault code (s)

A regen may not occur due to any of the following To view the status of Regen inhibitors, use an EST
conditions: with ServiceMaxx™ software, go to Tests > KOER
Aftertreatment Tests > Onboard Filter Cleanliness
• Inhibitors do not match their expected value
Test. Select the Inhibitor tab.
• Entry condition have not been met

322
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 319

Check Rolling Regen Inhibitors

1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, load the Aftertreatment session.
3. Start engine and run vehicle speed above 5 mph.
4. Verify all listed inhibitors are displaying "Not Inhibited."
Check Expected Results Comment
AFT Regen Inhibit Status Not Inhibited If inhibited, correct the cause. Check switches and
any DTC that may be causing the Regen inhibit.
Red Stop Alert Lamp Off If On, Regen can't be run. Go to appropriate
aftertreatment system diagnostic section in this
manual.
Regen Inhibit Switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.
PTO Enable Switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.
PTO Switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.

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If no inhibitors are active and Regen is needed, go to Parked Regen Checks (page 321).

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 320 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Check Parked Regen Inhibitors

1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, load the Aftertreatment session.
3. Verify all listed Inhibitors are displaying "Not Inhibited."
Checks Expected Results Comment
AFT Regen Inhibit status Not Inhibited If inhibited, correct the cause. Check switches and
any DTC that may be causing the Regen inhibit.
Red Stop Alert lamp Off If On, Regen can't be run. Go to appropriate
aftertreatment system diagnostic section in this
manual.
Regen inhibit switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.
PTO enable switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.
PTO switch Off If On, turn switch Off. If switch does not turn Off,
then diagnose circuit fault.
Parking brake switch On If Off, set parking brake, if switch does not turn

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On, then diagnose circuit fault.
Brake Pedal switch Off If On and foot is off pedal, then diagnose circuit
fault.
Accelerator Pedal Position 0% If above 0%, and foot is off pedal, then diagnose
circuit fault.
Clutch Pedal Switch Off If On and foot is off pedal, then diagnose circuit
fault.
Transmission Position Park or Neutral If engaged, disengage, or diagnose circuit fault.
If no inhibitors and a Regen is needed, go to the following Parked Regen Checks.

Parked Regen Checks • DOCOT: 550-600°C (1022-1112°F) (after 5-10

minutes)
During a Parked Regen the engine speed will ramp up
to 1200-1800 rpm. • DPFOT: 600-650°C (1112-1202°F) (after 10-15
minutes)
Typical readings:
• DPFDP: Decreasing steadily once DPFIT and
• ETV: 80% (closed).
DPFOT are steady and above 550°C (1022°F).
• EGR Position: 0% (closed)
Connect the EST, open the Aftertreatment session.
• DOCIT: 250-300°C (482-572°F) Start a Parked Regen and monitor signals.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 321

Parked Regen Checks

Connect EST, open the Aftertreatment session. Open the inhibitors tab and check for Inhibitors.
Checks Expected Results Comment
Engine condition Smooth, not stumbling If engine does not run smoothly, diagnose engine
performance problem. See “PERFORMANCE
DIAGNOSTICS."
DPF Status Regen Needed If signal reads “Not needed”, than a Regen cannot
be commanded to run.
Engine Coolant Temp Above 66 ºC (150 ºF) If below 66 ºC (150 ºF), warm engine above set
point.
AFT Regen Status Active If signal reads “Not Active”, check for fault codes
and Parked Regen Inhibitors.
EGR Position Closed If not closed, see EGR Valve (page 621).
ETV Position 80% ±5% If not within specifications, see ETV (page 640).
DOCIT 250 ºC (482 ºF) to 300ºC If below 250 ºC (482 ºF), using Electronic Service
(572 ºF) Tool (EST) with ServiceMaxx™ software, run the
KOER Air Management Test.

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If above 300 ºC (572 ºF), check for proper ETV
operation, and if engine is over fueling.
DOCOT After 5-10 minutes above If below 530 ºC (986 ºF), diagnose and repair any
530 ºC (986 ºF) active DOCOT fault code(s) (Ex. SPN 4766 FMI
10). If no active fault code(s), go to appropriate
aftertreatment system diagnostics section in this
manual.
DPFOT Below 700 ºC (1292 ºF) If above 700 ºC (1292 ºF), diagnose and repair
any active DPFOT fault code(s). If no active fault
code(s), go to appropriate aftertreatment system
diagnostics section in this manual.
DPFDP Below 0.5 psi (3.4 kPa) If above 0.5 psi, after the system completes a full
Parked Regen, diagnose and repair any active
DPFDP fault code(s). If no active fault code(s), go
to appropriate aftertreatment system diagnostics
section in this manual.
If the DPF is face plugged, measure the distance between the filter and outlet. If not within specification,
the filter cannot be cleaned and must be replaced.

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 322 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPF Filter Inspection

Normal DPF Inlet

.•...• • . .
•
' •

.....
.: .
~

. .:-
~

. .- -.
• , · ,I'

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Figure 156 DPF Inlet (Normal)

326
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 323

Normal DPF Outlet

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Figure 157 DPF Outlet (Normal)

Inspect the inlet and outlet of the DPF.

Insure all inlet channels are visible and the light
soot coating over the whole inlet face easily wiped
away with a finger. Soot amount on face may vary
depending on the time since last DPF regeneration,
but should be less than 1/8."

Possible Causes Action

System is working correctly None.

327
 324 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Restricted DPF Inlet

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T17103

Figure 158 DPF Face Plugged

Inspect Inlet of the DPF.

If no channels are visible and the face of the DPF has
a deep cake of soot greater than 1/8”, remove DPF for
external cleaning.

Possible Causes Action

• Drive cycle (Unable to complete 1. Interview the operator about his drive cycle.
Regen)
2. Verify there are no inhibitors (DTCs or switches).
• Engine over fueling
3. Replace the DPF.
• Boost problem
• Intake throttle problem

328
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 325

DPF Contaminated with Coolant

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T17104

Figure 159 Coolant Contamination

Inspect the inlet and outlet of the DPF.

DPF will show signs of coolant flowing through
exhaust system and contaminating the DPF.

Possible Causes Action

• Coolant is flowing through exhaust 1. Repair coolant problem.
• Failed Interstage cooler
• Failed EGR cooler
• Failed injector sleeve
• Leaking cylinder head cup plugs
• Cylinder head porosity

329
 326 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPF Contaminated with Oil

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Figure 160 Engine Oil Contamination, Soot Leakage
T17105

Inspect the inlet and outlet of the DPF.

DPF will show signs of soot leakage and oil.

Possible Causes Action

• Failed turbocharger 1. Repair engine oil to exhaust problem.
• Failed piston rings 2. The DPF cannot be cleaned, it must be replaced.
• Failed cylinder sleeves 3. Inspect the DOC for damage and replace if necessary.
• Failed valve guides

330
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 327

DPF Outlet Leaking Soot

·•U
A
V,. .·
..
. .
. . ;-
....
.... ..:.··:.~. ..
~ ·.,
. ...
..
.•.,--·.-.:
.'
-. ... ·.. ·...

BetterManuals.net T1710

Figure 161 DPF Filter Damage, Soot Leakage

Inspect the outlet of the DPF.

DPF will show signs of soot leakage as indicated by
the arrows in figure.

Possible Causes Action

• DPF is damaged 1. The DPF cannot be cleaned, it must be replaced.
2. Inspect the DOC for damage and replace if necessary.

331
 328 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

External Damage to DPF

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Figure 162 DPF Filter, Can Damage
T17107

Inspect the exterior of the DPF.

DPF will show signs of damage such as dents or
cracks.

Possible Causes Action

• Road debris 1. The DPF cannot be cleaned, it must be replaced.
• Vehicle accident

332
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 329

DPF Ceramic Filter Brick Measurement

DPF Brick Measurement from Outlet

a •

10.5" 11.25" 21 .7"

11 .25" 10.5" 55.12
6.67c 9.21 c
~9.21 cm 26.67 cm

2594165C91 2594131 C91 2594356C91 2593981C91 2594363C91 2594369C91 2595055C91

Brick to Outlet Brick to Outlet Brick to Outlet Brick to Outlet Brick to Outlet Brick to Outlet Brick to Outlet

mm inch mm inch mm inch mm inch mm inch mm inch mm inch

77.57 3.05 77.57 3.05 195.27 7.69 193.27 7.61 76.17 300 76.17 3.00 1869 7.36
Fraction 3 3 7 11/16 7 5/8 3 3 7 3/8

Outlet
Outlet
Meas ure

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Measure thi s distance
thi s distance

Ceramic Filter Ceramic Filter

T01189

Figure 163 DPF Ceramic Filter Brick Measurement

Measure the distance between the ceramic filter brick

and the outlet. If the distance is greater then the
specification, the ceramic filter brick has moved out
of its correct location. Replace the DPF Filter.

Possible Causes Action

Face plugged If the distance is greater then the specification, the DPF cannot
be cleaned. It must be replaced.

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 330 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFTFD (Aftertreatment Fuel Doser)

SPN FMI Condition Possible Causes

3479 3 AFT Fuel Doser Valve Short to PWR • AFTFD circuit short to PWR
• Failed AFTFD
3479 5 AFT Fuel Doser Valve open/load • AFT Fuel Doser valve circuit OPEN
circuit
• Failed AFT Fuel Doser valve
3479 6 AFT Fuel Doser Valve High Side Short • AFTFD-H circuit short to GND
circuit
• AFTFD-L circuit short to GND
• Failed AFT Fuel Doser valve

AFT Fuel AFT Fuel

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Shutoff AFT Fuel Doser AFT Fuel
Valve Inlet Sensor Valve Pressure 2

Fuel Supply
------<

After
Treatment
Fuel Injector
/1\
•
Figure 164 Functional diagram for AFTFD

334
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 331

AFTFD Circuit
AFTFD
21-Way On/Off
Engine Harness AFTFD
ECM, Interface Connector AFTFD
E1 Connector Connector
1
1-------1
2

V45002

Figure 165 AFTFD circuit diagram

Tools Required
• 180-Pin Breakout Box 00-00956-08
• ZTSE4498 – 3-Banana Plug Harness

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• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4828 (AFTFD)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

Connector Voltage Check – AFTFD Disconnected

Connect Breakout Harness ZTSE4828 to engine harness. Leave AFTFD disconnected. Turn ignition switch
to ON. Use DMM to measure voltage.
Test Point Spec Comment – < Less than, > Greater than
1 to GND 12.0 V ± 2.0 V If < 10.0 V, check for OPEN circuit. Do Harness Resistance
Check
2 to GND 0 V - 1.0 V If > 1.0 V, check for short to PWR. Do Harness Resistance
Check.
If measurements are within specifications, go to Operational Voltage Check.

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 332 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4828 between AFTFD and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the 2010 Actuator session.
3. Command AFT Fuel Doser On, then Off.
4. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND On = 12.0 V ± 2.0 V If < 10.0 V, check for OPEN circuit.
2 to GND Off = 1.0 V ± 0.5 V If > 1.5 V, check for OPEN circuit or failed AFTFD.

Actuator Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE4828 to AFTFD and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than

1 to 2 16 Ω If not within specification, replace AFTFD.

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If measurements are within specifications, do Harness Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and Breakout Harness ZTSE4828. Leave ECM
and AFTFD disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
1 to E1-53 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short to GND.
2 to E1-76 <5Ω If > 5 Ω, check for OPEN circuit.

336
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 333

AFTFIS (Aftertreatment Fuel Inlet Sensor)

SPN FMI Condition Possible Causes Actions

3480 2 AFTFP1 pressure sensor plausibility • Failed AFTFIS Step-Based Diagnostics
error (page 336)
• Down Stream
Injection (DSI) unit
or AFT Fuel Injector
(AFI) fuel lines or
connections loose,
leaking, restricted,
or damaged.
3480 3 AFTFP1 signal Out of Range HIGH • Failed AFTFIS Step-Based Diagnostics
(page 338)
• AFTFP1 circuit short
to power
• SIG GND circuit
Open or high
resistance
3480 4 AFTFP1 signal Out of Range LOW • Failed AFTFIS Step-Based Diagnostics
(page 341)

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• AFTFP1 signal
circuit short to GND
• AFTFP1 signal
circuit Open or high
resistance
• VREF-4 circuit
Open or high
resistance
5456 3 AFTFT signal Out of Range HIGH • AFTFT signal circuit Pin-Point Diagnostics
OPEN or short to (page 344)
PWR
• Failed AFTFIS
5456 4 AFTFT signal Out of Range LOW • AFTFT signal circuit Pin-Point Diagnostics
short to GND (page 344)
• Failed AFTFIS

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 334 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector
SIG GND
-1 1
C1-41 -
C1-26 o AFTFT 2
C2-08 _ VREF4 3
C1-25 _ AFTFP1 4
AFTFIS
'--

V45003

Figure 166 AFTFIS circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 • ZTSE4498 – 3-Banana Plug Harness

Engine and Aftertreatment Wiring Schematic
• ZTSE4497 – 500 Ohm Resistor Harness
Form 0000002941 for additional circuit
information. • ZTSE4899 – Big Bore Terminal Test Probe Kit

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• Breakout Harness ZTSE4830 (AFTFIS)
Overview
• Digital Multimeter (DMM)
The Engine Control Module (ECM) monitors the
Aftertreatment Fuel Pressure 1 (AFTFP1) signal • Electronic Service Tool (EST) with ServiceMaxx™
voltage to calculate fuel pressure in the aftertreatment software
system feeding the Aftertreatment Fuel Injector (AFI).
• J1939 and J1708 RP1210B Compliant Device
This is used during active and parked regeneration
only.
Tools Required
• 00-00956-08 – 180-Pin Breakout Box

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 335

AFT Fuel AFT Fuel

Shutoff AFT Fuel Doser AFT Fuel
Valve Inlet Sensor Valve Pressure 2
AFTFIS

After
Treatment
Fuel Injector
/1\ 0000046179

Figure 167 Functional diagram for AFTFIS

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 336 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3480 FMI 2 - AFTFP1 signal erratic, intermittent or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel AFTFIS not reading as Inactive: SPN 3246 FMI 2, 3, 3 seconds
Pressure 1 (AFTFP1) expected. 4 (DPFOT); SPN 3251 FMI
circuit voltage is in 0 (DPFDP); SPN 3480 FMI
range, but not rational. 3, 4 (AFTFP1); SPN 3482
(AFTFSV); SPN 3556 (AFI);
SPN 4765 FMI 2, 3, 4 (DOCIT);
SPN 4766 (DOCOT)

Fault Overview Associated Faults

Fault code sets when the Engine Control Module
(ECM) detects Aftertreatment Fuel Inlet Sensor
(AFTFIS) sensor stuck in-range fault. Diagnostics are
only performed prior to starting an active regeneration
of the DPF, or at Key ON if the active regeneration
is continuing across key cycles. If the diagnostics
fail, then the regeneration request is aborted. Active
regeneration of the aftertreatment diesel particulate
SPN 94 (FDP); SPN 108 (BARO); SPN 157 (FRP);
SPN 3246 FMI 2, 3, 4 (DPFOT); SPN 3251 FMI 0
(DPFDP); SPN 3480 FMI 3, 4 (AFTFP1); SPN 3482
(AFTFSV); SPN 3512 FMI 14 (VREF-4); SPN 3556
(AFI); SPN 4765 FMI 2, 3, 4 (DOCIT); SPN 4766
(DOCOT)
Drive Cycle to Determine Fault Status

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filter will be disabled until the next key cycle. Engine
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
torque will be reduced if the engine is operated for an
Manual.
extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

340
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 337

AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C 1 Connector

C1-41 ,., SIG GND

- 1
1

C1-26,., AFTFT 2
VREF4
C2-08 o 3
C1-25 o AFTFP1 4
AFTFIS
-
V45003

Figure 168 AFTFIS circuit diagram

Possible Causes
• Failed AFTFIS
• Down Stream Injection (DSI) unit or AFT Fuel
Injector (AFI) fuel lines or connections loose,

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leaking, restricted, or damaged.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 108;
108 (BARO); SPN 157 (FRP); SPN 3246 FMI 2, 3, 4 (DPFOT);
SPN 157; SPN 3246 FMI 2, 3,
SPN 3251 FMI 0 (DPFDP); SPN 3480 FMI 3, 4 (AFTFP1); SPN
4; SPN 3251 FMI 0; SPN 3480
3482 (AFTFSV); SPN 3512 FMI 14 (VREF-4); SPN 3556 (AFI);
FMI 3, 4; SPN 3482; SPN 3512
SPN 4765 FMI 2, 3, 4 (DOCIT); SPN 4766 (DOCOT).
FMI 14; SPN 3556; SPN 4765
Is EST DTC list free of SPN 94; SPN 108; SPN 157; SPN 3246 FMI 2, 3, 4; SPN 4766. After
FMI 2, 3, 4; SPN 3251 FMI 0; SPN 3480 FMI 3, 4; SPN 3482; repairs are complete, retest for
SPN 3512 FMI 14; SPN 3556; SPN 4765 FMI 2, 3, 4; SPN 4766? SPN 3480 FMI 2.

Step Action Decision

2 Check Down Stream Injection (DSI) unit and AFT Fuel Injector Yes: Repair or replace leaking,
(AFI) fuel lines and connections for: loose connections, leaks, restricted, or damaged fuel line
restrictions, or damage. or connection. After repairs are
complete, retest for SPN 3480
Are the DSI unit and AFI fuel lines and connections leaking,
FMI 2.
restricted, or damaged?
No: Install new AFTFIS sensor.
After repairs are complete, retest
for SPN 3480 FMI 2.

NOTE: After performing all diagnostic steps, if

SPN 3480 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 338 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3480 FMI 3 - AFTFP1 Signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel AFTFP1 circuit value > Key ON 0.5 seconds
Pressure 1 (AFTFP1) 4.8 V for more than 1
circuit voltage above second
normal or shorted to
high source.

Fault Overview Associated Faults

Fault code sets when the Engine Control Module SPN 3512 FMI 14 (VREF-4)
(ECM) detects Aftertreatment Fuel Pressure 1
(AFTFP1) signal voltage is more than 4.8 volts for Fault Facts
more than 1 second. Engine torque may be reduced
The ECM monitors the (AFTFP1) signal voltage to
if the engine is operated for an extended period of
calculate fuel pressure in the aftertreatment system.
time with this fault active. Active regeneration of the
aftertreatment system may be disabled until the next
Drive Cycle to Determine Fault Status
key cycle.
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Malfunction Indicator Lamp (MIL) Reaction Manual.

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MIL will illuminate when this fault is detected during
two consecutive drive cycles.

342
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 339

AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C 1 Connector

C1-41 ,., SIG GND

- 1
1

C1-26,., AFTFT 2
VREF4
C2-08 o 3
C1-25 o AFTFP1 4
AFTFIS
-
V45003

Figure 169 AFTFIS circuit diagram

Possible Causes
• Failed AFTFIS
• AFTFP1 circuit short to power

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• SIG GND circuit Open or high resistance

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3512 FMI 14
No: Repair SPN 3512 FMI 14.
(VREF-4).
After repairs are complete, retest
Is EST DTC list free of SPN 3512 FMI 14? for SPN 3480 FMI 3.

Step Action Decision

2 Inspect connections at AFT Fuel Inlet Sensor (AFTFIS) sensor. Yes: Go to step 3.
Key OFF, disconnect AFTFIS connector. Check AFTFIS sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3480 FMI 3.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Check AFTFP1 circuit for short to power. Key-On Engine-Off Yes: Go to step 4.
(KOEO), with Breakout Harness ZTSE4830 connected between
No: Repair short to power
AFTFIS and ECM, use a DMM to measure voltage between
between AFTFIS connector
AFTFIS pin-4 and a known good ground.
pin-4 and ECM connector
Is voltage with 0.5 volts of 5 volts? pin C1-25. After repairs are
complete, retest for SPN 3480
FMI 3.

343
 340 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Check SIG GND circuit for Open or high resistance. Key OFF, Yes: Replace AFTFIS. After
Connect Breakout Harness ZTSE4830 to vehicle harness and repairs are complete, retest for
leave AFTFIS disconnected. Connect 180-pin Breakout Box with SPN 3480 FMI 3.
Breakout Harness 00-01467-00 to vehicle harness and leave ECM
No: Repair Open or high
disconnected. Use a DMM to measure resistance from Breakout
resistance between AFTFIS
Harness ZTSE4830 pin-1 to 180-pin Breakout Box pin C1-41.
pin-1 and ECM connector C1-41.
Is resistance less than 5 ohms? After repairs are complete, retest
for SPN 3480 FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 3480 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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344
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 341

3480 FMI 4 - AFTFP1 Signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel AFTFP1 circuit < 0.25 Key ON 0.5 seconds
Pressure 1 (AFTFP1) volts
circuit voltage below
normal or shorted to low
source.

Fault Overview Associated Faults

Fault code sets when the Engine Control Module SPN 3512 FMI 14 (VREF-4)
(ECM) detects the signal from the Aftertreatment Fuel
Pressure Fuel Pressure 1 (AFTFP1) circuit is less Fault Facts
than 0.25 volts for 2 seconds. Active aftertreatment
The ECM monitors the (AFTFP1) signal voltage to
regeneration disabled until the next key cycle. Engine
calculate fuel pressure in the aftertreatment system.
torque will be reduced if fault is active for an extended
period of time.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

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MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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 342 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFTFIS Circuit
AFTFIS
AFTFIS Connector
ECM 58-Pin Connector (end view)
C1 Connector
SIG GND
-1 1
C1-41 -
C1-26 o AFTFT 2
C2-08 _ VREF4 3
C1-25 _ AFTFP1 4
AFTFIS
'--

V45003

Figure 170 AFTFIS circuit diagram

Possible Causes
• Failed AFTFIS
• AFTFP1 signal circuit short to GND

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• AFTFP1 signal circuit Open or high resistance
• VREF-4 circuit Open or high resistance

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3512 FMI 14
No: Repair SPN 3512 FMI 14.
(VREF-4).
After repairs are complete, retest
Is EST DTC list free of SPN 3512 FMI 14? for SPN 3480 FMI 4.

Step Action Decision

2 Inspect connections at AFT Fuel Inlet Sensor (AFTFIS). Key Yes: Go to step 3.
OFF, disconnect AFTFIS connector. Check AFTFIS sensor and
No: Repair connector, harness,
connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 3480 FMI 4.
Are the AFTFIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Check AFTFP1 circuit for short to ground. Connect Breakout Yes: Go to step 4.
Harness ZTSE4830 to vehicle harness and leave AFTFIS
No: Repair short to ground
disconnected. Key OFF, use a DMM to measure resistance
between AFTFIS pin-4 and ECM
between Breakout Harness pin-4 and a known good ground.
connector C1-25. After repairs
Is resistance greater than 1000 ohms? are complete, retest for SPN
3480 FMI 4.

346
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 343

Step Action Decision

4 Check VREF-4 circuit for Open or high resistance. Connect Yes: Go to step 5.
Breakout Harness ZTSE4830 to vehicle harness and leave
No: Repair Open or high
AFTFIS disconnected. Connect 180-pin Breakout Box with ECM
resistance between AFTFIS
Breakout Harness 00-01467-00 to vehicle harness and leave
pin-3 and ECM connector C2-08.
ECM disconnected. Use a DMM to measure resistance between
After repairs are complete, retest
Breakout Harness pin-3 and 180-pin Breakout Box pin C2-08.
for SPN 3480 FMI 4.
Is resistance less than 5 ohms?

Step Action Decision

5 Check AFTFP1 circuit for Open or high resistance. Connect Yes: Replace AFTFIS. After
Breakout Harness ZTSE4830 to vehicle harness and leave repairs are complete, retest for
AFTFIS disconnected. Connect 180-pin Breakout Box with ECM SPN 3480 FMI 4.
Breakout Harness 00-01467-00 to vehicle harness and leave
No: Repair Open or high
ECM disconnected. Use a DMM to measure resistance between
resistance between AFTFIS
Breakout Harness pin-4 and 180-pin Breakout Box pin C1-25.
pin-4 and ECM connector C1-25.
Is resistance less than 5 ohms? After repairs are complete, retest
for SPN 3480 FMI 4.

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NOTE: After performing all diagnostic steps, if
SPN 3480 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

347
 344 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Pinpoint Diagnostics With ServiceMaxx™

software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Cold Soak
Sensor Compare Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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Sensor Circuit Check
Connect Breakout Harness ZTSE4830 and leave sensor disconnected. Turn ignition switch to ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor 4.5 V - 5.0 V If < 4.5 V check AFTFP1 circuit for short to GND.
AFTFP1v
EST – Monitor AFTFTv 4.5 V - 5.0 V If < 4.5 V check AFTFT circuit for short to GND.
DMM – Measure volts 5 V ± 0.5 V If > 5.5 V, check VREF4 for short to PWR.
3 to GND If < 4.5 V, check VREF4 for OPEN or short to GND, go to
Harness Resistance Check.
DMM — Measure B+ If < B+, check SIG GND circuit for OPEN.
voltage
1 to B+
EST - Monitor AFTFTv 0V If > 0.5 V, check AFTFT circuit for OPEN.
short 1 to 2
EST - Monitor AFTFP1v 0 V If > 0.5 V, check AFTFIS circuit for OPEN.
short 1 to 4
If checks are within specification, connect sensor, clear DTCs, and cycle the accelerator pedal a few times.
If active code returns, replace sensor.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 345

Pinpoint Diagnostics Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4830. Leave sensor disconnected. Turn ignition switch ON. Use DMM to
measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to B+ B+ If < B+, check for OPEN in SIG GND circuit.
2 to GND 5V If < 4.5 V, check for OPEN in AFTFT circuit.
3 to GND 5V If < 4.5 V, check for OPEN in VREF4 circuit.
4 to GND 5V If < 4.5 V, check for OPEN in AFTFP1 circuit.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and sensor Breakout Harness ZTSE4830. Leave
ECM and sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check SIG GND circuit for short to GND.
1 to C1-41 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
2 to GND > 1k Ω If < 1k Ω, check AFTFT circuit for short to GND.

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2 to C1-26 <5Ω If > 5 Ω, check AFTFT circuit for OPEN.
3 to GND > 1k Ω If < 1k Ω, check VREF4 circuit for short to GND.
3 to C2-08 <5Ω If > 5 Ω, check VREF4 circuit for OPEN.
4 to GND > 1k Ω If < 1k Ω, check AFTFP1 circuit for short to GND.
4 to C1-25 <5Ω If > 5 Ω, check AFTFP1 circuit for OPEN.

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 346 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFTFP2 (Aftertreatment Fuel Pressure 2 Sensor)

SPN FMI Condition Possible Causes

4077 3 AFTFP2 signal Out of Range HIGH • AFTFP2 signal circuit OPEN or short to PWR
• Failed AFTFP2 sensor
4077 4 AFTFP2 signal Out of Range LOW • AFTFP2 signal circuit short to GND
• Failed AFTFP2 sensor
4077 14 AFTFP2 Sensor plausibility error • Biased AFTFP2 signal

AFT Fuel AFT Fuel

Shutoff AFT Fuel Doser AFT Fuel
Valve Inlet Sensor Valve Pressure 2

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Fuel Supply
------l

After
Treatment
Fuel Injector
/1\ 0000046178

Figure 171 Functional diagram AFTFP2 sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 347

AFTFP2 Circuit
AFTFP2
Connector
ECM, AFTFP2 (end view) AFTFP2
58-Pin Connector 1
C2 Connector
VREF4 -1
C2-08-
SIG GND
C2-42 ~ 2
C2-50,... AFTFP2 3
.__

V45004

Figure 172 AFTFP2 sensor circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

Software
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness WARNING: To prevent personal injury or
death, stay clear of rotating parts (belts and fan)

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• ZTSE4497 – 500 Ohm Resistor Harness
and hot engine surfaces.
• ZTSE4899 – Big Bore Terminal Test Probe Kit
1. Using Electronic Service Tool (EST) with
• Breakout Harness ZTSE6027 (AFTFP2) ServiceMaxx™ software, run the Continuous
• Digital Multimeter (DMM) Monitor test.

• Electronic Service Tool (EST) with ServiceMaxx™ 2. Monitor sensor voltage and verify an active
software DTC for this sensor.

• J1939 and J1708 RP1210B Compliant Device • If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Sensor
Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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 348 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check

Disconnect engine harness from sensor.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor 0V If > 0 V, check AFTFP2 signal circuit for short to PWR.
AFTFP2v
DMM — Measure volts 5.0 V ± 0.5 V If > 5.5 V, check VREF4 for short to PWR.
1 to GND If < 4.5 V, check VREF 4 for OPEN or short to GND. Do
Harness Resistance Check.
DMM — Measure 5 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
voltage Resistance Check.
1 to 2
EST – Monitor 0V If > 0.5 V, check AFTFP2 signal circuit for OPEN. Do
AFTFP2v Harness Resistance Check.
Short across Breakout
Harness ZTSE6027
pins 2 and 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace AFTFP2

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sensor.

Pinpoint Diagnostics Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE6027. Leave sensor disconnected. Turn ignition switch to ON. Use
DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5V If > 5.5 V, check VREF4 for short to PWR.
If < 4.5 V, check VREF4 for OPEN or short to GND. Do
Harness Resistance Check.
2 to GND 0V If > 0.25 V, check SIG GND circuit for short to PWR.
3 to GND 0V If > 0.25 V, check AFTFP2 circuit for short to PWR.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and sensor Breakout Harness ZTSE6027. Leave
ECM and sensor disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
1 to C2-08 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short to GND.
2 to C2-42 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short to GND.
3 to C2-50 <5Ω If > 5 Ω, check for OPEN circuit.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 349

AFTFSV (Aftertreatment Fuel Shutoff Valve)

SPN FMI Condition Possible Causes

3482 3 AFT Fuel Shutoff Valve short to PWR • AFTFSV-H circuit Step-Based Diagnostics
(Open or high resistance) short to PWR (page 351)
• AFTFSV-H circuit
Open or high
resistance
• AFTFSV-L circuit
Open or high
resistance
• Failed
Aftertreatment
Fuel Shutoff Valve
(AFTFSV)
3482 4 AFT Fuel Shutoff Valve short to GND • AFTFSV-H short to Step-Based Diagnostics
GND (page 354)
• AFTFSV-H shorted
to AFTFSV-L

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• Failed
Aftertreatment
Fuel Shutoff Valve
(AFTFSV)

AFTFSV Circuit
AFTFSV

ECM, AFTFSV
58-Pin AFTFSV
C2-Connector Connector
~-~~-..!:.A~F.!_.!TF~S~-H~-----7 1
C2-0? AFTFS-L
C2-20 rJ__~:..!..!:.~-----7 2

V15020

Figure 173 AFTFSV circuit diagram

Tools Required • Breakout Harness ZTSE4602 (AFTFSV)

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

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 350 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFT Fuel AFT Fuel

Shutoff AFT Fuel Doser AFT Fuel
Valve Inlet Sensor Valve Pressure 2

Fuel Supply
-----<

After
Treatment
Fuel Injector
/ I \ 0000046177

Figure 174 Functional diagram AFTFSV

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 351

3482 FMI 3 - AFT Fuel Shutoff Valve short to PWR (Open or High Resistance)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel The resistance between Key ON 1 second
Shutoff Valve (AFTFSV) AFTFSV-H circuit and
circuit voltage above AFTFSV-L circuit >
normal, shorted to high 500,000 ohms
source, or open or high
resistance. High signal
voltage detected at the
AFTFSV.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the voltage signal from the
Aftertreatment Fuel Shutoff Valve (AFTFSV) is high.
Active regeneration of the aftertreatment system is
disabled. Engine torque will be reduced if fault is
active for an extended period of time.

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Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 1 in 2013 HD-OBD Diagnostic Reference
Manual.

AFTFSV Circuit
AFTFSV

ECM, AFTFSV
58-Pin AFTFSV
Connector
C2-Connector H
L-~A~F:_!T~F:.::S:2-.!.__ _ _ _ _ __
m;
[ ~~:~~ ~ AFTFS-L

V15020

Figure 175 AFTFSV circuit diagram

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 352 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Possible Causes
• AFTFSV-H circuit short to PWR
• AFTFSV-H circuit Open or high resistance
• AFTFSV-L circuit Open or high resistance
• Failed Aftertreatment Fuel Shutoff Valve
(AFTFSV)

Step Action Decision

1 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 2.
disconnect ECM. Check ECM and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 3482 FMI 3.
undamaged?

Step Action Decision

2 Check Aftertreatment Fuel Shutoff Valve (AFTFSV) circuit for Yes: Go to step 6.
Open or high resistance. Connect 180-pin Breakout Box with

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No: Go to step 3.
Breakout Harness 00-01467-00 to vehicle harness and leave
ECM disconnected. Key OFF, use a DMM to measure resistance
between Breakout Box pin C2-07 and C2-20.
Is resistance less than 20 ohms?

Step Action Decision

3 Inspect connections at AFTFSV. Key OFF, disconnect AFTFSV. Yes: Go to step 4.
Check AFTFSV and connector terminals for: damaged or pinched
No: Repair connector, harness,
wires; corroded terminals; loose, bent, or broken pins; or broken
or terminal damage. After
connector housing.
repairs are complete, retest for
Are the AFTFSV connector, harness, and terminals clean and SPN 3482 FMI 3.
undamaged?

Step Action Decision

4 Check AFTFSV-H circuit for Open or high resistance. Connect Yes: Go to step 5.
Breakout Harness ZTSE4602 to vehicle harness and leave
No: Repair Open or high
AFTFSV disconnected. With 180-pin Breakout Box with Breakout
resistance between ECM pin
Harness 00-01467-00 connected to vehicle harness and ECM
C2-07 and AFTFSV pin-1. After
disconnected. Key OFF, use a DMM to measure resistance
repairs are complete, retest for
between Breakout Harness pin-1 and Breakout Box pin C2-07.
SPN 3482 FMI 3.
Is resistance less than 5 ohms?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 353

Step Action Decision

5 Check AFTFSV-L circuit for Open or high resistance. Connect Yes: Go to step 6.
Breakout Harness ZTSE4602 to vehicle harness and leave
No: Repair Open or high
AFTFSV disconnected. With 180-pin Breakout Box with Breakout
resistance between ECM pin
Harness 00-01467-00 connected to vehicle harness and ECM
C2-20 and AFTFSV pin-2. After
disconnected. Key OFF, use a DMM to measure resistance
repairs are complete, retest for
between Breakout Harness pin-2 and Breakout Box pin C2-20.
SPN 3482 FMI 3.
Is resistance less than 5 ohms?

Step Action Decision

6 Check Aftertreatment Fuel Shutoff Valve (AFTFSV-H) circuit for Yes: Replace AFTFSV. After
short to PWR. Connect Breakout Harness ZTSE4602 to vehicle repairs are complete, retest for
harness and leave AFTFSV disconnected. With 180-pin Breakout SPN 3482 FMI 3
Box with Breakout Harness 00-01467-00 connected to vehicle
No: Repair short to PWR
harness and ECM disconnected. Key-On Engine-Off (KOEO), use
between ECM pin C2-07 and
a DMM to measure resistance between Breakout Harness pin-1
AFTFSV pin-1. After repairs are
and Breakout Box pin C2-07.
complete, retest for SPN 3482
Is voltage less than 0.5 Volts? FMI 3.

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NOTE: After performing all diagnostic steps, if
SPN 3482 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 354 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3482 FMI 4- AFT Fuel Shutoff Valve short to GND

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Aftertreatment Fuel The resistance between Key ON 1 second
Shutoff Valve (AFTFSV) the AFTFSV driver line
The AFTFSV is commanded ON
driver control line is and ground < 0.2 Ohms
shorted to ground.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects a short to ground in the Aftertreatment
Fuel Shutoff Valve (AFTFSV) circuit. Active
regeneration of the Diesel Particulate Filter (DPF) is
disabled until the next key cycle, and engine torque
will be reduced if fault is active for an extended period
of time.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

AFTFSV Circuit
AFTFSV

ECM , AFTFSV
58-Pin AFTFSV
C2-Connector Connector
l
~-~~_..f:.A~F.!._!TF~S~-!:!.._H_ _ _ _ _ 1
C2-07 AFTFS-L 2
C2-20 rJ..-~~~-----7

V15020

Figure 176 AFTFSV circuit diagram

Possible Causes • Failed Aftertreatment Fuel Shutoff Valve

(AFTFSV)
• AFTFSV-H short to GND
• AFTFSV-H shorted to AFTFSV-L

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 355

Step Action Decision

1 Inspect connections at AFTFSV. Key OFF, disconnect AFTFSV. Yes: Go to step 2.
Check AFTFSV and connector terminals for: damaged or pinched
No: Repair connector, harness,
wires; corroded terminals; loose, bent, or broken pins; or broken
or terminal damage. After
connector housing.
repairs are complete, retest for
Are the AFTFSV connector, harness, and terminals clean and SPN 3482 FMI 4.
undamaged?

Step Action Decision

2 Check AFTFSV-H circuit for short to GND. Connect Breakout Yes: Go to step 3.
Harness ZTSE4602 to vehicle harness and leave AFTFSV
No: Repair short to PWR
disconnected. Key OFF, use a DMM to measure resistance
between ECM pin C2-07 and
between Breakout Harness pin-1 and a known good ground.
AFTFSV pin-1. After repairs are
Is resistance less than 1000 ohms? complete, retest for SPN 3482
FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.

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disconnect ECM. Check ECM and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 3482 FMI 4.
undamaged?

Step Action Decision

4 Check for AFTFSV-H circuit shorted to AFTFSV-L circuit. Connect Yes: Replace AFTFSV. After
Breakout Harness ZTSE4602 to vehicle harness and leave repairs are complete, retest for
AFTFSV disconnected. With ECM disconnected. Key OFF, use SPN 3482 FMI 4.
a DMM to measure resistance between Breakout Harness pin-1
No: Repair short between
and Breakout Harness pin-2.
AFTFSV-H circuit and AFTFSV-L
Is resistance greater than 1000 ohms? circuit. After repairs are
complete, retest for SPN 3482
FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 3482 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 356 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AMS (Air Management System)

SPN FMI Condition Possible Causes Actions

102 16 Intake Manifold Pressure Overboost • Turbocharger 2 (TC2) Pin-Point Diagnostics
wastegate stuck (page 358)
closed
102 18 Intake Manifold Pressure Underboost • TC2 wastegate stuck Pin-Point Diagnostics
open (page 358)
• Restricted intake air
system
• Charge Air Cooler
(CAC) hose leaking
• CAC leak
• Failed turbocharger
1173 16 TC2CIT signal above desired • Failed Coolant Flow Pin-Point Diagnostics
(Interstage CAC under cooling) Valve (CFV) or circuit (page 358)
• Failed Coolant Mixer
Valve (CMV) or circuit

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• Restricted interstage
CAC
• Inoperative engine fan
• Restricted
low-temperature
radiator
• Engine fan or shroud
problem

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 357

2659 20 EGR High Flow Rate detected • Biased O2S or circuit Step Based
Diagnostics (page
• Biased Turbocharger 1
360)
Turbo Outlet Pressure
(TC1TOP) sensor or
circuit
• Exhaust Gas
Recirculation (EGR)
Valve stuck open
• Low boost pressure
2659 21 EGR Low Flow Rate detected • Biased O2S or circuit Pin-Point Diagnostics
(page 359)
• Biased TC1TOP
sensor or circuit
• EGR Valve stuck
closed
• Restricted EGR cooler
• Restricted Diesel
Oxidation Catalyst
(DOC) or Diesel

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Particulate Filter
(DPF)

Input Output

CACOT

i ~--'-1'-'-'M..;_P_ _ _ I J 1939 Datalink

IMT

TC2CIS

V00141

Figure 177 Functional diagram for the AMS

Tools Required • J1939 and J1708 RP1210B Compliant Device

• Electronic Service Tool (EST) with ServiceMaxx™
software

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 358 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 102 FMI 16 – Intake Manifold Pressure Overboost

Pin-point AMS System Fault
1. Check for other active or inactive DTCs. Repair any electrical fault before continuing with this
procedure.
2. Check for biased IMP sensor. Verify BAP and IMP are within KOEO specification. See applicable
engine horsepower in “APPENDIX A: PERFORMANCE SPECIFICATIONS."
3. Run Air Management test while monitoring IMP sensor signal.
• If IMP does not change state when TC1WC and TC2WC are cycled, proceed to TC1WC (page
835) and TC2WC (page 838).

SPN 102 FMI 18 – Intake Manifold Pressure Underboost

Pin-point AMS System Fault
1. Check for other active or inactive DTCs. Repair any electrical fault before continuing with this
procedure.
2. Check for biased IMP sensor. Verify BAP and IMP are within KOEO specification. See applicable
engine horsepower in “APPENDIX A: PERFORMANCE SPECIFICATIONS."

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3. Run Air Management test while monitoring IMP sensor signal.
• If IMP does not change state when TC1WC, and TC2WC are cycled, proceed to TC1WC
(page 835) and TC2WC (page 838).
4. Inspect for leaks in the intake air system.
5. Inspect turbochargers in the Engine Service Manual.

SPN 1173 FMI 16 – TC2CIT signal above desired (Interstage CAC under cooling)
Pin-point AMS System Fault
1. Check for other active or inactive DTCs. Repair any electrical fault before continuing with this
procedure.
2. Check for biased TC2CIT sensor. Repair as necessary.
3. Using ServiceMaxx™ software, run Engine Fan Procedure to verify correct operation.
4. Need CFV and CMV procedure diagnostics.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 359

SPN 2659 FMI 21 – EGR Low Flow Rate detected

Pin-point AMS System Fault
1. Check for other active or inactive DTCs. Repair any electrical fault before continuing with this
procedure. If SPN 5298 is active, correct and then retest for SPN 2659 FMI 21.
2. Check for biased TC1TOP or DPFDP sensor.
3. Run Air Management test while monitoring IMP, during EGR portion of test.
• If IMP does not change state during EGR portion of Air Management test, proceed to EGR
Valve (page 621) diagnostics.
4. See EGR Cooler Leak Inspection in “ENGINE SYMPTOM DIAGNOSTICS."

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 360 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 2659 FMI 20 - EGR High Flow Rate Detected

Condition /
Description
High flow by O2control O2% in exhaust > 1.4%
error, valve closing.
Setting Criteria Enable Conditions / Values Time Required
Actual EGR Valve Position < 2.4 seconds
35%
Desired EGR Valve Position <
27%
Actual EGR Valve Position
deviation limit (from set point) <
100%
Time after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Limp Home Mode = Inactive
DPF Regeneration = Inactive
Power Takeoff (PTO) Mode =
Inactive

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Engine Coolant Temperature 1
(ECT1) > -44°F (–7°C) and <
239°F (115°C)
Ambient Air Temperature (AAT)
> -44°F (–7°C) <131°F (55°C)
Barometric pressure (BARO) >
11 psi (75 kPa)
O2 sensor at operating temp. >
1400°F (760°C) and < 1472°F
(800°C)
Engine operating in monitoring
region
Function of engine speed and
load: 700-1700 rpm and 50-60%
load

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

The Exhaust Gas Recirculation (EGR) valve is a
variable position actuator used to control exhaust flow
through the EGR cooler. The EGR valve contains an
internal position sensor that monitors valve position.
Valve position changes in response to Engine Control
Module (ECM) signals.
MIL will illuminate when this fault is detected during
two drive cycles.
Associated Faults
SPN’s 27, 91, 724, 2623, 2791, 3223, 5298, and 5541.
If SPN 5298 is active, correct and then retest for SPN
2659 FMI 20.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 361

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 2659 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 2659 FMI 20.

Step Action Decision

2 Check for biased Oxygen Sensor (O2S). Do O2S Biased Sensor Yes: Go to step 3.
or Circuit Check (page 819).
No: Repair O2 sensor or circuits.
Does O2 sensor pass biased sensor or circuit check? After repairs are complete, retest
for SPN 2659 FMI 20.

Step Action Decision

3 Check for biased Turbocharger 1 Turbine Outlet Pressure Yes: Go to step 4.
(TC1TOP) sensor or circuit. Using EST with ServiceMaxx™
No: Do TC1TOP sensor circuit

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software, run the Continuous Monitor test. Use the KOEO values
and voltage checks (page 833).
found in “Appendix A: Performance Specifications”.
After repairs are complete, retest
Is TC1TOP within specifications? for SPN 2659 FMI 20.

Step Action Decision

4 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 5.
out of specifications. Using EST with ServiceMaxx™ software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor Circuit Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 2659 FMI 20.

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 362 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

5 Verify IMP changes when Turbocharger 2 Wastegate Control No IMP pressure decrease when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air Air Control Valve (ACV) TC2WC
Management Test while monitoring IMP sensor signal. test (page 164). After repairs are
complete, retest for SPN 2659
While monitoring IMP signal:
FMI 20.
• Does IMP pressure decrease when TC2WC is commanded
No IMP pressure decrease when
On?
EGR is commanded On: Do
• Does IMP pressure decrease when EGR valve is commanded EGR Pinpoint Diagnostic (page
On? 622) with ServiceMaxx. After
repairs are complete, retest for
• Does IMP pressure decrease when Exhaust Back Pressure
SPN 2659 FMI 20.
Valve (EBPV) is commanded On?
No IMP pressure increase when
EBPV is commanded On: Do Air
Control Valve (ACV) EBPV test
(page 163). After repairs are
complete, retest for SPN 2659
FMI 20.
IMP signal does not change

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when any of the valves are
commanded On: Go to step 6.

Step Action Decision

6 Verify IMP sensor and bore are not restricted due to carbon Yes: After doing all diagnostic
buildup. Remove and inspect IMP sensor and bore for carbon steps, verify each step was
buildup. completed correctly and the
proper decision was made.
Is IMP sensor and bore free of carbon buildup?
Notify supervisor for further
action.
No: Clean IMP sensor bore of
carbon deposits. After repairs
are complete, retest for SPN
2659 FMI 20.

NOTE: After doing all diagnostic steps, if SPN

2659 FMI 20 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 363

APP Sensor (Accelerator Pedal Position)

SPN FMI Condition Possible Causes

91 2 APP1 and APP2 signal conflict • APP1 and APP2 mismatched
• Biased APP sensor or circuit
91 3 APP1 signal Out of Range HIGH • APP1 signal circuit short to PWR
• SIG GND circuit OPEN
• Failed APP sensor
91 4 APP1 signal Out of Range LOW • APP1 signal circuit OPEN or short to GND
• VREF5 circuit OPEN
• Failed APP sensor
2623 3 APP2 signal Out of Range HIGH • APP2 signal circuit short to PWR
• SIG GND circuit OPEN
• Failed APP sensor
2623 4 APP2 signal Out of Range LOW • APP2 signal circuit OPEN or short to GND

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• VREF1 circuit OPEN
• Failed APP sensor

APP circuit APP

ECM 58-Pin C2 connector connector
, APP2 " - APP
Pin C2 - 55 F
APP1 connector APP
Pin C2 - 54 A (end view) F sensor
\,;

~
/
PinC1-11
"' SIG GND " E
VREF5
Pin C1 - 50 D
~
VREF1
Pin C1 - 36 C
SIG GND
\..
Pin C1 - 23 B
V
- A
ECM 58-Pin C1 connector
V00049b

Figure 178 APP circuit diagram

Overview The ECM compares signals from two potentiometers

to determine accelerator pedal position, APP1 and
The Accelerator Pedal Position (APP) sensor is
APP2. APP1 is supplied 5 volts while APP2 is
a variable-resistance sensor that increases or
supplied 2.5 volts. As the pedal is pressed, resistance
decreases resistance as the accelerator pedal
decreases and change in voltage is interpreted by the
position changes. No mechanical attachment is
ECM.
present from the accelerator pedal to the engine.

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 364 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
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• Breakout Harness ZTSE4485A (APP)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Pinpoint Diagnostics With ServiceMaxx™
software
A WARNING: To prevent personal injury or
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
The ECM determines accelerator pedal position by
processing input signals from APP1 and APP2.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
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365
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Sensor
Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.
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 366 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check

Connect Breakout Harness ZTSE4485A to APP vehicle harness, and leave APP sensor disconnected.
Turn ignition ON
Test Point Specification Comment – < Less than, > Greater than
EST - Monitor APP1v 0V If > 0.5 V, check APP1 circuit for short to PWR.
EST - Monitor APP2v 0V If > 0.5 V, check APP2 circuit for short to PWR.
DMM – Measure volts 5 V ± 0.5 V If > 5.5 V, check VREF5 for short to PWR.
C to GND If < 4.5 V, check VREF5 for OPEN or short to GND, go to
Harness Resistance Check.
DMM – Measure volts 5 V ± 0.5 V If > 5.5 V, check VREF1 for short to PWR.
D to GND If < 4.5 V, check VREF1 for OPEN or short to GND, go to
Harness Resistance Check.
EST - Monitor APP1v 5V If < 4.5 V, check APP1 circuit for OPEN, go to Harness
Resistance check.
Short Pin A to C
EST - Monitor APP2v 5V If is < 4.5 V, check APP2 circuit for OPEN, go to Harness
Resistance Check.
Short Pin D to F

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DMM – Measure Volts B+ If < B+, check SIG GND for OPEN, go to Harness
Resistance Check.
B to Battery positive
DMM – Measure Volts B+ If < B+, check SIG GND for OPEN, go to Harness
Resistance Check.
E to Battery positive
If checks are within specification, connect sensor, clear DTCs, and cycle the accelerator pedal a few times.
If active DTC returns, replace sensor.

Pinpoint Diagnostics Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4485A to APP vehicle harness, and leave APP sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
A to B+ B+ If < B+, check APP1 for short to PWR.
B to Battery positive B+ If < B+, check SIG GND for OPEN circuit.
C to GND 5V If > 5.5 V, check VREF5 for short to PWR.
If < 4.5 V, check VREF5 for OPEN or short to GND.
D to GND 5V If > 5.5 V, check VREF5 for short to PWR.
If < 4.5 V, check VREF5 for OPEN or short to GND.
E to Battery positive B+ If < B+, check SIG GND for OPEN circuit.
F to B+ B+ If < B+, check APP2 for short to PWR.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 367

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4485A to APP vehicle harness,
and leave APP sensor disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
A to GND > 1k Ω If < 1k Ω, check for short circuit.
A to C2-54 <5Ω If > 5 Ω, check for OPEN circuit.
B to GND <5Ω If > 5 Ω, check for OPEN circuit.
B to C1-23 <5Ω If > 5 Ω, check for OPEN circuit.
C to GND > 1k Ω If < 1k Ω, check for short circuit.
C to C1-36 <5Ω If > 5 Ω, check for OPEN circuit.
D to GND > 1k Ω If < 1k Ω, check for short circuit.
D to C1-50 <5Ω If > 5 Ω, check for OPEN circuit.
E to GND <5Ω If > 5 Ω, check for OPEN circuit.
E to C1-11 <5Ω If > 5 Ω, check for OPEN circuit.
F to GND > 1k Ω If < 1k Ω, check for short circuit.

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F to C2-55 <5Ω If > 5 Ω, check for OPEN circuit.

Operational Voltage Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4485A to APP vehicle harness,
and leave APP sensor disconnected. Use DMM to measure voltage or EST to read signal.
Test Point Condition DMM EST Value
APP1 Foot off pedal 1.14 V ± 0.25V 0%
A to GND or Pedal to floor 4.32 V ± 0.25V 99.6%
C2-54 to GND
APP2 Foot off pedal 0.56 V ± 0.25 V 0%
F to GND or Pedal to floor 2.16 V ± 0.25 V 99.6%
C2-55 to GND

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 368 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CACOT Sensor (Charge Air Cooler Outlet

Temperature)

SPN FMI Condition Possible Causes Actions

2630 2 CACOT signal does not agree with • Biased Pin-Point
other sensors CACOT sensor Diagnostics (page
or circuit 371)
2630 3 CACOT signal Out of Range HIGH • CACOT signal Pin-Point
circuit OPEN or Diagnostics (page
short to PWR 370)
• SIG GND
circuit OPEN
• Failed CACOT
sensor
2630 4 CACOT signal Out of Range LOW • CACOT signal Pin-Point
circuit short to Diagnostics (page
GND 370)
• Failed CACOT
sensor

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2630 7 CACOT signal not responding as • Biased Pin-Point
expected CACOT sensor Diagnostics (page
or circuit 370)
2630 16 CACOT Undercooling • Restricted Step-Based
CAC Diagnostics (page
373)
• Engine fan
and/or engine
fan shroud
failure
• Inoperative
engine fan
• Winter front
installed
outside
recommended
temperatures
• Failed Coolant
Control Valve
(CCV)

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 369

CACOT circuit

CACOT
ECM 96-Pin CACOT sensor
E1 connector CACOT connector
connector (end view)
CACOT
PinE1-13

\--I-S~l~G~G=.!.N..:..::D::...__ _7 2
Pin E1 -43

V00042

Figure 179 CACOT sensor circuit diagram

Overview
The Charge Air Cooler Outlet Temperature (CACOT)
is a thermistor sensor that measures charged-air
temperature entering the Engine Throttle Valve (ETV).

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As temperature increases, resistance drops, causing
the voltage signal interpreted by the Engine Control
Module (ECM) to vary. The ECM monitors this signal
for Exhaust Gas Recirculation (EGR) system control
and CAC performance.
Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4993 (CACOT)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™ 0000047992
software
Figure 180 CACOT Sensor Location
• J1939 and J1708 RP1210B Compliant Device
1. Charge Air Cooler Outlet Temperature (CACOT)
sensor

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 370 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CACOT circuit

CACOT
ECM 96-Pin CACOT sensor
E1 connector CACOT connector
connector (end view)
CACOT
PinE1-13

Pin E1 -43
l--l-S~lc:::G:....::G::.:.N..:..:D:.....__ _7 2

V00042

Figure 181 CACOT sensor circuit diagram

Pinpoint Diagnostics With ServiceMaxx™ 2. Monitor sensor voltage and verify an active
Software DTC for this sensor.
• If DTC is previously active, monitor signal
WARNING: To prevent personal injury or while wiggling harness of suspect sensor.

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death, stay clear of rotating parts (belts and fan) If circuit is interrupted, signal will spike
and hot engine surfaces. and DTC will go active or pending.
1. Using Electronic Service Tool (EST) with • If DTC is pending or active, continue to
ServiceMaxx™ software, run the Continuous Cold Soak Sensor Compare Check.
Monitor test.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 371

SPN 2630 FMI 2 – CACOT signal does not agree with other sensors
Cold Soak Sensor Compare Check With ServiceMaxx™ Software
NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare CACOT to Ambient Air Temperature (AAT), Air Intake Temperature (IAT), and Intake
Manifold Temperature (IMT). Sensor temperatures should be within 5 °C (10 °F) of each other.
• If CACOT is 5 °C (10 °F) above or below AAT, IAT, or IMT, check for poor circuitry going to
the CACOT sensor.
• If circuits are within specification, replace CACOT sensor.

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 372 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4993 to CACOT engine harness, and leave CACOT sensor disconnected.
Turn ignition ON.
Test Point SpecificationsComment– < Less than, > Greater than
EST – Monitor CACOTv 5V If <4.5 V, check CACOT signal circuit for short to GND.
EST – Monitor CACOTv 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check (page 372).
Short pin 1 to 2
EST – Monitor CACOTv < 1.0 V If > 1.0 V, check CACOT signal circuit for short to PWR.
Short 500 Ω resistor across pins
1 and 2
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace CACOT
sensor.

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4993 to CACOT engine harness, and leave CACOT sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specifications Comment – < Less than, > Greater than

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1 to GND 4.5 V to 5 V If < 4.5 V, check for OPEN or short to GND. Do Harness Resistance Check
(page 372).
2 to B+ B+ If < B+, check for short to PWR.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and
E2 connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4993 to CACOT engine
harness, and leave CACOT sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-13 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-43 <5Ω If > 5 Ω, check for OPEN circuit.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 373

SPN 2630 FMI 16 - CACOT Undercooling

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Comparison of Charge CAC system cooling Function of engine speed and 3 events
Air Cooler Outlet efficiency less then 55% load: 100-1600 rpm and 30-90%
Temperature (CACOT) of modeled value. load > 0
sensor reading to
Time after Key On > 0 seconds
modeled value. Actual
cooler effectiveness is Battery voltage > 10.7 volts
less than the threshold
Battery voltage < 15 volts
effectiveness.
Vehicle speed > 6.2 mph
Limp Home Mode = Inactive
DPF Regeneration = Inactive
Power Takeoff (PTO) Mode =
Inactive
Ambient Air Temperature (AAT)
>50°F (10°C) and <131°F (55°C)

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Barometric pressure (BARO) >
11 psi (75 kPa)

Fault Overview Associated Faults

Fault sets when the Engine Control Module SPN 647
(ECM) determines the Charge Air Cooler Outlet
Temperature (CACOT) sensor reading is greater than Drive Cycle to Determine Fault Status
a predetermined value. The ECM uses vehicle speed
See 2013 HD-OBD Diagnostic Reference Manual.
and Ambient Air Temperature (AAT) to determine
CAC effectiveness.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

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 374 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CACOT circuit

CACOT
ECM 96-Pin CACOT sensor
E1 connector CACOT connector
connector (end view)
CACOT
PinE1-13

Pin E1 -43
l--l-S~lc:::G:....::G::.:.N..:..:D:.....__ _7 2

V00042

Figure 182 CACOT sensor circuit diagram

Possible Causes
• Restricted CAC
• Engine fan and/or engine fan shroud failure

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• Inoperative engine fan
• Winter front installed outside recommended
temperatures
• Failed Coolant Control Valve (CCV)

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 2630 FMI 16 the only fault code active? After repairs are complete, retest
for SPN 2630 FMI 16.

Step Action Decision

2 Determine if a winter front (grill cover) is installed during warm Yes: Go to step 3.
temperatures.
No: Remove winter front. After
Is winter front (grill cover) removed during warm temperatures repairs are complete, retest for
outside the recommended range? SPN 2630 FMI 16.

Step Action Decision

3 Inspect Charge Air Cooler (CAC) for damage, blockage, or Yes: Go to step 4.
anything that could prevent proper air flow through the CAC.
No: Repair CAC damage or
Is the CAC undamaged, not blocked, and is air able to flow blockage. After repairs are
through it properly? complete, retest for SPN 2630
FMI 16.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 375

Step Action Decision

4 Inspect for damage to the engine cooling fan and shroud. Yes: Go to step 5.
Are the engine cooling fan and shroud in good condition and not No: Repair engine cooling fan
damaged? or shroud damage. After repairs
are made, retest for SPN 2630
FMI 16.

Step Action Decision

5 Determine if engine cooling fan is working when engine is hot. Yes: Verify each step was
Using EST with ServiceMaxx go to: Tests > KOER Tests > Engine completed correctly and the
Fan Test. proper decision was made.
Notify supervisor for further
Does engine cooling fan come ON when the engine gets hot
action.
(approximately 205°F (96°C) to 225°F (107°C) and above)?
No: Diagnosis and repair engine
cooling fan or circuit. See EFC
(Engine Fan Control) Voltage
and Harness resistance checks
(page 617). After repairs are
complete, retest for SPN 2630

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FMI 16.

Step Action Decision

6 Determine if Coolant Flow Valve (CFV) and Coolant Mixture Valve Yes: Verify each step was
(CMV) are working correctly. Perform Coolant Control Valve completed correctly and the
(CCV) Test (page 93). proper decision was made.
Notify supervisor for further
Are the CFV and CMV operating correctly?
action.
No: Repair CCV. After repairs
are complete, retest for SPN
2630 FMI 16.

NOTE: After doing all diagnostic steps, if SPN

2630 FMI 16 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 376 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CCOSS Sensor (Crankcase Oil Separator Speed)

SPN FMI Condition Possible Causes

4227 7 CC Oil Separator Speed: Not spinning • Crankcase Oil Separator failure
• Crankcase Oil Separator circuit or sensor fault

CCOSS circuit

ccoss
sensor
ECM 96-Pin ccoss
E1 connector ccoss connector
connector (end view)
CCOSS-H
PinE1-31

PinE1-07 >---+---"C;_;;C;_;;O;_;;S;;..;:S;;...-L=----1-1---1 2

V00043

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Figure 183 CCOSS circuit diagram

Tools Required Pinpoint Crankcase Oil Separator: Not spinning

fault
• 00-00956-08 – 180-Pin Breakout Box
1. Using ServiceMaxx™ software, monitor
• ZTSE4498 – 3-Banana Plug Harness
Crankcase Oil Separator signal while running
• ZTSE4497 – 500 Ohm Resistor Harness the engine.
• ZTSE4899 – Big Bore Terminal Test Probe Kit • If CC Oil Separator signal stays at 0
rpm, verify sensor and voltage to sensor
• Breakout Harness ZTSE4951 (CCOSS)
are within specification, go to Connector
• Digital Multimeter (DMM) Voltage Check and Sensor Resistance
Check.
• Electronic Service Tool (EST) with ServiceMaxx™
software • If sensor resistance and sensor
connector voltage are within
• J1939 and J1708 RP1210B Compliant Device
specification, go to Crankcase
Oil Breather Separator Test in
WARNING: To prevent personal injury or “PERFORMANCE DIAGNOSTICS."
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 377

Sensor Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE4951 to CCOSS sensor and leave engine
harness disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to 2 300 Ω to 400 Ω If not within specification, replace CCOSS sensor.

Connector Voltage Check Without ServiceMaxx™ software

Connect Breakout Harness ZTSE4951 to CCOSS engine harness, and leave CCOSS sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point SpecificationsComment – < Less than, > Greater than
1 to GND 2.0 V – 2.5 V If < 2.0 V, check for OPEN of short to GND. Do Harness
Resistance Check.
2 to GND 2.0 V – 2.5 V If < 2.0 V, check for OPEN of short to GND. Do Harness
Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and

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E2 connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4951 to CCOSS engine
harness, and leave CCOSS sensor disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
E1-07 to 2 <5Ω If > 5 Ω, check for OPEN circuit.
E1-07 to GND > 1k Ω If < 1k Ω, check for short to GND.
E1-31 to 1 <5Ω If > 5 Ω, check for OPEN circuit.
E1-31 to GND > 1k Ω If < 1k Ω, check for short to GND.

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 378 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CCS (Cruise Control System)

SPN FMI Condition Possible Causes

None

Function
The CCS is a function of the Engine Control Module
(ECM). Using the cruise control switches, the operator
is able to set, resume, accelerate, or coast to any
desired vehicle speed within range of the system.
The ECM continuously monitors the clutch, brake, and
accelerator pedals before cruise can be activated, and
is used to deactivate after cruise speed has been set.

CCS Operation
The cruise control switches are wired to the Body
Controller (BC). The switch state is communicated to
the ECM through the J1939 Data Link network.

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CCS Pinpoint Diagnostics – With ServiceMaxx™
Software

Programmable Parameters
Turn ignition switch ON. Connect EST to vehicle Diagnostic Connector. Using ServiceMaxx™ software,
open the Programming session and verify all Parameters are set correctly.
Test Point Specification Comment
Cruse Control Enabled If Disabled, change to Enabled
Mode

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 379

Switch Checks
Using ServiceMaxx™ software, open the Driver Switch Controls session to monitor signals.
NOTE:
• If signals are not within specification, diagnose switch interface with Body Controller (BC) or
Multiplex System Module (MSM) module. See Chassis Electrical Circuit Diagnostic Manual and
Electrical System Troubleshooting Guides.
• If signals are within specification, go to next test point.
Test Point Specification Comment
Brake Switch Normal state = See Note
Released
Depressed = Applied
Park brake Normal state = OFF See Note
Depressed = ON
Cruise On/Off Unlatched = OFF See Note
Latched = ON
Cruise Set Normal state = OFF See Note

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Depressed = ON
Cruise Normal state = OFF See Note
Resume/Accel
Depressed = ON
If all switches are within specifications, drive the vehicle and verify the Vehicle Speed Sensor (VSS)
is working.

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 380 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CFV (Coolant Flow Valve)

SPN FMI Condition Possible Causes

5547 3 CFV short to PWR • CFV circuit short to PWR
• Failed CFV
5547 4 CFV short to GND • CFV circuit short to GND
• Failed CFV
5547 5 CFV open load/circuit • CFV circuit OPEN
• Failed CFV

CFV circuit

CFV CFV
ECM 96-Pin
CFV connector
E1 connector
connector (end view) 1

CFV
PinE1-74 1

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ECM PWROUT3
Pin E1 - 24 2

2
V00035

Figure 184 CFV circuit diagram

Connector Voltage Check

Connect Breakout Harness ZTSE4871 to CFV engine harness and leave CFV disconnected. Turn ignition
ON. Use DMM to measure voltage.
Test Point Specifications Comment – < Less than, > Greater than
Pin 1 to GND 4V±1V If < 3 V, check for OPEN or short to GND in CFV circuit.
If > 5 V, check for short to PWR in CFV circuit.
Pin 2 to GND B+ If < B+, check for OPEN in ECM PWR OUT 3 circuit.
If measurements are within specifications, go to Operational Voltage Check.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 381

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4871 between CFV and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the 2010 Actuator session.
3. Command Coolant Flow Valve to 5%, then 95%.
4. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5% = 12.0 V ± 2.0 V If < 10.0 V, check for OPEN circuit.
1 to GND 95% = 1.5 V ± 0.5 V If > 2.0 V, check for OPEN circuit or failed CFV.

Actuator Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE4871 to CFV and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment
1 to 2 4 Ω to 8 Ω If not within specification, replace the CFV.
If measurements are within specifications, go to Harness Resistance Check.

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Harness Resistance Check
Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4871 to CFV engine harness,
and leave CFV disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to E1-74 <5Ω If > 5 Ω, check for OPEN circuit.
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-24 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
If voltage and resistance checks are within specifications, the CFV is working correctly. See Coolant System
(page 79) in “ENGINE SYMPTOMS DIAGNOSTICS” to diagnose a mechanical fault.

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 382 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

CKP Sensor (Crankshaft Position)

SPN FMI Condition Possible Causes Actions

637 8 CKP signal noise • Debris Step-Based Diagnostics
accumulation on the (page 385)
Crankshaft Position
(CKP) sensor
• CKP-L circuit
intermittent high
resistance
• CKP-H circuit
intermittent high
resistance
• CKP-L circuit
intermittent short
to GND
• CKP-H circuit
intermittent short
to GND

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• CKP-L circuit
intermittent short
to CKP-H circuit
• Failed CKP sensor
637 10 CKP signal inactive • Debris Step-Based Diagnostics
accumulation on the (page 389)
Crankshaft Position
(CKP) sensor
• CKP-L circuit Open
or high resistance
• CKP-H circuit Open
or high resistance
• CKP-L circuit short
to GND
• CKP-H circuit short
to GND
• CKP-L circuit
shorted to CKP-H
circuit
• Failed CKP sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 383

CKP circuit

CKP
CKP
ECM 96-Pin
CKP connector
E1 connector
connector (end view)

CKP-H
PinE1-40

CKP-L
Pin E1 - 16 r - + - - - - - - - ~ 2

2
V00002

Figure 185 CKP sensor circuit diagram

Overview • Breakout Harness ZTSE6021 (CKP)

The Crankshaft Position (CKP) sensor is a magnetic • International Electrical Engine. Terminal Test Kit
pickup sensor that indicates crankshaft speed and ZTSE4435C
position. The CKP sensor is compared with the

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• 500 Ohm Resistor Jumper Harness ZTSE4497
Camshaft Position (CMP) sensor by the Engine
Control Module (ECM) to calculate the RPM and • Digital Multimeter (DMM)
timing of the engine. The engine will still start with
• Electronic Service Tool (EST) with ServiceMaxx™
a failed CKP or CMP sensor, but will have a longer
software
crank time.
• Interface cable (RP1210B compliant supporting
Tools Required
J1939 and J1708)
• 180-Pin Breakout Box 00-00956-08
• ECM Breakout Harness 00-01468-00

387
 384 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

BetterManuals.net
0000063534

Figure 186 CKP Sensor Location (Back of engine)

1. Crankshaft Position (CKP)
sensor

388
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 385

SPN 637 FMI 8 - CKP signal noise

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft Position CKP signal > 8000 rpm Engine cranking 8 engine
(CKP) sensor signal revolutions (per
OR
greater than expected. cam signal)
Key-On Engine-Running
(KOER)

Fault Overview
Fault Code sets when the Engine Control Module
(ECM) detects the signal from the Crankshaft Position
(CKP) sensor indicates engine speed is greater than
8000 rpm.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

CKP circuit

CKP
CKP
ECM 96-Pin
CKP connector
E1 connector
connector (end view)

CKP-H
PinE1-40

CKP-L
Pin E1 - 16 ~+ -------~ 2

2
V00002

Figure 187 CKP sensor circuit diagram

Possible Causes • CKP-L circuit intermittent short to GND

• Debris accumulation on the Crankshaft Position • CKP-H circuit intermittent short to GND
(CKP) sensor
• CKP-L circuit intermittent short to CKP-H circuit
• CKP-L circuit intermittent high resistance
• Failed CKP sensor
• CKP-H circuit intermittent high resistance

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 386 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Crankshaft Position (CKP) sensor. Key Yes: Go to step 2.
OFF, disconnect CKP sensor. Check sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the CKP sensor connector, harness, and terminals clean and SPN 637 FMI 8.
undamaged?

CAUTION: To prevent damage, do not use chemical

cleaners to clean crankshaft position sensor.

Step Action Decision

2 Remove CKP sensor. Inspect sensor for debris build up on the Yes: Go to step 3.
sensor.
No: Clean CKP sensor with a
Is the sensor free of damage or debris on the sensor surface? rag or towel. After repairs are
complete, retest for SPN 637
FMI 8.

Step Action Decision

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3 Check for a failed CKP sensor. Connect Breakout Harness Yes: Go to step 4.
ZTSE6021 to CKP sensor, and leave vehicle harness
No: Replace CKP sensor. After
disconnected. Key OFF, use a DMM to measure resistance
repairs are complete, retest for
between Breakout Harness pin-1 and pin-2.
SPN 637 FMI 8.
Is resistance 774 - 946 Ohms?

Step Action Decision

4 Check for intermittent short to GND in CKP-H circuit. Connect Yes: Go to step 5.
Breakout Harness ZTSE6021 to vehicle harness and leave CKP
No: Repair short to GND
sensor disconnected. Key OFF Use a DMM to measure resistance
between CKP connector pin-1
between Breakout Harness pin-1 and a known good ground.
and ECM pin E1-10. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 637 FMI 8.

Step Action Decision

5 Check for intermittent short to GND in CKP-L circuit. Connect Yes: Go to step 6.
Breakout Harness ZTSE6021 to vehicle harness and leave
No: Repair short to GND
CKP sensor disconnected. Key OFF, Use a DMM to measure
between CKP connector pin-2
resistance between Breakout Harness pin-2 and a known good
and ECM pin E1-16. After
ground.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 637 FMI 8.

390
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 387

Step Action Decision

6 Check CKP-H circuit for intermittent high resistance (voltage drop). Yes: Go to step 7.
1. Key OFF, disconnect CKP sensor and Engine Control No: Repair intermittent high
Module (ECM). resistance between CKP
connector pin-1 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-40. After repairs are
and leave CKP sensor disconnected.
complete, retest for SPN 637
3. Using a jumper wire, connect Breakout Harness pin-1 to a FMI 8.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-40.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to pin previously installed, and the
other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-1 and ECM pin E1-40.
Is voltage less than 0.3 volts?

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Step Action Decision
7 Check CKP-L circuit for intermittent high resistance (voltage drop). Yes: Go to step 8.
1. Key OFF, disconnect CKP sensor and Engine Control No: Repair intermittent high
Module (ECM). resistance between CKP
connector pin-2 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-16. After repairs are
and leave CKP sensor disconnected.
complete, retest for SPN 637
3. Using a jumper wire, connect Breakout Harness pin-2 to a FMI 8.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-16.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to pin previously installed, and the
other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-2 and ECM pin E1-16.
Is voltage less than 0.3 volts?

Step Action Decision

8 Check for intermittent short CKP-L to CKP-H. With ECM Yes: Go to step 9.
Disconnected, connect Breakout Harness ZTSE6021 to vehicle
No: Repair short between
harness, and leave CKP sensor disconnected. Key OFF, use a
CKP-L and CKP-H circuits. After
DMM to measure resistance between Breakout Harness pin-1
repairs are complete, retest for
to pin-2.
SPN 637 FMI 8.
Is resistance greater than 1000 ohms?

391
 388 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 Check for incorrect output from the CKP sensor. With ECM Yes: Clear code and retest for
connected, connect Breakout Harness ZTSE6021 between CMP SPN 637 FMI 8.
sensor and vehicle harness. Using DMM set to AC Volts - RPM2.
No: Replace CKP sensor. After
Measure RPM between pin-1 and pin-2 during cranking, low idle,
repairs are complete, retest for
and high idle.
SPN 637 FMI 8.
Is RPM measured 99 RPM to 250 RPM at cranking, 549 RPM to
700 RPM at low idle, and 1250 RPM to 1500 RPM at high idle?

NOTE: After performing all diagnostic steps, if

SPN 637 FMI 8 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

392
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 389

SPN 637 FMI 10 - CKP signal inactive

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
No Crankshaft Position CKP circuit voltage < 0.40 Engine cranking 10 camshaft
(CKP) signal volts revolutions
OR
Key-On Engine-Running
(KOER)

Fault Overview
Fault code sets when the Engine Control Module
(ECM) receives no signal from the Crankshaft Position
(CKP) sensor.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

BetterManuals.net
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

CKP circuit

CKP
CKP
ECM 96-Pin
E1 connector CKP
connector
CKP-H
PinE1-40

CKP-L
~+-::...;_;,;___;;::,___ _ _____J 2
Pin E1 - 16

2
V00002

Figure 188 CKP sensor circuit diagram

Possible Causes • CKP-L circuit short to GND

• Debris accumulation on the Crankshaft Position • CKP-H circuit short to GND
(CKP) sensor
• CKP-L circuit shorted to CKP-H circuit
• CKP-L circuit Open or high resistance
• Failed CKP sensor
• CKP-H circuit Open or high resistance

393
 390 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Crankshaft Position (CKP) sensor. Key Yes: Go to step 2.
OFF, disconnect CKP sensor. Check sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the CKP sensor connector, harness, and terminals clean and SPN 637 FMI 10.
undamaged?

CAUTION: To prevent damage, do not use chemical

cleaners to clean crankshaft position sensor.

Step Action Decision

2 Remove CKP sensor. Inspect sensor for debris build up on the Yes: Go to step 3.
sensor.
No: Clean CKP sensor with a
Is the sensor free of damage or debris on the sensor surface? rag or towel. After repairs are
complete, retest for SPN 637
FMI 10.

Step Action Decision

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3 Check for a failed CKP sensor. Connect Breakout Harness Yes: Go to step 4.
ZTSE6021 to CKP sensor and leave Breakout Harness
No: Replace CKP sensor. After
disconnected from vehicle. Key OFF, use a DMM to measure
repairs are complete, retest for
resistance between Breakout Harness pin-1 and pin-2.
SPN 637 FMI 10.
Is resistance 774 – 946 Ohms?

Step Action Decision

4 Check for short to GND in CKP-H circuit. Connect Breakout Yes: Go to step 5.
Harness ZTSE6021 to vehicle harness and leave CKP sensor
No: Repair short to GND
disconnected. Key OFF Use a DMM to measure resistance
between CKP connector pin-1
between Breakout Harness pin-1 and a known good ground.
and ECM pin E1-10. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 637 FMI 10.

Step Action Decision

5 Check for short to GND in CKP-L circuit. Connect Breakout Yes: Go to step 6.
Harness ZTSE6021 to vehicle harness and leave CKP sensor
No: Repair short to GND
disconnected. Key OFF, Use a DMM to measure resistance
between CKP connector pin-2
between Breakout Harness pin-2 and a known good ground.
and ECM pin E1-16. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 637 FMI 10.

394
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 391

Step Action Decision

6 Check CKP-H circuit for Open or high resistance (voltage drop). Yes: Go to step 7.
1. Key OFF, disconnect CKP sensor and Engine Control No: Repair Open or high
Module (ECM). resistance between CKP
connector pin-1 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-40. After repairs are
and leave CKP sensor disconnected.
complete, retest for SPN 637
3. Using a jumper wire, connect Breakout Harness pin-1 to a FMI 10.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-40.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to pin previously installed, and the
other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-1 and ECM pin E1-40.
Is voltage less than 0.3 volts?

BetterManuals.net
Step Action Decision
7 Check CKP-L circuit for Open or high resistance (voltage drop). Yes: Go to step 8.
1. Key OFF, disconnect CKP sensor and Engine Control No: Repair Open or high
Module (ECM). resistance between CKP
connector pin-2 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-16. After repairs are
and leave CKP sensor disconnected.
complete, retest for SPN 637
3. Using a jumper wire, connect Breakout Harness pin-2 to a FMI 10.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-16.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to pin previously installed, and the
other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-2 and ECM pin E1-16.
Is voltage less than 0.3 volts?

Step Action Decision

8 Check for CKP-H shorted to CKP-L. With ECM Disconnected, Yes: Go to step 9.
connect Breakout Harness ZTSE6021 to vehicle harness and
No: Repair short between
leave CMP sensor disconnected. Key OFF, use a DMM to
CKP-H and CKP-L circuits. After
measure resistance between Breakout Harness pin-1 and pin-2.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 637 FMI 10.

395
 392 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 Check for a failed CKP sensor. Reconnect ECM. Connect Yes: Clear code and retest for
Breakout Harness ZTSE6021 between CKP sensor and vehicle SPN 637 FMI 10.
harness. Using a DMM set to measure AC frequency (Hz),
No: Replace CKP sensor. After
measure the voltage of the sensor when cranking, low idle, and
repairs are complete, retest for
high idle (100-250 RPM).
SPN 637 FMI 10.
Is RPM measured 99 RPM to 250 RPM at cranking, 549 RPM to
700 RPM at low idle, and 1250 RPM to 1500 RPM at high idle?

NOTE: After performing all diagnostic steps, if

SPN 637 FMI 10 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

396
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 393

CMP Sensor (Camshaft Position)

SPN FMI Condition Possible Causes Actions

636 2 CMP and CKP Synchronization Error • Debris Step-Based Diagnostics
accumulation on the (page 397)
Camshaft Position
(CMP) sensor
• CMP-L high
resistance
• CMP-H high
resistance
• CMP-L short to
GND
• CMP-H short to
GND
• CMP-L shorted to
CMP-H
• Camshaft and

BetterManuals.net
Crankshaft not
synchronized
• Failed CMP

397
 394 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

636 8 CMP signal noise • Debris Step-Based Diagnostics

accumulation on the (page 401)
Camshaft Position
(CMP) sensor
• CMP-L intermittent
high resistance
• CMP-H intermittent
high resistance
• CMP-L intermittent
short to GND
• CMP-H intermittent
short to GND
• CMP-L intermittent
short to CMP-H
• Failed CMP
636 10 CMP signal inactive • Debris Step-Based Diagnostics
accumulation on the (page 405)
Camshaft Position

BetterManuals.net
(CMP) sensor
• CMP-L Open or
high resistance
• CMP-H Open or
high resistance
• CMP-L short to
GND
• CMP-H short to
GND
• CMP-L shorted to
CMP-H
• Failed CMP

398
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 395

CMP circuit

CMP
CMP
ECM 96-Pin
CMP connector
E1 connector
connector (end view)

CMP-L
PinE1-41

CMP-H
~+-;__;_;__;_.:,___ _ _____J 2
PinE1-17

2
V00004

Figure 189 CMP sensor circuit diagram

Overview • Breakout Harness ZTSE6021

The Camshaft Position (CMP) sensor is a magnetic • International Electrical Engine. Terminal Test Kit
pickup sensor that indicates camshaft speed and ZTSE4435C
position. The CMP sensor is compared with the

BetterManuals.net
• 500 Ohm Resistor Jumper Harness ZTSE4497
Crankshaft Position (CKP) sensor by the Engine
Control Module (ECM) to calculate the RPM and • Digital Multimeter (DMM)
timing of the engine. The engine will still start with
• Electronic Service Tool (EST) with ServiceMaxx™
a failed CMP or CKP sensor, but will have a longer
software
crank time.
• Interface cable (RP1210B compliant supporting
Tools Required
J1939 and J1708)
• 180-Pin Breakout Box 00-00956-08
• ECM Breakout Harness 00-01468-00

399
 396 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

BetterManuals.net 0000063141

Figure 190 CMP Sensor Location

1. Camshaft Position (CMP) sensor

400
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 397

SPN 636 FMI 2 - CMP and CKP Synchronization Error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Camshaft position Camshaft position signal Engine cranking 2 consecutive
signal error error > 20 crank degrees camshaft
OR
OR < -20 crank degrees revolutions
Key-On Engine-Running
(KOER)

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the difference between the camshaft
and crankshaft position signals is > 20 degrees.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

BetterManuals.net
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

CMP circuit

CMP
CMP
ECM 96-Pin
CMP connector
E1 connector
connector (end view)

CMP-L
PinE1-41

CMP-H_ _ _ __J
}-+-'::..:.=___:_: 2
PinE1-17

2
V00004

Figure 191 CMP sensor circuit diagram

Possible Causes • CMP-H short to GND

• Debris accumulation on the Camshaft Position • CMP-L shorted to CMP-H
(CMP) sensor
• Camshaft and Crankshaft not synchronized
• CMP-L high resistance
• Failed CMP
• CMP-H high resistance
• CMP-L short to GND

401
 398 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Camshaft Position (CMP) sensor. Key Yes: Go to step 2.
OFF, disconnect CMP sensor. Check CMP sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the CMP sensor connector, harness, and terminals clean and SPN 636 FMI 2.
undamaged?

CAUTION: To prevent damage, do not use chemical

cleaners to clean camshaft position sensor.

Step Action Decision

2 Inspect CMP sensor and bore for damage or debris build up. Yes: Go to step 3.
Remove CMP sensor and inspect sensor and bore.
No: Clean or replace CMP
Is the sensor and bore free of damage or debris? sensor with a rag or towel and
clean sensor bore. After repairs
are complete, retest for SPN 636
FMI 2.

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Step Action Decision
3 Check for a failed CMP sensor. Connect Breakout Harness Yes: Go to step 4.
ZTSE6021 to CMP sensor and leave Breakout Harness
No: Replace the CMP sensor.
disconnected from vehicle harness. Key OFF, use a DMM to
After repairs are complete, retest
measure resistance between pin-1 and pin-2.
for SPN 636 FMI 2.
Is CMP sensor resistance 774 to 946 ohms?

Step Action Decision

4 Check for short to GND in CMP-H circuit. Connect Breakout Yes: Go to step 5.
Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair short to GND
disconnected. Key OFF, use a DMM to measure resistance
between CMP connector pin-2
between Breakout Harness pin-2 and a known good ground.
and ECM pin E1-17. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 2.

Step Action Decision

5 Check for short to GND in CMP-L circuit. Connect Breakout Yes: Go to step 6.
Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair short to GND
disconnected. Key OFF, use a DMM to measure resistance
between CMP connector pin-1
between Breakout Harness pin-1 and a known good ground.
and ECM pin E1-41. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 2.

402
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 399

Step Action Decision

6 Check CMP-L circuit for high resistance (voltage drop). Yes: Go to step 7.
1. Key OFF, disconnect CMP sensor and Engine Control No: Repair high resistance
Module (ECM). between CMP connector pin-1
and ECM pin E1-41. After
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
repairs are complete, retest for
and leave CMP sensor disconnected.
SPN 636 FMI 2.
3. Using a jumper wire, connect Breakout Harness pin-1 to a
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-41.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-1 and ECM pin E1-41.
Is voltage less than 0.3 volts?

BetterManuals.net
Step Action Decision
7 Check CMP-H circuit for high resistance (voltage drop). Yes: Go to step 8.
1. Key OFF, disconnect CMP sensor and Engine Control No: Repair high resistance
Module (ECM). between CMP connector pin-2
and ECM pin E1-17. After
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
repairs are complete, retest for
and leave CMP sensor disconnected.
SPN 636 FMI 2.
3. Using a jumper wire, connect Breakout Harness pin-2 to a
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-17.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-2 and ECM pin E1-17.
Is voltage less than 0.3 volts?

Step Action Decision

8 Check for CMP-L shorted to CMP-H. With ECM Disconnected, Yes: Go to step 9.
connect Breakout Harness ZTSE6021 to vehicle harness and
No: Repair short between
leave CMP sensor disconnected. Key OFF, use a DMM to
CMP-L and CMP-H. After
measure resistance between Breakout Harness pin-1 and pin-2.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 636 FMI 2.

403
 400 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 Check for incorrect output from the CMP sensor. With ECM Yes: Go to step 10.
connected, connect Breakout Harness ZTSE6021 between CMP
No: Replace the CMP sensor.
sensor and vehicle harness. Using DMM set to AC Volts - RPM2.
After repairs are complete, retest
Measure RPM between pin-1 and pin-2 during cranking, low idle,
for SPN 636 FMI 2.
and high idle.
Is RPM measured 99 RPM to 250 RPM at cranking, 549 RPM to
700 RPM at low idle, and 1250 RPM to 1500 RPM at high idle?

Step Action Decision

10 Check for correct camshaft / crankshaft synchronization (see Yes: Clear code and retest for
Engine Service Manual, "Cylinder Head, Camshaft and Valve SPN 636 FMI 2.
Train" section).
No: Check for damage and
Are the camshaft and crankshaft timed properly? re-time the camshaft and
crankshaft. (see Engine Service
Manual). After repairs are
complete, retest for SPN 636
FMI 2.

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NOTE: After performing all diagnostic steps, if
SPN 636 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

404
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 401

SPN 636 FMI 8 - CMP signal noise

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Camshaft Position CMP signal difference Engine cranking 4 engine
(CMP) sensor signal revolutions
OR
difference greater than
expected. Key-On Engine-Running
(KOER)

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects Camshaft Position (CMP) sensor
signal difference is greater than expected.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

BetterManuals.net
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

CMP circuit

CMP
CMP
ECM 96-Pin
CMP connector
E1 connector
connector (end view)

CMP-L
PinE1-41

CMP-H_ _ _ __J
}-+-'::..:.=___:_: 2
PinE1-17

2
V00004

Figure 192 CMP sensor circuit diagram

Possible Causes • CMP-L intermittent short to GND

• Debris accumulation on the Camshaft Position • CMP-H intermittent short to GND
(CMP) sensor
• CMP-L intermittent short to CMP-H
• CMP-L intermittent high resistance
• Failed CMP
• CMP-H intermittent high resistance

405
 402 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Camshaft Position (CMP) sensor. Key Yes: Go to step 2.
OFF, disconnect CMP sensor. Check CMP sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the CMP sensor connector, harness, and terminals clean and SPN 636 FMI 8.
undamaged?

CAUTION: To prevent damage, do not use chemical

cleaners to clean camshaft position sensor.

Step Action Decision

2 Remove CMP sensor. Inspect sensor for damage or debris build Yes: Go to step 3.
up on the sensor.
No: Clean CMP sensor with a
Is the sensor free of damage or debris on the sensor surface? rag or towel. After repairs are
complete, retest for SPN 636
FMI 8.

Step Action Decision

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3 Check for a failed CMP sensor. Connect Breakout Harness Yes: Go to step 4.
ZTSE6021 to CMP sensor and leave Breakout Harness
No: Replace the CMP sensor.
disconnected from vehicle. Key OFF, use a DMM to measure
After repairs are complete, retest
resistance between Breakout Harness pin-1 and pin-2.
for SPN 636 FMI 8.
Is resistance 774 to 946 ohms?

Step Action Decision

4 Check for intermittent short to GND in CMP-H circuit. Connect Yes: Go to step 5.
Breakout Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair intermittent short to
disconnected. Key OFF, use a DMM to measure resistance
GND between CMP connector
between Breakout Harness pin-2 and a known good ground.
pin-2 and ECM pin E1-17. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 8.

Step Action Decision

5 Check for short to GND in CMP-L circuit. Connect Breakout Yes: Go to step 6.
Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair intermittent short to
disconnected. Key OFF, use a DMM to measure resistance
GND between CMP connector
between Breakout Harness pin-1 and a known good ground.
pin-1 and ECM pin E1-41. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 8.

406
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 403

Step Action Decision

6 Check CMP-L circuit for intermittent high resistance (voltage drop). Yes: Go to step 7.
1. Key OFF, disconnect CMP sensor and Engine Control No: Repair intermittent high
Module (ECM). resistance between CMP
connector pin-1 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-41. After repairs are
and leave CMP sensor disconnected.
complete, retest for SPN 636
3. Using a jumper wire, connect Breakout Harness pin-1 to a FMI 8.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-41.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-1 and ECM pin E1-41.
Is voltage less than 0.3 volts?

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Step Action Decision
7 Check CMP-H circuit for intermittent high resistance (voltage Yes: Go to step 8.
drop).
No: Repair intermittent high
1. Key OFF, disconnect CMP sensor and Engine Control resistance between CMP
Module (ECM). connector pin-2 and ECM
pin E1-17. After repairs are
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
complete, retest for SPN 636
and leave CMP sensor disconnected.
FMI 8.
3. Using a jumper wire, connect Breakout Harness pin-2 to a
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-17.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-2 and ECM pin E1-17.
Is voltage less than 0.3 volts?

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 404 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

8 Check for intermittent short CMP-L to CMP-H. With ECM Yes: Go to step 9.
disconnected, connect Breakout Harness ZTSE6021 to vehicle
No: Repair short between
harness and leave CMP sensor disconnected. Key OFF, use a
CMP-L and CMP-H circuits.
DMM to measure resistance between Breakout Harness pin-1
After repairs are complete, retest
and pin-2.
for SPN 636 FMI 8.
Is resistance greater than 1000 ohms?

Step Action Decision

9 Check for incorrect output from the CMP sensor. Connect Yes: Clear code and retest for
Breakout Harness ZTSE6021 between CMP sensor and vehicle SPN 636 FMI 8.
harness. Using DMM set to AC Volts - RPM2. Measure RPM
No: Replace the CMP Sensor.
between pin-1 and pin-2 during cranking, low idle, and high idle.
After repairs are complete, retest
Is RPM measured 99 RPM to 250 RPM at cranking, 549 RPM to for SPN 636 FMI 8.
700 RPM at low idle, and 1250 RPM to 1500 RPM at high idle?

NOTE: After performing all diagnostic steps, if

SPN 636 FMI 8 remains, verify each step was
completed correctly and the proper decision was

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made. Notify supervisor for further action.

408
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 405

SPN 636 FMI 10 - CMP signal inactive

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
No Camshaft Position CMP circuit voltage < Engine cranking 4 engine
(CMP) signal. 0.405 volts revolutions
OR
Key-On Engine-Running
(KOER)

Fault Overview
Fault code sets when the Engine Control Module
(ECM) receives no signal from the Camshaft Position
(CMP) sensor.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

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Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

CMP circuit

CMP
CMP
ECM 96-Pin
CMP connector
E1 connector
connector (end view)

CMP-L
PinE1-41

CMP-H_ _ _ __J
}-+-'::..:.=___:_: 2
PinE1-17

2
V00004

Figure 193 CMP sensor circuit diagram

Possible Causes • CMP-L short to GND

• Debris accumulation on the Camshaft Position • CMP-H short to GND
(CMP) sensor
• CMP-L shorted to CMP-H
• CMP-L Open or high resistance
• Failed CMP
• CMP-H Open or high resistance

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 406 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Camshaft Position (CMP) sensor. Key Yes: Go to step 2.
OFF, disconnect CMP sensor. Check CMP sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the CMP sensor connector, harness, and terminals clean and SPN 636 FMI 10.
undamaged?

CAUTION: To prevent damage, do not use chemical

cleaners to clean camshaft position sensor.

Step Action Decision

2 Remove CMP sensor. Inspect sensor for damage or debris build Yes: Go to step 3.
up on the sensor.
No: Clean CMP sensor with a
Is the sensor free of damage or debris on the sensor surface? rag or towel. After repairs are
complete, retest for SPN 636
FMI 10.

Step Action Decision

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3 Check for a failed CMP sensor. Connect Breakout Harness Yes: Go to step 4.
ZTSE6021 to CMP sensor and leave Breakout Harness
No: Replace the CMP sensor.
disconnected from vehicle. Using DMM, measure resistance
After repairs are complete, retest
between pin-1 and pin-2.
for SPN 636 FMI 10.
Is resistance 774 – 946 ohms?

Step Action Decision

4 Check for short to GND in CMP-H circuit. Connect Breakout Yes: Go to step 5.
Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair short to GND
disconnected. Key OFF, use a DMM to measure resistance
between CMP connector pin-2
between Breakout Harness pin-2 and a known good ground.
and ECM pin E1-17. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 10.

Step Action Decision

5 Check for short to GND in CMP-L circuit. Connect Breakout Yes: Go to step 6.
Harness ZTSE6021 to vehicle harness and leave sensor
No: Repair short to GND
disconnected. Key OFF, use a DMM to measure resistance
between CMP connector pin-1
between Breakout Harness pin-1 and a known good ground.
and ECM pin E1-41. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 636 FMI 10.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 407

Step Action Decision

6 Check CMP-L circuit for Open or high resistance (voltage drop). Yes: Go to step 7.
1. Key OFF, disconnect CMP sensor and Engine Control No: Repair Open or high
Module (ECM). resistance between CMP
connector pin-1 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-41. After repairs are
and leave CMP sensor disconnected.
complete, retest for SPN 636
3. Using a jumper wire, connect Breakout Harness pin-1 to a FMI 10.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-41.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-1 and ECM pin E1-41.
Is voltage less than 0.3 volts?

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Step Action Decision
7 Check CMP-H circuit for Open or high resistance (voltage drop). Yes: Go to step 8.
1. Key OFF, disconnect CMP sensor and Engine Control No: Repair Open or high
Module (ECM). resistance between CMP
connector pin-2 and ECM
2. Connect Breakout Harness ZTSE6021 to vehicle harness,
pin E1-17. After repairs are
and leave CMP sensor disconnected.
complete, retest for SPN 636
3. Using a jumper wire, connect Breakout Harness pin-2 to a FMI 10.
known good ground.
4. Insert proper terminal into the ECM vehicle harness pin
E1-17.
5. Connect one end of the 500 Ohm Resistor Jumper
Harness ZTSE4497 to terminal previously installed, and
the other end to PWR (use a jumper wire if needed).
6. Using a DMM, measure voltage between Breakout
Harness pin-2 and ECM pin E1-17.
Is voltage less than 0.3 volts?

Step Action Decision

8 Check for CMP-L shorted to CMP-H. With ECM Disconnected, Yes: Go to step 9.
connect Breakout Harness ZTSE6021 to vehicle harness and
No: Repair short between
leave CMP sensor disconnected. Key OFF, use a DMM to
CMP-L and CMP-H. After
measure resistance between Breakout Harness pin-1 and pin-2.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 636 FMI 10.

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 408 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 Check for incorrect output from the CMP sensor. Connect Yes: Clear code and retest for
Breakout Harness ZTSE6021 between CMP sensor and vehicle SPN 636 FMI 10.
harness. Using DMM set to AC Volts - RPM2. Measure RPM
No: Replace the CMP sensor.
between pin-1 and pin-2 during cranking, low idle, and high idle.
After repairs are complete, retest
Is RPM measured 99 RPM to 250 RPM at cranking, 549 RPM to for SPN 636 FMI 10.
700 RPM at low idle, and 1250 RPM to 1500 RPM at high idle?

NOTE: After performing all diagnostic steps, if

SPN 636 FMI 10 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 409

CMV (Coolant Mixer Valve)

SPN FMI Condition Possible Causes

5546 3 CMV short to PWR • CMV circuit short to PWR
• Failed CMV
5546 4 CMV short to GND • CMV circuit short to GND
• Failed CMV
5546 5 CMV open load/circuit • CMV circuit OPEN
• Failed CMV

CMV Circuit

CMV
ECM 96-Pin CMV
E1 connector CMV Connector
Connector (end view)
CMV
Pin E1 -48

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ECM PWR OUT2
PinE1-28 2

2
V00034

Figure 194 CMV sensor circuit diagram

Tools Required • Breakout Harness ZTSE4870 (CMV)

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

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 410 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check

Connect Breakout Harness ZTSE4870 to CMV engine harness and leave CMV disconnected. Turn ignition
ON. Use DMM to measure voltage.
Test Point Specifications Comment – < Less than, > Greater than
Pin 1 to GND 4V±1V If < 3 V, check for OPEN or short to GND in CMV circuit.
If > 5 V, check for short to PWR in CMV circuit.
Pin 2 to GND B+ If < B+, check for OPEN in ECM PWR OUT 2 circuit.
If measurements are within specifications, go to Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4870 between CMV and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Coolant Mixer Valve from the drop-down menu.
3. Command Coolant Mixer Valve to 5%, then 95%.
4. Use DMM to measure voltage.

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Test Point Specification Comment – < Less than, > Greater than
1 to GND 5% = 12.0 V ± 2.0 V If < 10.0 V, check for OPEN circuit.
1 to GND 95% = 1.5 V ± 0.5 V If > 2.0 V, check for OPEN circuit or failed CMV.

Actuator Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE4870 to CMV and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment
1 to 2 4 Ω to 8 Ω If not within specification, replace CMV.
If measurements are within specifications, go to Harness Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4870 to CMV engine harness,
and leave CMV disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to E1-48 <5Ω If > 5 Ω, check for OPEN circuit.
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-28 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
If voltage and resistance checks are within specifications, the CMV is working correctly. See Coolant System
in the “ENGINE SYMPTOMS DIAGNOSTICS” section in this manual, to diagnose a mechanical fault.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 411

IAHFI (Inlet Air Heater Fuel Igniter)

SPN FMI Condition Possible Causes Actions

626 18 Inlet Air Heater fault: Lack of heat in • Biased IMT sensor Pin-Point Diagnostics
the Intake Manifold or circuit (page 416)
• Inlet air heater
system failure
• Failed Inlet Air
Heater Fuel
Solenoid (IAHFS)
• Failed IAHFI
• Failed Inlet Air
Heater Relay (IAHR)
• Inlet air heater circuit
faults
• Aftermarket engine
block heater
5548 3 IAHFI short to PWR • IAHFI circuit short to Circuit Checks (page

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PWR 416)
• Failed IAHFI
5548 4 IAHFI short to GND • OUT1 short to GND Step-Based Diagnostics
(page 413)
• OUT2 short to GND
• IAHRE short to GND
• IAHRD / IAHRE
shorted together
• Failed IAHFI
5548 5 IAHFI open load/circuit • IAHFI circuit OPEN Circuit Checks (page
416)
• Failed IAHFI
5548 7 Inlet Air Heater Relay return (relay, or • IAHR circuit fault Circuit Checks (page
igniter, or circuit failure) 416)
• Failed IAHR

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 412 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

IAHFI circuit IAHR

Fuselink
connector IAHFI
B+ ------------.

15-21
L-------------1
21-Way On/Off
3
OUT 1
~
ECM 96-Pin
E1 connector
s
' §§ '
14 Engine Harness
Interface connector
1
2 OUT2
5
Pin E1 - 96 \--1--I_A_H_R_E---'(~en_a_b_le~)-___, 21 f-----------1 6 IAHR

Pin E1 - 72
Pin E1 - 67
IAHRC (control)
l-+---~--~------120
IAHRD (diagnostic) 19
7
a ' I"~ ~1 '
2
7
=D • 1
IAHR
connector
s (end view)

3 0000058100

Figure 195 IAHFI circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 • ZTSE4498 – 3-Banana Plug Harness

Engine and Aftertreatment Wiring Schematic
• ZTSE4497 – 500 Ohm Resistor Harness
Form 0000002941 for additional circuit
information. • ZTSE4899 – Big Bore Terminal Test Probe Kit

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• Breakout Harness ZTSE4885 (IAHR)
Overview
• Amp clamp
The Inlet Air Heater (IAH) system warms the incoming
air to aid emissions reduction. When inlet air heating • Digital Multimeter (DMM)
is needed, the Engine Control Module (ECM) sends
• Electronic Service Tool (EST) with ServiceMaxx™
a signal to the IAH relay (IAHR). The IAHR then
software
supplies B+ to the IAH fuel ignitor (IAHFI). The IAHFI
is grounded through the intake manifold. • J1939 and J1708 RP1210B Compliant Device
Tools Required
• 00-00956-08 – 180-Pin Breakout Box

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 413

5548 FMI 4- Inlet Air Heater Fuel Ignitor short to GND

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
IAH circuit short to GND The resistance between Key ON 1 second
the IAHRE or OUT1 /
Inlet Air Heater commanded ON
OUT2 circuits and ground
< 0.2 Ohms

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects a short to GND in the Inlet Air Heater
(IAH) circuits.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference

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Manual.
IAHFI circuit IAHR
Fuselink
connector IAHFI

~
'= '
ECM 96-Pin
E1 connector

Pin E1 - 96
15-21
a 14
'-------------13
21-Way On/Off
Engine Harness
Interface connector
1

2
'\----1---IA_H_R_E-'('-e_na_b_le....:..)_ _, 21 f--------, 6
OUT 1
OUT2
5
IAHR
IAHRC (control) IAHR
\---l-------'---~-----,20 7
Pin E1 - 72
IAHRD (diagnostic) 19 t-----1
8
, 1•~ =• •~1 .
2 1 connector
Pin E1 - 67 7 s (end view)
3 0000058100

Figure 196 IAHFI circuit diagram

Possible Causes • IAHRE short to GND

• OUT1 short to GND • IAHRD / IAHRE shorted together
• OUT2 short to GND • Failed IAHFI

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 414 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Inlet Air Heater Fuel Igniter (IAHFI). Check Yes: Go to step 2.
IAHFI connector and connector terminals for: damaged or pinched
No: Repair connector, harness,
wires; corroded terminals; loose, bent, or broken pins; or broken
or terminal damage. After
connector housing.
repairs are complete, retest for
Are the IAHFI harness and terminals clean and undamaged? SPN 5548 FMI 4.

Step Action Decision

2 Inspect connections at Inlet Air Heater Relay (IAHR). Key-Off, Yes: Go to step 3.
disconnect IAHR connector. Check IAHR connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the IAHR connector, harness, and terminals clean and SPN 5548 FMI 4.
undamaged?

Step Action Decision

3 Check IAHRE circuit for short to GND. Connect Breakout Harness Yes: Go to step 4.
ZTSE4885 to vehicle harness and leave IAHR disconnected.
No: Repair short to GND in

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Key OFF, use a DMM to measure resistance between Breakout
IAHRE circuit between IAHR
Harness ZTSE4885 pin-6 and a known good ground.
pin-6 and ECM pin E1-96. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 5548 FMI 4.

Step Action Decision

4 Check IAHRE circuit for short to IAHRD. Key OFF with Breakout Yes: Go to step 5.
Harness ZTSE4885 connected to vehicle harness and IAHR
No: Repair short between IAHR
disconnected. Use a DMM to measure resistance between
pin-6 and IAHR pin-8. After
Breakout Harness pin-6 and pin-8.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 5548 FMI 4.

Step Action Decision

5 Check OUT1 circuit for short to GND. With Breakout Harness Yes: Go to step 6.
ZTSE4885 connected to vehicle harness and IAHR disconnected.
No: Repair short to GND in
Disconnect IAHFI and leave terminals disconnected. Key OFF,
OUT1 circuit between IAH relay
use a DMM to measure resistance between Breakout Harness
pin-1 and IAHFI terminal. After
pin-1 and a known good ground.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 5548 FMI 4.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 415

Step Action Decision

6 Check OUT2 circuit for short to GND. With Breakout Harness Yes: Replace IAHFI. After
ZTSE4885 connected to vehicle harness and IAHR disconnected. repairs are complete, retest for
Key OFF with IAHFI disconnected, use a DMM to measure SPN 5548 FMI 4.
resistance between Breakout Harness pin-2 and a known good
No: Repair short to GND in
ground.
OUT2 circuit between IAH relay
Is resistance greater than 1000 ohms? pin-2 and IAHFI terminal. After
repairs are complete, retest for
SPN 5548 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 5548 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 416 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Cold Soak Sensor Compare Check With ServiceMaxx™ Software

SPN 626 FMI 18 – Inlet Air Heater fault: Lack of heat in the Intake Manifold
During cold start DTC sets when Intake Manifold Temperature (IMT) signal does not raise 50°F (10°C).
NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Inspect for aftermarket engine block heater. Is engine free of an aftermarket engine block heater?
• Yes: Go to step 2.
• No: Disconnect aftermarket engine block heater and retest for SPN 626 FMI 18.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, Key-On Engine Off, load the
Default session. Compare IMT, Ambient Air Temperature (AAT), and Inlet Air Temperature (IAT).
Are IMT, Ambient Air Temperature (AAT), and Inlet Air Temperature (IAT) sensor temperatures
within 10°F (5°C) of each other.
• Yes: IMT circuit is in specification, see Inlet Air Heater System Test in “HARD START AND NO
START DIAGNOSTICS."
• No: Go to IMT sensor Circuit Checks (page 727).

Voltage Check on IAHFI - Actuator Test

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NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Inlet Air Heater Fuel Igniter from the drop-down menu.
2. Command Inlet Air Heater Fuel Igniter to 95%.
3. Use DMM to measure voltage.
Test Point Specifications Comment – < Less than, > Greater than
IAHFI to GND B+ If > 0 V to B+, do Amperage Draw Check - Actuator Test.
If 0 V, do Voltage Checks on Relay Connector (page 417).

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 417

Amperage Draw Check - Actuator Test

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Amp Clamp ZTSE4575 to DMM. Set the DMM to DCmV and Zero the Amp clamp.
2. Connect Amp Clamp ZTSE4575 around the IAHFI wires.
3. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Inlet Air Heater Fuel Igniter from the drop-down menu.
4. Command Inlet Air Heater Fuel Igniter to 95%.
5. Use DMM to measure voltage from the Amp Clamp, representing amperage through the IAHFI.
Test Point Specifications Comment
DMM - Measure amperage to IAHFI
IAHFI 30 Amps (within 2 If within specification, IAHR and IAHFI are working correctly.
seconds)
If not within specification, do Voltage Checks on Relay -
Actuator Test (page 418).
If Amps are within specification, do Harness Resistance Check (page 420) for IAHRD circuit.

Voltage Checks on Relay Connector

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Connect Breakout Harness ZTSE4885 to IAHR engine harness, and leave IAHR disconnected. Turn ignition
ON. Use DMM to measure voltage after 60 seconds.
Test Point Specifications Comment – < Less than, > Greater than
1 to GND 0V If > 0 V, check for short to PWR.
2 to GND 0V If > 0 V, check for short to PWR.
3 to GND B+ If < B+, check for OPEN or short to GND.
6 to GND 1.5 V ± 0.5 V If < 8 V, check for OPEN or short to GND.
7 to GND 0.5 V ± 0.5 V If < 3 V, check for OPEN or short to GND.
If > 5.5 V, check for short to PWR.
8 to GND 6V±1V If < 4 V, check for OPEN or short to GND.
If > 6 V, check for short to PWR.
If voltages are within specification, do Voltage Checks on Relay - Actuator Test (page 418).

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 418 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Voltage Checks on Relay - Actuator Test

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4885 between IAHR and engine harness.
2. Use DMM to measure voltage.
3. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Inlet Air Heater Fuel Igniter from the drop-down menu.
4. Command Inlet Air Heater Fuel Igniter to 5%.
5. Use DMM to measure voltage.
6. Command Inlet Air Heater Fuel Igniter to 95%.
7. Use DMM to measure voltage.
Connect Breakout Harness ZTSE4885 between IAHR and engine harness. Turn the ignition switch to ON.
Use DMM to measure voltage. Batteries must be fully charged before performing this test.
Test Point Specifications Comment – < Less than, > Greater than
6 to GND, Run Actuator Test
Normal state >1V If < 1 V, check IAHRE circuit for OPEN or short to GND. Do
Harness Resistance Check (page 420).

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Actuator state LOW > 10 V If < 10 V, check IAHRE circuit for OPEN or short to GND.
(5%) Do Harness Resistance Check (page 420).
> 10 V If < 10 V, check IAHRE circuit for OPEN or short to GND.
Actuator state HIGH Do Harness Resistance Check (page 420).
(95%)
7 to GND, Run Actuator Test.
Normal state <1V If > 1 V, check IAHRC circuit for short to PWR. Do Harness
Resistance Check (page 420).
Actuator state LOW >8V If < 8 V, check IAHRC circuit for OPEN or short to GND. Do
(5%) Harness Resistance Check (page 420).
<1 V If > 1 V, check IAHRD circuit for short to PWR. Do Harness
Actuator state HIGH Resistance Check (page 420).
(95%)
8 to GND, Run Actuator Test.
Normal state 6 V ± 1.5 V If < 4.5 V, check IAHRD circuit for OPEN or short to GND.
Do Harness Resistance Check (page 420).
Actuator state LOW 6 V ± 1.5 V If < 4.5 V, check IAHRD circuit for OPEN or short to GND.
(5%) Do Harness Resistance Check (page 420).
1 V ± 0.5 V If < 0.5 V, check IAHRD circuit for OPEN or short to GND.
Actuator state HIGH Do Harness Resistance Check (page 420).
(95%)
1 to GND, Run Actuator Test.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 419

Voltage Checks on Relay - Actuator Test (cont.)

Normal state 0V If > 0 V, replace IAHR.
Actuator state LOW 0V If > 0 V, replace IAHR.
Actuator state HIGH B+ If < B+, replace IAHR.
2 to GND, Run Actuator Test.
Normal state 0V If > 0 V, replace IAHR.
Actuator state LOW 0V If > 0 V, replace IAHR.
Actuator state HIGH B+ If < B+, replace IAHR.
If measurements are not within specifications, do Harness Resistance Check (page 420).

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 420 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

IAHFI Resistance Check

Turn ignition switch to OFF. Use DMM to measure resistance between IAHFI and engine GND.
Test Point Specifications Comment – < Less than, > Greater than
IAHFI to GND <5Ω If > 5 Ω, replace failed IAHFI.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4885 to IAHR engine harness,
and leave IAHR disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to IAHFI <5Ω If > 5 Ω, check for OPEN circuit.
1 to GND <5Ω If > 5 Ω, check for OPEN IAHFI.
2 to IAHFI <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND <5Ω If > 5 Ω, check for OPEN IAHFI.
3 to B+ <5Ω If > 5 Ω, check for OPEN circuit.
6 to E1-96 <5Ω If > 5 Ω, check for OPEN circuit.

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6 to GND > 1k Ω If < 1k Ω check for short to GND.
7 to E1-72 <5Ω If > 5 Ω, check for OPEN circuit.
7 to GND > 1k Ω If < 1k Ω check for short to GND.
8 to E1-67 <5Ω If > 5 Ω, check for OPEN circuit.
8 to GND > 1k Ω If < 1k Ω check for short to GND.
If all checks are within specification, but DTCs are still active, replace the IAHR.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 421

IAHFS (Inlet Air Heater Fuel Solenoid)

SPN FMI Condition Possible Causes

626 3 IAHFS short to PWR • IAHFS circuit short to PWR
626 4 IAHFS short to GND • IAHFS circuit short to GND
626 5 IAHFS open load/circuit • IAHFS circuit OPEN
• IAHFS failure
626 18 Inlet Air Heater fault: Lack of heat in • Biased IMT sensor or circuit
the Intake Manifold
• Inlet Air Heater System failure
• Failed Inlet Air Heater Fuel Solenoid
• Failed Inlet Air Heater Fuel Igniter
• Failed Inlet Air Heater Relay
• Inlet Air Heater circuit faults
• Aftermarket engine block heater
• Restricted Fuel Igniter supply line

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Figure 197 IAHFS circuit diagram

Tools Required • Electronic Service Tool (EST) with ServiceMaxx™

software
• 00-00956-08 – 180-Pin Breakout Box
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness A WARNING: To prevent personal injury or
death, stay clear of rotating parts (belts and fan)
• ZTSE4899 – Big Bore Terminal Test Probe Kit
and hot engine surfaces.
• Breakout Harness ZTSE4827 (IAHFS)
• Digital Multimeter (DMM)

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 422 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check – IAHFS Disconnected

Connect Breakout Harness ZTSE4827 to engine harness. Leave IAHFS disconnected. Use DMM to
measure voltage.
Test Point Specifications Comment – < Less than, > Greater than
2 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check (page 423).
1 to GND 3.5 V ± 1.0 V If < 2.5 V, check for OPEN circuit. Do Harness Resistance
Check (page 423).
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4827 between IAHFS and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Inlet Air Heater Fuel Solenoid from the drop-down menu.
3. Command Inlet Air Heater Fuel Solenoid to 5%.

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4. Use DMM to measure voltage.
5. Command Inlet Air Heater Fuel Solenoid to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5% = 12 V ± 2.0 V If < 10 V, check for OPEN circuit.
1 to GND 95% = 0.5 V ± 0.5 V If > 1 V, check for OPEN circuit or failed IAHFS.

Actuator Resistance Check

Turn ignition switch OFF. Connect Breakout Harness ZTSE4827 to IAHFS and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment – < Less than, > Greater than
1 to 2 8Ω If not within specification, replace IAHFS.

If measurements are within specifications, do Harness Resistance Check.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 423

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4827 to IAHFS engine harness,
and leave IAHFS disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-03 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-29 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, replace the IAHFS valve.

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 424 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Cylinder Balance

SPN FMI Condition Possible Causes Actions

651 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics
parameter error IQA (page 429)
651 16 Injector 1 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
high error (page 431)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
651 18 Injector 1 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
low error (page 433)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
652 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics

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parameter error IQA (page 435)
652 16 Injector 2 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
high error (page 437)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
652 18 Injector 2 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
low error (page 439)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
653 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics
parameter error IQA (page 441)
653 16 Injector 3 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
high error (page 443)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 425

653 18 Injector 3 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics

low error (page 445)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
654 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics
parameter error IQA (page 447)
654 16 Injector 4 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
high error (page 449)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
654 18 Injector 4 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
low error (page 451)
• Failed injector
(Mechanical)

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• Base engine
compression
imbalance
655 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics
parameter error IQA (page 453)
655 16 Injector 5 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
high error (page 455)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
655 18 Injector 5 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
low error (page 457)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
656 13 Injector 1 programmable • Incorrect Programmed Step-Based Diagnostics
parameter error IQA (page 459)

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 426 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

656 16 Injector 6 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics

high error (page 461)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
656 18 Injector 6 Fuel quantity/timing • Contaminated fuel Step-Based Diagnostics
low error (page 463)
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
1322 31 Misfire – Multiple cylinders • Low Fuel Delivery Step-Based Diagnostics
Pressure (FDP) (page 465)
• Low Fuel Rail
Pressure (FRP)
• Crankshaft Position
(CKP) sensor out of

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calibration
• Contaminated fuel
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
1323 31 Misfire – Cylinder 1 • Low Fuel Delivery Step-Based Diagnostics
Pressure (FDP) (page 469)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)
• Base engine
compression
imbalance

430
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 427

1324 31 Misfire – Cylinder 2 • Low Fuel Delivery Step-Based Diagnostics

Pressure (FDP) (page 472)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
1325 31 Misfire – Cylinder 3 • Low Fuel Delivery Step-Based Diagnostics
Pressure (FDP) (page 475)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)

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• Base engine
compression
imbalance
1326 31 Misfire – Cylinder 4 • Low Fuel Delivery Step-Based Diagnostics
Pressure (FDP) (page 478)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)
• Base engine
compression
imbalance

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 428 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

1327 31 Misfire – Cylinder 5 • Low Fuel Delivery Step-Based Diagnostics

Pressure (FDP) (page 481)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)
• Base engine
compression
imbalance
1328 31 Misfire – Cylinder 6 • Low Fuel Delivery Step-Based Diagnostics
Pressure (FDP) (page 484)
• Low Fuel Rail
Pressure (FRP)
• Contaminated fuel
• Failed injector
(Mechanical)

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• Base engine
compression
imbalance

Overview a nominal instantaneous engine speed value based

Many factors influence the combustion process in
a power cylinder. This can affect the production of
torque or horsepower from that cylinder. Some of the
factors include piston and cylinder geometry, injector
performance, and fuel rail pressure. Variations in
these factors can cause unevenness in torque and
horsepower from one cylinder to the next. Power
cylinder unevenness also causes increased engine
noise and vibration, especially at low idle. This is also
referred to as rough idle.
The Engine Control Module (ECM) uses a Cylinder
Balance control strategy to even the power
contribution of the cylinders, particularly at low idle.
This strategy incorporates information from the
Crankshaft Position (CKP) sensor. The ECM uses
the instantaneous engine speed near Top Dead
Center (TDC) for each cylinder as an indication of that
cylinder's power contribution. The ECM computes
on all cylinders. The nominal value would be the
expected value from all cylinders if the engine is
balanced.
By knowing the error quantities, the ECM can add or
subtract fuel from a particular cylinder. The control
strategy attempts to correct the cylinder unbalance by
using fuel quantity compensation through adjustments
of the pulse width values for each fuel injector. This
method of compensation is repeated until all error
quantities are close to zero causing all cylinders to
contribute the same amount.
Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• Interface cable (RP1210B compliant supporting
J1939 and J1708)

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 429

SPN 651 FMI 13- Injector 1 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

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433
 430 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 651
1. Remove valve cover (see Engine Service Manual) and
FMI 13.
engine brake housing. Document the IQA code for all six
injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 651 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 651 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 431

SPN 651 FMI 16- Injector 1 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 651 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

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 432 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 651 FMI 4, 5, and 13 (CYL/INJ); and SPN 3055
SPN 651 FMI 4, 5, and 13; and
FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 651 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 651 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 651 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

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Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 651 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 1. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 651 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 651 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 651 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

436
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 433

SPN 651 FMI 18- Injector 1 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 651 FMI 4,
5, and 13 (CYL/INJ)

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 434 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 651 FMI 4, 5, and 13 (CYL/INJ).
and SPN 651 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 651 FMI 4, After repairs are complete, retest
5, and 13? for SPN 651 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 651 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

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SPN 651 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 651 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 651 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 651 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 651 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

438
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 435

SPN 652 FMI 13- Injector 2 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

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439
 436 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 652
1. Remove valve cover (see Engine Service Manual) and
FMI 13.
engine brake housing. Document the IQA code for all six
injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 652 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 652 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

440
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 437

SPN 652 FMI 16- Injector 2 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 652 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

441
 438 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 652 FMI 4, 5, and 13 (CYL/INJ); and SPN 3055
SPN 652 FMI 4, 5, and 13; and
FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 652 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 652 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 652 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

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Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 652 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 2. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 652 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 652 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 652 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

442
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 439

SPN 652 FMI 18- Injector 2 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 652 FMI 4,
5, and 13 (CYL/INJ)

443
 440 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 652 FMI 4, 5, and 13 (CYL/INJ).
and SPN 652 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 652 FMI 4, After repairs are complete, retest
5, and 13? for SPN 652 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 652 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

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SPN 652 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 652 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 652 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 652 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 652 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

444
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 441

SPN 653 FMI 13- Injector 3 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

BetterManuals.net

445
 442 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 653
1. Remove valve cover (see Engine Service Manual) and
FMI 13.
engine brake housing. Document the IQA code for all six
injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 653 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 653 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

446
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 443

SPN 653 FMI 16- Injector 3 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 653 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

447
 444 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 653 FMI 4, 5, and 13 (CYL/INJ); and SPN 3055
SPN 653 FMI 4, 5, and 13; and
FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 653 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 653 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 653 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

BetterManuals.net
Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 653 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 3. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 653 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 653 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 653 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

448
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 445

SPN 653 FMI 18- Injector 3 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 653 FMI 4,
5, and 13 (CYL/INJ)

449
 446 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 653 FMI 4, 5, and 13 (CYL/INJ).
and SPN 653 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 653 FMI 4, After repairs are complete, retest
5, and 13? for SPN 653 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 653 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

BetterManuals.net
SPN 653 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 653 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 653 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 653 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 653 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

450
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 447

SPN 654 FMI 13- Injector 4 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

BetterManuals.net

451
 448 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 654
1. Remove upper valve cover (see Engine Service Manual)
FMI 13.
and engine brake housing. Document the IQA code for
all six injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 654 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 654 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

452
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 449

SPN 654 FMI 16- Injector 1 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 654 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

453
 450 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 652 FMI 4, 5, 13, 20 and 21(CYL/INJ); and SPN
SPN 654 FMI 4, 5, and 13; and
3055 FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 654 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 654 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 654 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

BetterManuals.net
Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 654 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 4. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 654 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 654 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 654 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

454
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 451

SPN 654 FMI 18- Injector 4 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 654 FMI 4,
5, and 13 (CYL/INJ)

455
 452 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 654 FMI 4, 5, and 13 (CYL/INJ).
and SPN 654 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 654 FMI 4, After repairs are complete, retest
5, and 13? for SPN 654 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 654 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

BetterManuals.net
SPN 654 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 654 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 654 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 654 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 654 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

456
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 453

SPN 655 FMI 13- Injector 5 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

BetterManuals.net

457
 454 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

BetterManuals.net
Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 655
1. Remove upper valve cover (see Engine Service Manual)
FMI 13.
and engine brake housing. Document the IQA code for
all six injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 655 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 655 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

458
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 455

SPN 655 FMI 16- Injector 5 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 655 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

459
 456 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 655 FMI 4, 5, and 13 (CYL/INJ); and SPN 3055
SPN 655 FMI 4, 5, and 13; and
FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 655 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 655 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 655 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

BetterManuals.net
Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 655 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 5. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 655 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 655 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 655 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

460
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 457

SPN 655 FMI 18- Injector 5 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

BetterManuals.net
and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 655 FMI 4,
5, and 13 (CYL/INJ)

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 458 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 655 FMI 4, 5, and 13 (CYL/INJ).
and SPN 655 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 655 FMI 4, After repairs are complete, retest
5, and 13? for SPN 655 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 655 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

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SPN 655 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 655 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 655 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 655 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 655 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 459

SPN 656 FMI 13- Injector 6 programmable parameter error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Incorrect Injector IQA checksum or range Key ON (runs once per key Immediate
Quantity Adjustment error cycle)
(IQA) programed to
Engine Control Module
(ECM).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Engine Control Module (ECM) Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
detects an incorrect Injector Quantity Adjustment Manual.
(IQA) has been programmed into the ECM.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Incorrect Programmed IQA
MIL will illuminate when this fault is detected during
one drive cycle.

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 460 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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Step Action
V21001

Decision
1 Check that the proper Injector Quantity Adjustment (IQA) is Yes: Clear fault code. Recheck
programed into the Engine Control Module (ECM). IQA codes. After repairs are
complete, retest for SPN 656
1. Remove upper valve cover (see Engine Service Manual)
FMI 13.
and engine brake housing. Document the IQA code for
all six injectors. No: Reprogram ECM with
correct IQA codes (follow on
2. Using Electronic Service Tool (EST) with ServiceMaxx,
screen instructions). After
select Procedures > KOEO Procedures > Injection
repairs are complete, retest for
Quantity Adjustment.
SPN 656 FMI 13.
Do the IQA codes displayed in ServiceMaxx match the injectors
in the engine?

NOTE: After performing all diagnostic steps, if

SPN 656 FMI 13 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 461

SPN 656 FMI 16- Injector 6 Fuel quantity/timing high error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized for longer learned energizing time > Temperature (CACOT) > 14°F
than expected. 580 microseconds (-10°C)
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine Speed Steady: Engine
speed variation < 100 rpm, per
time > 3 seconds
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized longer than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low Fuel Delivery Pressure (FDP)
MIL will illuminate when this fault is detected during • Aerated fuel delivery
two consecutive drive cycles.
• Failed injector (Mechanical)
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); SPN 656 FMI 4, 5,
and 13 (CYL/INJ); and SPN 3055 FMI 0, 1, 15, and
17

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 462 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 656 FMI 4, 5, and 13 (CYL/INJ); and SPN 3055
SPN 656 FMI 4, 5, and 13; and
FMI 0, 1, 15, and 17.
SPN 3055 FMI 0, 1, 15 and 17.
Is EST DTC list free of SPN 94; SPN 157; SPN 656 FMI 4, 5, and After repairs are complete, retest
13; and SPN 3055 FMI 0, 1, 15, and 17? for SPN 656 FMI 16.

Step Action Decision

2 Check for low Fuel Delivery Pressure (FDP). Using EST, monitor Yes: Go to step 3.
FDP at idle.
No: Perform Low-pressure Fuel
Is FDP above 85 psi?? System tests (page 166). After
repairs are complete, retest for
SPN 656 FMI 16.

Step Action Decision

3 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 4.
Aeration Test (page 131).
No: Repair aeration in

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Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 656 FMI 16.

Step Action Decision

4 Run the fault monitors to determine source of fault. Yes: Clear fault.
• Using EST, load the HD-OBD monitors session. Click the No: Replace Injector 6. After
refresh button at the bottom to load the values. Save a screen repairs are complete, retest for
shot documenting the Injector quantity/timing error values. SPN 656 FMI 16.
• Clear all faults, Start the engine and run for 5 minutes at high
idle. Verify that the engine coolant temperature is above
160°F (71°C).
• Return the engine to normal idle for 5 minutes
• Using the HD-OBD monitors session monitor the injector
timing quantity error values. Refresh the page using the
refresh button at the bottom and save a screen shot of the
new values.
• Compare last screen shot to the previous. Verify all values
changed from the previous screen shot indicating the monitors
have run properly.
Is EST DTC list free from SPN 656 FMI 16?

NOTE: After performing all diagnostic steps, if

SPN 656 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 463

SPN 656 FMI 18- Injector 6 Fuel quantity/timing low error

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel injector is The sum of actual and Charge Air Cooler Outlet 1 second
energized shorter than learned fuel rail pressure Temperature (CACOT) > 14°F
expected. energizing times < 320 (-10°C)
microseconds
Engine Coolant Temperature 1
(ECT1) > 158°F (70°C) and <
239°F (115°C)
Engine speed steady: Engine
speed variation < 100 rpm, per
time > 3 seconds]
Ambient air pressure (BARO) >
11.6 psi (80 kpa) and < 16 psi
(110 kpa)
Idle speed error < 50 rpm
Engine speed < 800 rpm
Fuel command > 6 mg/stroke

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and < 66 mg / stroke
Vehicle stationary
Time in entry conditions > 2
seconds
Fuel rail pressure deviation <
725 psi (5000 kpa)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects fuel injector is energized shorter than Manual.
expected.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Contaminated fuel
MIL will illuminate when this fault is detected during • Failed injector (Mechanical)
two consecutive drive cycles.
• Base engine compression imbalance
Associated Faults
SPN 94 (FDP); SPN 157 (FRP); and SPN 656 FMI 4,
5, and 13 (CYL/INJ)

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 464 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); and SPN 656 FMI 4, 5, and 13 (CYL/INJ).
and SPN 656 FMI 4, 5, and 13.
Is EST DTC list free of SPN 94; SPN 157; and SPN 655 FMI 4, After repairs are complete, retest
5, and 13? for SPN 656 FMI 18.

Step Action Decision

2 Check fuel for contamination. Perform Fuel Quality Check (page Yes: Drain fuel tank and fill fuel
154). tank with appropriate diesel fuel.
After repairs are complete, retest
Is the fuel contaminated?
for SPN 656 FMI 18.
No: Go to step 3.

Step Action Decision

3 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for

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SPN 656 FMI 18.
Does engine have excessive crankcase pressure?
No: Go to step 4.

Step Action Decision

4 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 5.
Cylinder Cutout Test (page 182).
No: Retest for SPN 656 FMI 18.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

5 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 656 FMI 18.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 656 FMI
18.

NOTE: After performing all diagnostic steps, if

SPN 656 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

468
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 465

SPN 1322 FMI 31- Misfire- Multiple Cylinders

Condition /
Description
Crankshaft acceleration Misfire Count > 180
indicates misfire on
multiple cylinders.
Setting Criteria Enable Conditions / Values Time Required
Engine Running 440 engine
revolutions
Engine speed > 500 rpm and <
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
2798 (INJ)
Fault code sets when the Engine Control Module

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(ECM) detects multiple cylinder misfires from the
Drive Cycle to Determine Fault Status
Crankshaft Position (CKP) sensor signal.
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Malfunction Indicator Lamp (MIL) Reaction Manual.
MIL will illuminate when this fault is detected during Possible Causes
two consecutive drive cycles.
• Low Fuel Delivery Pressure (FDP)
Associated Faults • Low Fuel Rail Pressure (FRP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and • Crankshaft Position (CKP) sensor out of
SPN 3055 (FRP) calibration
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP); • Contaminated fuel
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN
• Failed injector (Mechanical)
1323 (CYL); SPN 1324 (CYL); SPN 1325 (CYL); SPN
1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL) • Base engine compression imbalance
SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /

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 466 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1322 FMI 31.

Step Action Decision

2 Using EST with ServiceMaxx™ software, check Diagnostic Yes: Go to step 3.
Trouble Code (DTC) list for SPN 111 (EWPS); SPN 636 FMI 2, 8,
No: Repair SPN 111; SPN 636
and 10 (CMP); SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL);
FMI 2, 8, and 10; SPN 637 FMI
SPN 1323 (CYL); SPN 1324 (CYL); SPN 1325 (CYL); SPN 1326
8 and 10; SPN 731; SPN 1323;
(CYL); SPN 1327 (CYL); and SPN 1328 (CYL).
SPN 1324; SPN 1325; SPN
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN 1326; SPN 1327; and SPN 1328.
637 FMI 8 and 10; SPN 731; SPN 1323; SPN 1324; SPN 1325; After repairs are complete, retest
SPN 1326; SPN 1327; and SPN 1328? for SPN 1322 FMI 31.

Step Action Decision

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3 Using EST with ServiceMaxx™ software, check Diagnostic Yes: Go to step 4.
Trouble Code (DTC) list for SPN 651 (CYL/INJ); SPN 652 (CYL/
No: Repair SPN 651; SPN
INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
652; SPN 653; SPN 654; SPN
INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN 2798 (INJ).
655; SPN 656; SPN 2797; and
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; SPN 2798. After repairs are
SPN 655; SPN 656; SPN 2797; and SPN 2798? complete, retest for SPN 1322
FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1322 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 467

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1322 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1322 FMI 31.

Step Action Decision

7 Using EST with ServiceMaxx software, perform crank sensor Yes: Go to step 8.
relearn procedure.
1. Select Sessions > Programming > Service Interval (tab) >
Crankshaft Position Learning Reset Request (ID 95232).
2. In Value field select Yes from the drop-down menu.
3. Select Program Engine button (when finished
programming Value field will switch back to No).

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4. Clear Fault Code and perform drive cycle 2.
Did SPN 1322 FMI 31 become active?

Step Action Decision

8 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1322 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 9.

Step Action Decision

9 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 10.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1322 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

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 468 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

10 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1322 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1322
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1322 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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472
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 469

SPN 1323 FMI 31- Misfire- Cylinder 1

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 1.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

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INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 1 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1324 (CYL); SPN 1325 (CYL); SPN
• Base engine compression imbalance
1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL)

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 470 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1323 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637 FMI
SPN 731 (CYL); SPN 1322 (CYL); SPN 1324 (CYL); SPN 1325
8 and 10; SPN 731; SPN 1322;
(CYL); SPN 1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL).
SPN 1324; SPN 1325; SPN
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN 1326; SPN 1327; and SPN 1328.
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1324; SPN 1325; After repairs are complete, retest
SPN 1326; SPN 1327; and SPN 1328? for SPN 1323 FMI 31.

Step Action Decision

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3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1323
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1323 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

474
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 471

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1323 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1323 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1323 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

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8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1323 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1323 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1323
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1323 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

475
 472 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1324 FMI 31- Misfire- Cylinder 2

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 2.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

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INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 2 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1324 (CYL); SPN 1325 (CYL); SPN
• Base engine compression imbalance
1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL)

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 473

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1324 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637 FMI
SPN 731 (CYL); SPN 1322 (CYL); SPN 1324 (CYL); SPN 1325
8 and 10; SPN 731; SPN 1322;
(CYL); SPN 1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL).
SPN 1323; SPN 1325; SPN
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN 1326; SPN 1327; and SPN 1328.
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1324; SPN 1325; After repairs are complete, retest
SPN 1326; SPN 1327; and SPN 1328? for SPN 1324 FMI 31.

Step Action Decision

BetterManuals.net
3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1324
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1324 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

477
 474 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1324 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1324 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1324 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

BetterManuals.net
8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1324 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1324 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1324
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1324 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

478
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 475

SPN 1325 FMI 31- Misfire- Cylinder 3

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 3.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

BetterManuals.net
INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 3 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1323 (CYL); SPN 1324 (CYL); SPN
• Base engine compression imbalance
1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL)

479
 476 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1325 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637 FMI
SPN 731 (CYL); SPN 1322 (CYL); SPN 1323 (CYL); SPN 1324
8 and 10; SPN 731; SPN 1322;
(CYL); SPN 1325 (CYL); SPN 1326 (CYL); SPN 1327 (CYL); and
SPN 1323; SPN 1324; SPN
SPN 1328 (CYL).
1326; SPN 1327; and SPN 1328.
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN After repairs are complete, retest
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1323; SPN 1324; for SPN 1325 FMI 31.
SPN 1325 ; SPN 1326; SPN 1327; and SPN 1328?

Step Action Decision

BetterManuals.net
3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1325
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1325 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

480
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 477

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1325 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1325 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1325 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

BetterManuals.net
8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1325 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1325 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1325
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1325 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

481
 478 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1326 FMI 31- Misfire- Cylinder 4

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 4.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

BetterManuals.net
INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 4 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1323 (CYL); SPN 1324 (CYL); SPN
• Base engine compression imbalance
1325 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL)

482
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 479

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1326 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637 FMI
SPN 731 (CYL); SPN 1322 (CYL); SPN 1323 (CYL); SPN 1324
8 and 10; SPN 731; SPN 1322;
(CYL); SPN 1325 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL).
SPN 1323; SPN 1324; SPN
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN 1325; SPN 1327; and SPN 1328.
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1323; SPN 1324; After repairs are complete, retest
SPN 1325; SPN 1327; and SPN 1328? for SPN 1326 FMI 31.

Step Action Decision

BetterManuals.net
3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1326
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1326 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

483
 480 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1326 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1326 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1326 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

BetterManuals.net
8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1326 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1326 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1326
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1326 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

484
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 481

SPN 1327 FMI 31- Misfire- Cylinder 5

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 5.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

BetterManuals.net
INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 5 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1323 (CYL); SPN 1324 (CYL); SPN
• Base engine compression imbalance
1325 (CYL); SPN 1326 (CYL); and SPN 1328 (CYL)

485
 482 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1327 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637 FMI
SPN 731 (CYL); SPN 1322 (CYL); SPN 1323 (CYL); SPN 1324
8 and 10; SPN 731; SPN 1322;
(CYL); SPN 1325 (CYL); SPN 1326 (CYL); and SPN 1328 (CYL).
SPN 1323; SPN 1324; SPN
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN 1325 ; SPN 1326; SPN 1327;
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1323; SPN 1324; and SPN 1328. After repairs are
SPN 1325; SPN 1326; and SPN 1328? complete, retest for SPN 1327
FMI 31.

Step Action Decision

BetterManuals.net
3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1327
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1327 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

486
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 483

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1327 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1327 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1327 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

BetterManuals.net
8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1327 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1327 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1327
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1327 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

487
 484 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1328 FMI 31- Misfire- Cylinder 6

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Crankshaft acceleration Misfire Count > 180 Engine Running 440 engine
indicates misfire on revolutions
Engine speed > 500 rpm and <
cylinder 6.
950 rpm
Idle speed error < 200 rpm
Fuel command > 2 mg / stroke
and < 60mg / stroke
Engine Coolant Temperature 1
(ECT1) > 86°F (30°C)
Vehicle speed < 2 mph (3 km/h)
Diesel Particulate Filter (DPF)
Not regenerating

Fault Overview SPN 651 (CYL/INJ); SPN 652 (CYL/ INJ); SPN 653
(CYL / INJ); SPN 654 (CYL / INJ); SPN 655 (CYL /
Fault code sets when the Engine Control Module

BetterManuals.net
INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and SPN
(ECM) detects a cylinder 6 misfire from the Crankshaft
2798 (INJ)
Position (CKP) sensor.
Drive Cycle to Determine Fault Status
Malfunction Indicator Lamp (MIL) Reaction
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
MIL will illuminate when this fault is detected during
Manual.
two consecutive drive cycles.
Possible Causes
Associated Faults
• Low Fuel Delivery Pressure (FDP)
SPN 94 (FDP); SPN 157 (FRP); SPN 633 (FPCV); and
• Low Fuel Rail Pressure (FRP)
SPN 3055 (FRP)
• Contaminated fuel
SPN 111 (EWPS); SPN 636 FMI 2, 8, and 10 (CMP);
SPN 637 FMI 8 and 10 (CKP); SPN 731 (CYL); SPN • Failed injector (Mechanical)
1322 (CYL); SPN 1324 (CYL); SPN 1325 (CYL); SPN
• Base engine compression imbalance
1326 (CYL); SPN 1327 (CYL); and SPN 1328 (CYL)

488
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 485

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 (FDP); SPN
No: Repair SPN 94; SPN 157;
157 (FRP); SPN 633 (FPCV); and SPN 3055 (FRP).
SPN 633; and SPN 3055. After
Is EST DTC list free of SPN 94; SPN 157; SPN 633; and SPN repairs are complete, retest for
3055? SPN 1328 FMI 31.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 111 (EWPS);
No: Repair SPN 111; SPN 636
SPN 636 FMI 2, 8, and 10 (CMP); SPN 637 FMI 8 and 10 (CKP);
FMI 2, 8, and 10; SPN 637
SPN 731 (CYL); SPN 1322 (CYL); SPN 1323 (CYL); SPN 1324
FMI 8 and 10; SPN 731; SPN
(CYL); SPN 1325 (CYL); SPN 1326 (CYL); and SPN 1327 (CYL).
1322; SPN 1323; SPN 1324;
Is EST DTC list free of SPN 111; SPN 636 FMI 2, 8, and 10; SPN SPN 1325 ; SPN 1326; and
637 FMI 8 and 10; SPN 731; SPN 1322; SPN 1323; SPN 1324; SPN 1327. After repairs are
SPN 1325 ; SPN 1326; and SPN 1327? complete, retest for SPN 1328
FMI 31.

Step Action Decision

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3 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
check Diagnostic Trouble Code (DTC) list for SPN 651 (CYL/INJ);
No: Repair SPN 651; SPN
SPN 652 (CYL/ INJ); SPN 653 (CYL / INJ); SPN 654 (CYL / INJ);
652; SPN 653; SPN 654; SPN
SPN 655 (CYL / INJ); SPN 656 (CYL / INJ); SPN 2797 (INJ); and
655; SPN 656; SPN 2797; and
SPN 2798 (INJ).
SPN 2798. After repairs are
Is EST DTC list free of SPN 651; SPN 652; SPN 653; SPN 654; complete, retest for SPN 1328
SPN 655; SPN 656; SPN 2797; and SPN 2798? FMI 31.

Step Action Decision

4 Check for poor fuel quality or contaminants. Perform Fuel Quality Yes: Go to step 5.
Check (page 154).
No: Drain fuel and fill with new
Is fuel sample clean and free of sediments, traces of gasoline or or known good diesel fuel. After
kerosene, and waxing or icing? repairs are complete, retest for
SPN 1328 FMI 31.

Step Action Decision

5 Using EST with ServiceMaxx software, check Fuel Rail Pressure Yes: Go to step 7.
(FRP). Select Sessions > Performance. Start engine and monitor
No: Go to step 6.
FRP.
Is Fuel Rail Pressure 10,500 psi (72,395 kPa) or greater?

489
 486 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Using EST with ServiceMaxx software, check Fuel Delivery Yes: Perform High-pressure
Pressure (FDP). Select Sessions > Performance. Start engine Fuel System tests (page 174).
and monitor FDP. After repairs are complete, retest
for SPN 1328 FMI 31.
Is Fuel Delivery Pressure 60 psi (414 kpa) or greater?
No: Perform Low-pressure Fuel
System tests (page 166). After
repairs are complete, retest for
SPN 1328 FMI 31.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 1328 FMI 31.
Does engine have excessive crankcase pressure?
No: Go to step 8.

Step Action Decision

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8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Retest for SPN 1328 FMI
Did one or more cylinders have significant speed difference(s) 31.
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 1328 FMI 31.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 1328
FMI 31.

NOTE: After performing all diagnostic steps, if

SPN 1328 FMI 31 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

490
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 487

DOCIT Sensor (Diesel Oxidation Catalyst Inlet

Temperature)

SPN FMI Condition Possible Causes Actions

4765 2 DOCIT signal erratic, intermittent, or incorrect • Failed DOCIT Step-Based
sensor Diagnostics (page
490)
• High resistance
in DOCIT circuit
• High resistance
in SIG GND
circuit
4765 3 DOCIT signal Out-of-Range HIGH • High resistance Step-Based
or open in SIG Diagnostics (page
GND circuit 493)
• High resistance
or open in
DOCIT circuit
• Short to PWR in
DOCIT circuit

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• Failed DOCIT
sensor
4765 4 DOCIT signal Out-of-Range LOW • Short to GND in Step-Based
DOCIT circuit Diagnostics (page
496)
• SIG GND circuit
shorted to
DOCIT circuit
• Failed DOCIT
sensor

491
 488 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

4765 20 DOCIT signal drifted HIGH • DOCIT signal Step-Based

short to PWR Diagnostics (page
498)
• SIG GND circuit
high resistance
• Failing DOCIT
sensor
4765 21 DOCIT signal drifted LOW • Failing DOCIT Step-Based
sensor Diagnostics (page
500)
• Exhaust system
leak
• DOCIT signal
circuit short to
GND
• DOCIT signal
circuit high
resistance

DOCIT circuit

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ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view)
connector
DOCIT_ _ _ _ _.....
>---+-___,;_....;.._ 1
Pin C1 - 28 2
1--+-=S'-'-IG.: ;. . . ;: G;.;. .N=D_ _ ____..... 2 1
Pin C1 - 22

~
1: I LJ
I:
Exhaust Sensor
connector (end view) V00050

Figure 204 DOCIT circuit diagram

NOTE: See latest version of Maxxforce 11 / 13
Engine and Aftertreatment Wiring Schematic
Form 0000002941 for additional circuit
information.
Overview
The Diesel Oxidation Catalyst Inlet Temperature
(DOCIT) sensor is a thermistor-style sensor that
measures temperature between the Pre-Diesel
Oxidation Catalyst (Pre-DOC) and the Diesel
Oxidation Catalyst (DOC). As temperature increases,
resistance values drop. This change of resistance
varies the voltage that is sent to the Engine Control
Module (ECM). The DOCIT sensor works with
the Diesel Oxidation Catalyst Outlet Temperature
(DOCOT), Diesel Particulate Filter Outlet Temperature
(DPFOT), and Diesel Particulate Filter Differential
Pressure (DPFDP) sensors to indicate operation and
control the regeneration cycles of the Aftertreatment
(AFT) system via the ECM.
Tools Required
• 00-00956-08 - 180-Pin Breakout Box
• ZTSE4498 - 3-Banana Plug Harness
• ZTSE4497 - 500 Ohm Resistor Harness
• ZTSE4899 - Big Bore Terminal Test Probe Kit

492
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 489

• Breakout Harness ZTSE4760A (DOCIT)

• Digital Multimeter (DMM)
1

• Electronic Service Tool (EST) with ServiceMaxx™

software
• J1939 and J1708 RP1210B Compliant Device

0000047039

Figure 205 DOCIT Sensor Location (Typical)

1. Diesel Oxidation Catalyst Inlet Temperature (DOCIT)

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sensor

493
 490 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4765 FMI 2 DOCIT signal does not agree with other exhaust sensors
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
The Diesel Oxidation Difference between Key-On Engine-Running 5 seconds
Catalyst Inlet DOCIT, Diesel Oxidation (KOER) > 120 seconds
Temperature (DOCIT) Catalyst Outlet
Engine is cold soaked
is not changing with Temperature (DOCOT),
engine operating and Diesel Particulate Engine speed > 1300 RPM
conditions (in-range Filter Outlet Temperature
Injection Quantity > 150 mg /
but not rational). (DPFOT) > 27°F (15°C).
stroke
DOCIT < 212°F (100°C).
Intake Manifold Pressure (IMP)
> 200 kpa
Enable Condition met > 45
seconds

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

Fault code sets when the Engine Control Module MIL will illuminate when this fault is detected during
(ECM) detects the difference between the Diesel two consecutive drive cycles.

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Oxidation Catalyst Inlet Temperature (DOCIT), Diesel
Oxidation Catalyst Outlet Temperature (DOCOT), and Associated Faults
Diesel Particulate Filter Outlet Temperature (DPFOT)
SPN 3246 FMI 3 and 4 (DPFOT); SPN 4766 FMI 3
readings do not match expected values for engine
and 4 (DOCOT)
operating conditions. Active and parked regeneration
of the DPF will be disabled. Engine torque will be
Drive Cycle to Determine Fault Status
reduced if the engine is operated for an extended
period of time with this fault active. Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

494
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 491

DOCIT circuit
ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view)
connector 2
DOCIT
Pin C1 - 28 2
SIG GND
Pin C1 - 22

~
1: I LJ
I~
Exhaust Sensor
connector (end view) V00050

Figure 206 DOCIT circuit diagram

Possible Causes
• Failed Diesel Oxidation Catalyst Inlet (DOCIT)
sensor

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• High resistance in DOCIT circuit
• High resistance in SIG GND circuit

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 3 and
No: Repair SPN 3246 FMI 3 and
4 (DPFOT); SPN 4766 FMI 3 and 4 (DOCOT).
4; SPN 4766 FMI 3 and 4. After
Is EST DTC list free of SPN 3246 FMI 3 and 4; SPN 4766 FMI 3 repairs are complete, retest for
and 4? SPN 4765 FMI 2.

Step Action Decision

2 Inspect connections at Diesel Oxidation Catalyst Inlet Temperature Yes: Go to step 3.
(DOCIT) sensor. Key OFF, disconnect DOCIT sensor connector.
No: Repair connector, harness,
Check DOCIT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 4765 FMI 2.
Are the DOCIT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4765 FMI 2.
undamaged?

495
 492 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Check DOCIT circuit for high resistance. Connect Breakout Yes: Go to step 5.
Harness ZTSE4760A to DOCIT harness and leave DOCIT
No: Repair high resistance
disconnected. Connect 180-pin Breakout Box with ECM Breakout
between DOCIT connector pin-2
Harness 00-01467-00 to ECM C1 harness, and leave ECM
and ECM connector pin C1-28.
disconnected. Key OFF, use a DMM to measure resistance from
After repairs are complete, retest
Breakout Harness pin-2 and Breakout Box pin C1-28.
for SPN 4765 FMI 2.
Is resistance less than 5 ohms?

Step Action Decision

5 Check SIG GND circuit for high resistance. Connect Breakout Yes: Replace DOCIT sensor.
Harness ZTSE4760A to DOCIT harness and leave DOCIT After repairs are complete, retest
disconnected. Connect 180-pin Breakout Box with ECM Breakout for SPN 4765 FMI 2.
Harness 00-01467-00 to Chassis C1 harness, and leave ECM
No: Repair high resistance
disconnected. Key OFF, use a DMM to measure resistance from
between DOCIT connector pin-1
Breakout Harness pin-1 and Breakout Box pin C1-22.
and ECM connector pin C1-22.
Is resistance less than 5 ohms? After repairs are complete, retest
for SPN 4765 FMI 2.

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NOTE: After performing all diagnostic steps, if
SPN 4765 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

496
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 493

SPN 4765 FMI 3 DOCIT signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation DOCIT sensor input Key ON 0.5 seconds
Catalyst Inlet voltage ≥ 5 volts
Temperature (DOCIT)
circuit short to PWR.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) sensor signal voltage is greater
than expected. Active and parked regeneration of the
DPF will be disabled. Engine torque will be reduced if
the engine is operated for an extended period of time
with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DOCIT circuit
ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view)
connector
DOCIT
Pin C1 - 28 1 2
SIG GND
>---+-""---"---'----------, 2 1
Pin C1 - 22

~
1: I LJ
I:
Exhaust Sensor
connector (end view) V00050

Figure 207 DOCIT circuit diagram

Possible Causes • Short to PWR in DOCIT circuit

• High resistance or open in SIG GND circuit • Failed DOCIT sensor
• High resistance or open in DOCIT circuit

497
 494 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Diesel Oxidation Catalyst Inlet Temperature Yes: Go to step 2.
(DOCIT) sensor. Key OFF, disconnect DOCIT sensor connector.
No: Repair connector, harness,
Check DOCIT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 4765 FMI 3.
Are the DOCIT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DOCIT circuit for short to PWR. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DOCIT sensor
No: Repair short to power in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DOCIT circuit between ECM pin
between Breakout Harness pin-2 and a known good ground.
C1-28 and DOCIT sensor pin-2.
Is voltage within 0.5 volts of 5 volts? After repairs are complete, retest
for SPN 4765 FMI 3.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4765 FMI 3.
undamaged?

Step Action Decision

4 Check DOCIT circuit for high resistance or Open. Connect 180-pin Yes: Go to step 5.
Breakout Box with Breakout Harness 00-01467-00 to vehicle
No: Repair Open or high
harness, and leave ECM disconnected. With Breakout Harness
resistance in DOCIT circuit
ZTSE4760A connected to vehicle harness and with DOCIT sensor
between ECM pin C1-28 and
disconnected. Use a DMM to measure resistance from Breakout
DOCIT sensor pin-2. After
Box pin C1-28 and Breakout Harness pin-2.
repairs are complete, retest for
Is resistance less than 5 ohms? SPN 4765 FMI 3.

498
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 495

Step Action Decision

5 Check SIG GND circuit for high resistance or Open. Connect Yes: Replace DOCIT sensor.
180-pin Breakout Box with Breakout Harness 00-01467-00 to After repairs are complete, retest
vehicle harness, and leave ECM disconnected. With Breakout for SPN 4765 FMI 3.
Harness ZTSE4760A connected to vehicle harness and with
No: Repair Open or high
DOCIT sensor disconnected. Use a DMM to measure resistance
resistance in SIG GND circuit
from Breakout Box pin C1-22 and Breakout Harness pin-1.
between ECM pin C1-22 and
Is resistance less than 5 ohms? DOCIT sensor pin-1. After
repairs are complete, retest for
SPN 4765 FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 4765 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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499
 496 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4765 FMI 4 DOCIT signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation DOCIT signal ≤ 0.05 volt Key-On Engine-Running 0.5 seconds
Catalyst Inlet (KOER)
Temperature (DOCIT)
circuit short to ground.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) sensor signal voltage is less
than 0.05 volts for more than 0.5 seconds. Active
and parked regeneration of the DPF will be disabled.
Engine torque will be reduced if the engine is operated
for an extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DOCIT circuit
ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view)
connector 2
DOCIT
Pin C1 - 28 1 2
SIG GND
Pin C1 - 22 ---'--'----'------~2 1
~
1: I LJ
I:
Exhaust Sensor
connector (end view) V00050

Figure 208 DOCIT circuit diagram

Possible Causes • SIG GND circuit shorted to DOCIT circuit

• Short to GND in DOCIT circuit • Failed DOCIT sensor

500
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 497

Step Action Decision

1 Inspect connections at Diesel Oxidation Catalyst Inlet Temperature Yes: Go to step 2.
(DOCIT) sensor. Key OFF, disconnect DOCIT sensor connector.
No: Repair connector, harness,
Check DOCIT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 4765 FMI 4.
Are the DOCIT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DOCIT circuit for short to GND. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DOCIT sensor
No: Repair short to GND in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DOCIT circuit between ECM pin
between Breakout Harness pin-2 and a known good ground.
C1-28 and DOCIT sensor pin-2.
Is voltage within 0.5 volts of 5 volts? After repairs are complete, retest
for SPN 4765 FMI 4.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4765 FMI 4.
undamaged?

Step Action Decision

4 Check for short between DOCIT and SIG GND circuits. Connect Yes: Replace DOCIT sensor.
Breakout Harness ZTSE4760A and leave DOCIT sensor After repairs are complete, retest
disconnected. Key OFF, disconnect ECM and measure resistance for SPN 4765 FMI 4.
between Breakout Harness pin-1 and pin-2.
No: Repair short between
Is resistance greater than 1000 ohms? DOCIT and SIG GND circuits.
After repairs are complete, retest
for SPN 4765 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 4765 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

501
 498 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4765 FMI 20 - DOCIT signal drifted HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Oxidation Catalyser Time after successful regen 10 Seconds
Catalyst Inlet Upstream temperature > Complete > 10 minutes
Temperature (DOCIT) 842°F (450°C)
Time after Key On > 0 seconds
sensor rationality offset
high. Battery voltage > 10.7 Volts
Battery voltage <15 Volts

Fault Overview
Fault sets when the Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) sensor is reading above 842°F
(450°C) for approximately 300–600 seconds after
aftertreatment regeneration is completed.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

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Associated Faults
SPN 2659

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DOCIT circuit
ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view) sensor
connector 2
DOCIT
l---+--;;;_;;;;.....;;;..;..'--------1 1
Pin C1 - 28 2
SIG GND
Pin C1 - 22

~
1: I LJ
I:
Exhaust Sensor
connector (end view) V00050

Figure 209 DOCIT circuit diagram

502
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 499

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4765 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 4765 FMI 20.

Step Action Decision

2 Inspect connections at Diesel Oxidation Catalyst Inlet (DOCIT) Yes: Go to step 3.
sensor. Key OFF, disconnect DOCIT sensor connector. Check
No: Repair connector, harness,
DOCIT sensor and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 4765 FMI 20.
Is the DOCIT sensor connector, harness, and terminal clean and
undamaged?

Step Action Decision

3 Check DOCIT circuit for short to power. In ServiceMaxx start Yes: Go to step 4.
Continuous Monitor test. Key-On Engine-Off, with DOCIT sensor
No: Repair short to power

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connected.
between DOCIT connector pin 2
Does ServiceMaxx™ software show DOCIT voltage less than to ECM 58-pin connector C1 pin
5.5 volts? 28 . After repairs are complete,
retest for SPN 4765 FMI 20.

Step Action Decision

4 Check SIG GND circuit for high resistance. With DOCIT sensor Yes: Replace DOCIT sensor.
disconnected, connect Breakout Harness ZTSE4760A. Measure
No: Repair high resistance
resistance between DOCIT connector pin 1 and a known good
between DOCIT connector pin
ground.
1 and ECM 58-pin connector
Is resistance less then 5 ohms? C1 pin 22 . After repairs are
complete, retest for SPN 4765
FMI 20.

NOTE: After doing all diagnostic steps, if SPN

4765 FMI 20 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

503
 500 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4765 FMI 21 - DOCIT signal drifted LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation Oxidation Catalyser Engine speed > 1400 rpm 10 Seconds
Catalyst Inlet Upstream temperature >
Injection quantity > 115 mg /
Temperature (DOCIT) 392°F (200°C)
stroke
sensor rationality offset
low. Intake Manifold Pressure (IMP)
> 120 kPa
In above conditions > 45
seconds
Time after Key On > 0 seconds
Battery voltage > 10.7 Volts
Battery voltage <15 Volts

Fault Overview Associated Faults

Fault sets when the Diesel Oxidation Catalyst Inlet SPN 2659
Temperature (DOCIT) sensor is reading below 392°F

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(200°C) for approximately 45 seconds with enable Drive Cycle to Determine Fault Status
conditions met.
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Malfunction Indicator Lamp (MIL) Reaction
When fault is active, MIL will not illuminate.

504
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 501

DOCIT circuit
ECM 58-Pin DOCIT
C1 connector connector DOCIT
DOCIT
(end view)
connector 2
DOCIT
Pin C1 - 28 2
SIG GND
Pin C1 - 22

~
1: I LJ
I~
Exhaust Sensor
connector (end view) V00050

Figure 210 DOCIT circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 4765 FMI 21 the only fault code active? After repairs are complete, retest

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for SPN 4765 FMI 21.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air leaks,
system from fuel tank to AFI valve for leaks or physical damage.
fuel leaks or physical damage.
Is air intake system, exhaust system, fuel system and air filter free After repairs are complete, retest
of restrictions, leaks, and physical damage? for SPN 4765 FMI 21.

Step Action Decision

3 Inspect connections at Diesel Oxidation Catalyst Inlet (DOCIT) Yes: Go to step 4.
sensor. Key OFF, disconnect DOCIT sensor connector. Check
No: Repair connector, harness,
DOCIT sensor and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 4765 FMI 21.
Is the DOCIT sensor connector, harness, and terminal clean and
undamaged?

505
 502 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Check DOCIT circuit for short to ground. Connect Breakout Yes: Go to step 4.
Harness ZTSE4760A to DOCIT sensor connector and leave
No: Repair short to ground
DOCIT sensor disconnected. Use a DMM to measure resistance
between DOCIT connector pin
between Breakout harness ZTSE4760A test point 2 and a known,
2 and ECM 58-pin connector
good ground.
C1 pin 28. After repairs are
Is resistance greater than 1000 ohms? complete, retest for SPN 4765
FMI 21.

Step Action Decision

5 Check DOCIT circuit for high resistance or Open. In ServiceMaxx Yes: Replace DOCIT sensor.
start Continuous Monitor test. Key-On Engine-Off, with Breakout
No: Repair high resistance
Harness ZTSE4760A connected, short DOCIT connector pin 1
between DOCIT connector pin
to pin 2.
2 and ECM 58-pin connector
Does ServiceMaxx software show DOCIT voltage of 4.5 volts or C1 pin 28. After repairs are
more? complete, retest for SPN 4765
FMI 21.

NOTE: After doing all diagnostic steps, if SPN

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4765 FMI 21 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

506
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 503

DOCOT Sensor (Diesel Oxidation Catalyst Outlet

Temperature)

SPN FMI Condition Possible Causes Actions

4766 2 DOCOT signal does not agree with other • Failed DOCOT Step-Based
exhaust sensors sensor Diagnostics (page
505)
• High resistance
in DOCOT
circuit
• High resistance
in SIG GND
circuit
4766 3 DOCOT signal Out of Range HIGH • High resistance Step-Based
or open in SIG Diagnostics (page
GND circuit 509)
• High resistance
or open in
DOCOT circuit
• Short to PWR in

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DOCOT circuit
• Failed DOCOT
sensor
4766 4 DOCOT signal Out of Range LOW • Short to GND in Step-Based
DOCOT circuit Diagnostics (page
512)
• SIG GND circuit
shorted to
DOCOT circuit
• Failed DOCOT
sensor

507
 504 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DOCOT circuit
ECM 58-Pin DOCOT
connector DOCOT
C1 connector DOCOT
(end view) sensor
connector
PinC1-16

Pin C1 - 55
}--+....oo::..:.o=c....oo""'"T-=-------,
SIG GND
3
4
-!27
------W 1

~
1: I LJ
I;
Exhaust Sensor
connector (end view)
V00051

Figure 211 DOCOT sensor circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 (DPFDP) sensors to indicate operation and control
Engine and Aftertreatment Wiring Schematic the regeneration cycles of the Aftertreatment (AFT)
Form 0000002941 for additional circuit system via the ECM.
information.
Tools Required

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Overview • 00-00956-08 - 180-Pin Breakout Box
The Diesel Oxidation Catalyst Outlet Temperature • ZTSE4498 - 3-Banana Plug Harness
(DOCOT) sensor is a thermistor-style sensor
• ZTSE4497 - 500 Ohm Resistor Harness
that measures temperature between the Diesel
Oxidation Catalyst (DOC) and the Diesel Particulate • ZTSE4899 - Big Bore Terminal Test Probe Kit
Filter (DPF). As temperature increases, resistance
• Breakout Harness ZTSE4760A (DOCOT)
values drop. This change of resistance varies the
voltage that is sent to the Engine Control Module • Digital Multimeter (DMM)
(ECM). The DOCOT sensor works with the Diesel
• Electronic Service Tool (EST) with ServiceMaxx™
Oxidation Catalyst Inlet Temperature (DOCIT), Diesel
software
Particulate Filter Outlet Temperature (DPFOT),
and Diesel Particulate Filter Differential Pressure • J1939 and J1708 RP1210B Compliant Device

508
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 505

SPN 4766 FMI 2 - DOCOT signal does not agree with other exhaust sensors
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
The Diesel Oxidation Difference between Engine is cold soaked 0.5 seconds
Catalyst Outlet Diesel Oxidation Catalyst
Temperature (DOCOT) Inlet Temperature
is not changing with (DOCIT), DOCOT, and
engine operating Diesel Particulate Filter
conditions (in-range Outlet Temperature
but not rational). (DPFOT) > 27°F (15°C).

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

Fault code sets when the Engine Control Module MIL will illuminate when this fault is detected during
(ECM) detects the difference between the Diesel two consecutive drive cycles.
Oxidation Catalyst Inlet Temperature (DOCIT), Diesel
Oxidation Catalyst Outlet Temperature (DOCOT), and Associated Faults
Diesel Particulate Filter Outlet Temperature (DPFOT)
SPN 3246 FMI 3 and 4 (DPFOT); SPN 4765 FMI 3
readings do not match expected values for engine
and 4 (DOCIT)
operating conditions. Active and parked regeneration
of the DPF will be disabled. Engine torque will be

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reduced if the engine is operated for an extended
period of time with this fault active.
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

509
 506 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DOCOT circuit
ECM 58-Pin DOCOT
connector DOCOT
C1 connector DOCOT
(end view) sensor
connector
PinC1-16

Pin C1 - 55
}--+....oo::..:.o=c....oo""'"T-=-------,
SIG GND
3
4
-!27
------W
1

~
1: I LJ
I;
Exhaust Sensor
connector (end view)
V00051

Figure 212 DOCOT sensor circuit diagram

Possible Causes
• Failed Diesel Oxidation Catalyst Inlet (DOCOT)
sensor

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• High resistance in DOCOT circuit
• High resistance in SIG GND circuit

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 3 and
No: Repair SPN 3246 FMI 3 and
4 (DPFOT); SPN 4765 FMI 3 and 4 (DOCIT).
4; SPN 4765 FMI 3 and 4. After
Is EST DTC list free of SPN 3246 FMI 3 and 4; SPN 4765 FMI 3 repairs are complete, retest for
and 4? SPN 4766 FMI 2.

Step Action Decision

2 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 3.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT
No: Repair connector, harness,
sensor connector. Check DOCOT sensor and connector terminals
or terminal damage. After
for: damaged or pinched wires; corroded terminals; loose, bent, or
repairs are complete, retest for
broken pins; or broken connector housing.
SPN 4766 FMI 2.
Are the DOCOT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4766 FMI 2.
undamaged?

510
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 507

Step Action Decision

4 Check DOCOT circuit for high resistance. Connect Breakout Yes: Go to step 5.
Harness ZTSE4760A to DOCOT harness and leave DOCOT
No: Repair high resistance
disconnected. Connect 180-pin Breakout Box with ECM Breakout
between DOCOT connector
Harness 00-01467-00 to ECM C1 harness, and leave ECM
pin-2 and ECM connector
disconnected. Key OFF, use a DMM to measure resistance from
pin C1-16. After repairs are
Breakout Harness ZTSE4760A pin-2 and 180-pin Breakout Box
complete, retest for SPN 4766
pin C1-16.
FMI 2.
Is resistance less than 5 ohms?

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511
 508 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

5 Check SIG GND circuit for high resistance. Connect Breakout Yes: Replace DOCOT sensor.
Harness ZTSE4760A to DOCOT harness and leave DOCOT After repairs are complete, retest
disconnected. Connect 180-pin Breakout Box with ECM Breakout for SPN 4766 FMI 2.
Harness 00-01467-00 to Chassis C1 harness, and leave ECM
No: Repair high resistance
disconnected. Key OFF, use a DMM to measure resistance from
between DOCOT connector
Breakout Harness ZTSE4760A pin-1 and 180-pin Breakout Box
pin-1 and ECM connector
pin C1-55.
pin C1-55. After repairs are
Is resistance less than 5 ohms? complete, retest for SPN 4766
FMI 2.

NOTE: After performing all diagnostic steps, if

SPN 4766 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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512
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 509

SPN 4766 FMI 3 - DOCOT signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation DOCOT sensor input Key ON 0.5 seconds
Catalyst Outlet voltage ≥ 5 volts
Temperature (DOCOT)
circuit short to PWR.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the Diesel Oxidation Catalyst
Outlet Temperature (DOCOT) sensor signal voltage
is greater than expected. Active and parked
regeneration of the DPF will be disabled. Engine
torque will be reduced if the engine is operated for an
extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DOCOT circuit
ECM 58-Pin DOCOT
connector DOCOT
C1 connector DOCOT
(end view) sensor
connector 2
PinC1-16

Pin C1 - 55
)...
--1-...::D:..:..:O::...C..::::O.:....:T=-----, 3
SIG G ND 4
-127
-----GJ 1

~
,: I ., I~
Exhaust Sensor
connector (end view)
V00051

Figure 213 DOCOT sensor circuit diagram

Possible Causes • Short to PWR in DOCOT circuit

• High resistance or open in SIG GND circuit • Failed DOCOT sensor
• High resistance or open in DOCOT circuit

513
 510 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 2.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT
No: Repair connector, harness,
sensor connector. Check DOCOT sensor and connector terminals
or terminal damage. After
for: damaged or pinched wires; corroded terminals; loose, bent, or
repairs are complete, retest for
broken pins; or broken connector housing.
SPN 4766 FMI 3.
Are the DOCOT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DOCOT circuit for short to PWR. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DOCOT sensor
No: Repair short to power in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DOCOT circuit between ECM pin
between Breakout Harness pin-2 and a known good ground.
C1-16 and DOCOT sensor pin-2.
Is voltage within 0.5 volts of 5 volts? After repairs are complete, retest
for SPN 4766 FMI 3.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4766 FMI 3.
undamaged?

Step Action Decision

4 Check DOCOT circuit for high resistance or Open. Connect Yes: Go to step 5.
180-pin Breakout Box with Breakout Harness 00-01467-00 to
No: Repair Open or high
vehicle harness, and leave ECM disconnected. With Breakout
resistance in DOCOT circuit
Harness ZTSE4760A connected to vehicle harness and with
between ECM pin C1-16 and
DOCOT sensor disconnected. Use a DMM to measure resistance
DOCOT sensor pin-2. After
from Breakout Box pin C1-16 and Breakout Harness pin-2.
repairs are complete, retest for
Is resistance less than 5 ohms? SPN 4766 FMI 3.

514
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 511

Step Action Decision

5 Check SIG GND circuit for high resistance or Open. Connect Yes: Replace DOCOT sensor.
180-pin Breakout Box with Breakout Harness 00-01467-00 to After repairs are complete, retest
vehicle harness, and leave ECM disconnected. With Breakout for SPN 4766 FMI 3.
Harness ZTSE4760A connected to vehicle harness and with
No: Repair Open or high
DOCOT sensor disconnected. Use a DMM to measure resistance
resistance in SIG GND circuit
from Breakout Box pin C1-55 and Breakout Harness pin-1.
between ECM pin C1-55 and
Is resistance less than 5 ohms? DOCOT sensor pin-1. After
repairs are complete, retest for
SPN 4766 FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 4766 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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515
 512 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 4766 FMI 4 - DOCOT signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Oxidation DOCOT signal ≤ 0.5 volts Key-On Engine-Running 0.5 seconds
Catalyst Outlet (KOER)
Temperature (DOCOT)
circuit short to ground.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the Diesel Oxidation Catalyst Outlet
Temperature (DOCOT) sensor signal voltage is less
than 0.5 volts for more than 0.5 seconds. Active
and parked regeneration of the DPF will be disabled.
Engine torque will be reduced if the engine is operated
for an extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DOCOT circuit
ECM 58-Pin DOCOT
connector DOCOT
C1 connector DOCOT
(end view) sensor
connector
PinC1-16

Pin C1 - 55
)-
-+~D:.:..:O~C..:::O:.:...:T:..:::.,__ _--1 3
SIG G ND 4
-127
------GJ 1

~
,: I ., I~
Exhaust Sensor
connector (end view)
V00051

Figure 214 DOCOT sensor circuit diagram

Possible Causes • SIG GND circuit shorted to DOCOT circuit

• Short to GND in DOCOT circuit • Failed DOCOT sensor

516
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 513

Step Action Decision

1 Inspect connections at Diesel Oxidation Catalyst Outlet Yes: Go to step 2.
Temperature (DOCOT) sensor. Key OFF, disconnect DOCOT
No: Repair connector, harness,
sensor connector. Check DOCOT sensor and connector terminals
or terminal damage. After
for: damaged or pinched wires; corroded terminals; loose, bent, or
repairs are complete, retest for
broken pins; or broken connector housing.
SPN 4766 FMI 4.
Are the DOCOT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DOCOT circuit for short to GND. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DOCOT sensor
No: Repair short to GND in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DOCOT circuit between ECM
between Breakout Harness pin-2 and a known good ground.
pin C1-16 and DOCOT sensor
Is voltage within 0.5 volts of 5 volts? pin-2. After repairs are complete,
retest for SPN 4766 FMI 4.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 4766 FMI 4.
undamaged?

Step Action Decision

4 Check for short between DOCOT and SIG GND circuits. Connect Yes: Replace DOCOT sensor.
Breakout Harness ZTSE4760A and leave DOCOT sensor After repairs are complete, retest
disconnected. Key OFF, disconnect ECM and measure resistance for SPN 4766 FMI 4.
between Breakout Harness pin-1 and pin-2.
No: Repair short between
Is resistance greater than 1000 ohms? DOCOT and SIG GND circuits.
After repairs are complete, retest
for SPN 4766 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 4766 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

517
 514 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPFDP Sensor (Diesel Particulate Filter

Differential Pressure)

SPN FMI Condition Possible Causes Actions

3251 2 DPFDP signal erratic, intermittent, or • DPFDP circuit high Step-Based Diagnostics
incorrect resistance (page 517)
• Leaking or
Restricted DPFDP
hoses
• Failed DPFDP
sensor
3251 3 DPFDP signal Out of Range HIGH • SIG GND Open or Step-Based Diagnostics
high resistance (page 521)
• DPFDP shorted to
PWR
• Failed DPFDP
Sensor
3251 4 DPFDP signal Out of Range LOW • VREF-4 circuit Step-Based Diagnostics

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Open or high (page 523)
resistance
• DPFDP circuit
shorted to GND
• DPFDP circuit Open
or high resistance
• Failed DPFDP
Sensor

518
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 515

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
SIG GND connector sensor
Pin C2 _ 4 1
(end view)
2
VREF-4

s
Pin C2 _ OS 3 1~ 3

ECM 58-Pin
C1 connector
Pin C1 _ 12
DPFDP n
1: I I;
Exhau;t Sensor
connector (end view)
.
V00022

Figure 215 DPFDP sensor circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 between the inlet pressure and outlet pressure of the
Engine and Aftertreatment Wiring Schematic DPF. Aftertreatment regeneration will not run with
Form 0000002941 for additional circuit DPFDP sensor module fault codes present.
information.

BetterManuals.net
Overview
The Diesel Particulate Filter Differential Pressure
(DPFDP) sensor measures the pressure difference

519
 516 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Tools Required
• 180-Pin Breakout Box 00-00956-08
• Breakout Harness 00-01467-00
• Breakout Harness ZTSE4761
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• Interface cable (RP1210B compliant supporting
J1939 and J1708)

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2
0000046718

Figure 216 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

520
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 517

SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Particulate Filter Absolute value of DPFDP Inactive: SPN 3251 FMI 3, 4 Immediate
Differential Pressure > 0.25 psi (1.5 kPa)
Engine Speed ≤ 200 RPM
(DPFDP) sensor Key
Range of DPFDP since
ON check indicates Elapsed time since key ON > 1
last monitor decision
signal in-range but not sec
when Enable Conditions
rational or stuck in
are met < 0.15 psi (1 kpa) Range of exhaust volumetric
range.
flow since last monitor > 0.4 m3/
sec
DPFDP sensor signal not
saturated at high exhaust flow:
(DPFDP <= 5.1 psi (35 kpa) OR
(Exhaust flow <= 1 m3/sec)
Key-On Engine-Running
(KOER)

Fault Overview Associated Faults

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Fault code sets when the Engine Control Module SPN 3251 FMI 3, 4 (DPFDP); SPN 3512 FMI 14
(ECM) detects the aftertreatment Diesel Particulate (VREF-4)
Filter Differential Pressure (DPFDP) is greater than
0.25 psi (1.5 kpa), is not changing with engine Drive Cycle to Determine Fault Status
conditions, or range since last monitor < 0.15 psi (1
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
kpa).
Manual.
Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

521
 518 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
SIG GND connector sensor
Pin C2 _ 4 1 7 1
(end view)

---l___J 8
n
Pin C2 - 08 C::,rV..:..R:.::E:..'....F.:..-'.!._4_ _ 2 1~ 3

ECM 58-Pin
C1 connector 5
10 61
3 s
PinC1-12 DPFDP 1 1
Exhau;t Sensor
connector (end view)
.
V00022

Figure 217 DPFDP sensor circuit diagram

Possible Causes
• DPFDP circuit high resistance
• Leaking or Restricted DPFDP sensor hoses

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• Failed DPFDP sensor
I- I l
Step I Action Decision
1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3251 FMI 3 and
No: Repair SPN 3251 FMI 3
4 (DPFDP); SPN 3512 FMI 14 (VREF-4).
and 4; SPN 3512 FMI 14. After
Is EST DTC list free of SPN 3251 FMI 3 and 4; SPN 3512 FMI 14? repairs are complete, retest for
L I I SPN 3251 FMI 2. J

522
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 519

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0000046718

Figure 218 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

2 Inspect hoses and tube connections at the Diesel Particulate Filter Yes: Go to step 3.
Differential Pressure (DPFDP) sensor. Check sensor, tubes, and
No: Repair leaking, restricted
passages for leaks, restrictions, and damage.
or damaged hoses and
Are the DPFDP sensor module connections free of leaks, connections. After repairs
restrictions, and damage? are complete, retest for SPN
3251 FMI 2.

Step Action Decision

3 Inspect connections at DPFDP sensor. Key OFF, disconnect Yes: Go to step 4.
DPFDP sensor. Check DPFDP sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the DPFDP sensor connector, harness, and terminals clean SPN 3251 FMI 2.
and undamaged?

523
 520 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Inspect connections at Engine Control Module (ECM) sensor. Key Yes: Go to step 5.
OFF, disconnect ECM sensor. Check ECM sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM sensor connector, harness, and terminals clean and SPN 3251 FMI 2.
undamaged?

Step Action Decision

5 Check DPFDP circuit for high resistance. Connect Breakout Yes: Replace the DPFDP
Harness ZTSE4761 to vehicle harness and leave DPFDP sensor. After repairs are
sensor disconnected. Connect 180-Pin Breakout Box and complete retest for SPN 3251
Breakout Harness 00-01467-00 to vehicle harness and leave FMI 2.
ECM disconnected. Key OFF, use a DMM to measure resistance
No: Repair high resistance
between Breakout Harness pin-2 and Breakout Box pin C1-12.
between the DPFDP sensor
Is resistance less than 5 ohms? module connector pin-2 and
ECM connector pin C1-12. After
repairs are complete retest for
SPN 3251 FMI 2.

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NOTE: After performing all diagnostic steps, if
SPN 3251 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

524
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 521
-

SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH

I I I I -1
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
~
-
Diesel Particulate Filter Aftertreatment DPFDP Key ON 2 seconds
Differential Pressure sensor value > 4.25 volts
(DPFDP) sensor
reading greater than
specified operating
range for a specified
amount of time. I I I
I, J
Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the aftertreatment Diesel
Particulate Filter Differential Pressure (DPFDP) signal
voltage is greater than 4.75 volts for more than 2
seconds.

Malfunction Indicator Lamp (MIL) Reaction

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MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Fault
SPN 3512 FMI 14 (VREF-4)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
connector sensor
Pin C2 - 41 SIG GND
(end view)

e
1~ 3

ECM 58-Pin
C1 connector
Pin C1 - 12
DPFDP
1: ~ n
Exhau;t Sensor
I:
connector (end view)
.
V00022

Figure 219 DPFDP sensor circuit diagram

Possible Causes • DPFDP shorted to PWR

• SIG GND Open or high resistance • Failed DPFDP sensor

525
 522 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3512 FMI 14
No: Repair SPN 3512 FMI 14.
(VREF-4).
After repairs are complete, retest
Is EST DTC list free of SPN 3512 FMI 14? for SPN 3251 FMI 3.

Step Action Decision

2 Inspect connections at DPFDP sensor. Key OFF, disconnect Yes: Go to step 3.
DPFDP sensor. Check DPFDP sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the DPFDP sensor connector, harness, and terminals clean SPN 3251 FMI 3.
and undamaged?

Step Action Decision

3 Check DPFDP circuit for Short to power. Key-On Engine-Off Yes: Go to step 4.
(KOEO), with Breakout Harness ZTSE4761 connected between
No: Repair short to power
DPFDP sensor and vehicle harness. Use a DMM to measure
between DPFDP sensor

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voltage between DPFDP sensor module pin-2 and a known good
connector pin-2 and ECM
ground.
connector pin C1-12. After
Is voltage at pin-2 less than 4.7 volts? repairs are complete retest for
SPN 3251 FMI 3.

Step Action Decision

4 Check SIG GND circuit for Open or high resistance. Key OFF, Yes: Replace the DPFDP
Connect Breakout Harness ZTSE4761 to vehicle harness and sensor. After repairs are
leave DPFDP disconnected. Connect 180-pin Breakout Box with complete retest for SPN 3251
Breakout Harness 00-01467-00 to vehicle harness and leave FMI 3.
Engine Control Module (ECM) disconnected. Use a DMM to
No: Repair Open or high
measure resistance from Breakout Harness pin-1 to Breakout
resistance between DPFDP
Box pin C2-41.
sensor connector pin-1 and
Is resistance less than 5 ohms? ECM connector pin C2-41. After
repairs are complete, retest for
SPN 3251 FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 3251 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

526
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 523
-

SPN 3251 FMI 4- DPFDP signal Out of Range LOW

I I I I -1
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
~
-
Diesel Particulate Filter DPFDP < 0.25 volts Key ON 2 seconds
Differential Pressure
(DPFDP) signal voltage
is less than 0.25 V for
I,
more than 2 seconds. I I I I

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the aftertreatment Diesel Particulate
Filter Differential Pressure (DPFDP) signal voltage is
greater than 0.25 volts for more than 2 seconds.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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Associated Faults
SPN 3512 FMI 14 (VREF-4)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DPFDP circuit
ECM 58-Pin Connector
C2 connector Harness DPFDP
Pin C2 - 41 i:.....:::.!.!!:'...___~
SIG GND 7 1
connector
(end view)
sensor

Pin C2 - 08 ~-,-v...:....R:.::E~F:..:-4~---1--_J 8 2 1~ 3

s
ECM 58-Pin
C1 connector
Pin C1 _ 12
DPFDP
1: I n
Exhau;t Sensor
I;
connector (end view)
.
3

V00022

Figure 220 DPFDP sensor circuit diagram

527
 524 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Possible Causes
• VREF-4 circuit Open or high resistance
• DPFDP circuit shorted to GND
• DPFDP circuit Open or high resistance
• Failed DPFDP sensor

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3512 FMI 14
No: Repair SPN 3512 FMI 14.
(VREF-4).
After repairs are complete, retest
Is EST DTC list free of SPN 3512 FMI 14? for SPN 3480 FMI 4.

Step Action Decision

2 Inspect connections at DPFDP sensor. Key OFF, disconnect Yes: Go to step 3.
DPFDP sensor. Check DPFDP sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for

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Are the DPFDP sensor connector, harness, and terminals clean SPN 3251 FMI 4.
and undamaged?

Step Action Decision

3 Check DPFDP circuit for Short to ground. Key OFF, with Breakout Yes: Go to step 4.
Harness ZTSE4761 connected to vehicle harness and leave
No: Repair short to GND
DPFDP sensor disconnected. Use a DMM to measure resistance
between DPFDP sensor
between DPFDP sensor connector pin-2 and a known good
connector pin-2 and ECM
ground.
connector pin C1-12. After
Is resistance greater than 1000 ohms? repairs are complete retest for
SPN 3251 FMI 4.

Step Action Decision

4 Check VREF-4 circuit for Open or high resistance. Connect Yes: Go to step 5.
Breakout Harness ZTSE4761 to vehicle harness and leave
No: Repair Open or high
DPFDP sensor disconnected. Connect 180-pin Breakout Box
resistance between DPFDP
with Breakout Harness 00-01467-00 to vehicle harness and
sensor connector pin-3 and
leave Engine Control Module (ECM) disconnected. Use a DMM
ECM connector pin C2-08. After
to measure resistance between Breakout Harness pin-3 and
repairs are complete, retest for
Breakout Box pin C2-08.
SPN 3251 FMI 4.
Is resistance less than 5 ohms?

528
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 525

Step Action Decision

5 Check DPFDP signal circuit for Open or high resistance. Connect Yes: Replace DPFDP sensor.
Breakout Harness ZTSE4761 to vehicle harness and leave After repairs are complete, retest
DPFDP sensor disconnected. Connect 180-pin Breakout Box for SPN 3251 FMI 4.
with Breakout Harness 00-01467-00 to vehicle harness and leave
No: Repair Open or high
ECM disconnected. Use a DMM to measure resistance between
resistance between DPFDP
Breakout Harness pin-2 and Breakout Box pin C1-12.
sensor module pin-2 and ECM
Is resistance less than 5 ohms? connector pin C1-12. After
repairs are complete, retest for
SPN 3251 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 3251 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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529
 526 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

DPFOT Sensor (Diesel Particulate Filter Outlet

Temperature)

SPN FMI Condition Possible Causes Actions

3246 2 DPFOT signal does not agree with other • Failed DPFOT Step-Based
exhaust sensors sensor Diagnostics (page
530)
• High resistance
in DPFOT circuit
• High resistance
in SIG GND
circuit
3246 3 DPFOT signal Out of Range HIGH • High resistance Step-Based
or open in SIG Diagnostics (page
GND circuit 533)
• High resistance
or open in
DPFOT circuit
• Short to PWR in
DPFOT circuit

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• Failed DPFOT
sensor
3246 4 DPFOT signal Out of Range LOW • Short to GND in Step-Based
DPFOT circuit Diagnostics (page
536)
• SIG GND circuit
shorted to
DPFOT circuit
• Failed DPFOT
sensor
3246 20 DPFOT signal drifted HIGH • Restricted air Step-based
filter Diagnostics (page
538)
• Fuel leaks
• Biased DPFOT
sensor or circuit
• Engine over
fueling
• Failed Down
Stream Injection
(DSI) unit
• Oil
contamination
of exhaust
system

530
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 527

SPN FMI Condition Possible Causes Actions

3246 21 DPFOT signal drifted LOW • Exhaust leaks Step-based
Diagnostics (page
• Restricted air
544)
filter
• Biased DPFOT
sensor or circuit
• Low FDP
• Failed DSI unit
• Leaking or
restricted DSI
fuel supply line
• AFTFD valve
and AFTFSV
connectors
swapped
• Leaking or
damaged AFI
supply line

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• Restricted
exhaust system

DPFOT circuit

ECM 58- Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
sensor
DPF OT
>-----+~~~--7 5 t-------, 2 2
Pin C1 - 27

PinC1-10 )-~S~IG~G~N=D----6'-------,1

~1
5 [e"• 1111,!QI II•]
10
..,
ffjl II Ii 6

Exhaust sensor
connector (end view)
0000047994

Figure 221 DPFOT sensor circuit diagram

NOTE: See latest version of Maxxforce 11 / 13

Engine and Aftertreatment Wiring Schematic
Form 0000002941 for additional circuit
information.

531
 528 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Overview • ZTSE4498 - 3-Banana Plug Harness

The Diesel Particulate Filter Outlet Temperature • ZTSE4497 - 500 Ohm Resistor Harness
(DPFOT) is a thermistor-style sensor that measures
• ZTSE4899 - Big Bore Terminal Test Probe Kit
Diesel Particulate Filter (DPF) outlet temperature.
As temperature increases, resistance decreases, • Breakout Harness ZTSE4760A (DPFOT)
causing the voltage signal sent to the Engine
• Digital Multimeter (DMM)
Control Module (ECM) to vary. The Diesel
Oxidation Catalyst Inlet Temperature (DOCIT) • Electronic Service Tool (EST) with ServiceMaxx™
sensor works with the Diesel Oxidation Catalyst software
Outlet Temperature (DOCOT), DPFOT, and Diesel
• J1939 and J1708 RP1210B Compliant Device
Particulate Filter Differential Pressure (DPFDP)
sensors for operation and control the regeneration
cycles of the Aftertreatment (AFT) system via the
ECM.
Tools Required
• 00-00956-08 - 180-Pin Breakout Box

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532
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 529

0000047843

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Figure 222 DPFOT Sensor Location (Typical)
1. Diesel Particulate Filter Outlet
Temperature (DPFOT) sensor

533
 530 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3246 FMI 2 - DPFOT signal does not agree with other exhaust sensors
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
The Diesel Particulate Difference between Engine is cold soaked 0.5 seconds
Filter Outlet Diesel Oxidation Catalyst
Temperature (DPFOT) Inlet Temperature
is not changing with (DOCIT), Diesel
engine operating Oxidation Catalyst Outlet
conditions (in-range Temperature (DOCOT),
but not rational). and DPFOT > 27°F
(15°C).

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

Fault code sets when the Engine Control Module MIL will illuminate when this fault is detected during
(ECM) detects the difference between the Diesel two consecutive drive cycles.
Oxidation Catalyst Inlet Temperature (DOCIT), Diesel
Oxidation Catalyst Outlet Temperature (DOCOT), and Associated Faults
Diesel Particulate Filter Outlet Temperature (DPFOT)
SPN 3246 FMI 3 and 4 (DPFOT); SPN 4765 FMI 3
readings do not match expected values for engine
and 4 (DOCIT); SPN 4766 FMI 3 and 4 (DOCOT)
operating conditions. Active and parked regeneration

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of the DPF will be disabled. Engine torque will be
Drive Cycle to Determine Fault Status
reduced if the engine is operated for an extended
period of time with this fault active. Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

534
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 531

DPFOT circuit

ECM 58- Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
2 sensor
Pin C1 - 27

Pin C1 - 10

~ 1

10
5 [e"• iiIIJQI II il
ffjl I Iii 6
L'>

Exhaust sensor
connector (end view)
0000047994

Figure 223 DPFOT sensor circuit diagram

Possible Causes
• Failed Diesel Particulate Filter Outlet Temperature

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(DPFOT) sensor
• High resistance in DPFOT circuit
• High resistance in SIG GND circuit

Step Action Decision

1 Using Engine Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 3
No: Repair SPN 3246 FMI 3 and
and 4 (DPFOT); SPN 4765 FMI 3 and 4 (DOCIT); SPN 4766 FMI
4; SPN 4765 FMI 3 and 4; SPN
3 and 4 (DOCOT).
4766 FMI 3 and 4. After repairs
Is EST DTC list free of SPN 3246 FMI 3 and 4; SPN 4765 FMI 3 are complete, retest for SPN
and 4; SPN 4766 FMI 3 and 4? 3246 FMI 2.

Step Action Decision

2 Inspect connections at Diesel Particulate Outlet Temperature Yes: Go to step 3.
(DPFOT) sensor. Key OFF, disconnect DPFOT sensor connector.
No: Repair connector, harness,
Check DPFOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3246 FMI 2.
Are the DPFOT sensor, connector, harness, and terminals clean
and undamaged?

535
 532 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 3246 FMI 2.
undamaged?

Step Action Decision

4 Check DPFOT circuit for high resistance. Connect Breakout Yes: Go to step 5.
Harness ZTSE4760A to DPFOT harness and leave DPFOT
No: Repair high resistance
disconnected. Connect 180-pin Breakout Box with Breakout
between DPFOT connector
Harness 00-01467-00 to ECM C1 harness, and leave ECM
pin-2 and ECM connector
disconnected. Key OFF, use a DMM to measure resistance from
pin C1-27. After repairs are
Breakout Harness pin-2 and Breakout Box pin C1-27.
complete, retest for SPN 3246
Is resistance less than 5 ohms? FMI 2.

Step Action Decision

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5 Check SIG GND circuit for high resistance. Connect Breakout Yes: Replace DPFOT sensor.
Harness ZTSE4760A to DPFOT harness and leave DPFOT After repairs are complete, retest
disconnected. Connect 180-pin Breakout Box with ECM Breakout for SPN 3246 FMI 2.
Harness 00-01467-00 to Chassis C1 harness, and leave ECM
No: Repair high resistance
disconnected. Key OFF, use a DMM to measure resistance from
between DPFOT connector
Breakout Harness pin-1 and Breakout Box pin C1-10.
pin-1 and ECM connector
Is resistance less than 5 ohms? pin C1-10. After repairs are
complete, retest for SPN 3246
FMI 2.

NOTE: After performing all diagnostic steps, if

SPN 3246 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

536
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 533

SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Particulate Filter DPFOT sensor input Key ON 0.5 seconds
Outlet Temperature voltage ≥ 5 volts
(DPFOT) circuit short to
PWR.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that the Diesel Particulate Filter
Outlet Temperature (DPFOT) sensor signal voltage
is greater than expected. Active and parked
regeneration of the DPF will be disabled. Engine
torque will be reduced if the engine is operated for an
extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DPFOT circuit

ECM 58- Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
2 sensor
Pin C1 - 27

Pin C1 - 10

~1
5 ['' ii.!QI ii I]
10 I ii fEjj ii ii 6
L'>

Exhaust sensor
connector (end view)
0000047994

Figure 224 DPFOT sensor circuit diagram

Possible Causes • Short to PWR in DPFOT circuit

• High resistance or open in SIG GND circuit • Failed DPFOT sensor
• High resistance or open in DPFOT circuit

537
 534 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Diesel Particulate Filter Outlet Temperature Yes: Go to step 2.
(DPFOT) sensor. Key OFF, disconnect DPFOT sensor connector.
No: Repair connector, harness,
Check DPFOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3246 FMI 3.
Are the DPFOT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DPFOT circuit for short to PWR. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DPFOT sensor
No: Repair short to power in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DPFOT circuit between ECM pin
between Breakout Harness pin-2 and a known good ground.
C1-27 and DPFOT sensor pin-2.
Is voltage within 0.5 volts of 5 volts? After repairs are complete, retest
for SPN 3246 FMI 3.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 3246 FMI 3.
undamaged?

Step Action Decision

4 Check DPFOT circuit for high resistance or Open. Connect Yes: Go to step 5.
180-pin Breakout Box with Breakout Harness 00-01467-00 to
No: Repair Open or high
vehicle harness, and leave ECM disconnected. With Breakout
resistance in DPFOT circuit
Harness ZTSE4760A connected to vehicle harness and with
between ECM pin C1-27 and
DPFOT sensor disconnected. Use a DMM to measure resistance
DPFOT sensor pin-2. After
from Breakout Box pin C1-27 and Breakout Harness pin-2.
repairs are complete, retest for
Is resistance less than 5 ohms? SPN 3246 FMI 3.

538
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 535

Step Action Decision

5 Check SIG GND circuit for high resistance or Open. Connect Yes: Replace DPFOT sensor.
180-pin Breakout Box with Breakout Harness 00-01467-00 to After repairs are complete, retest
vehicle harness, and leave ECM disconnected. With Breakout for SPN 3246 FMI 3.
Harness ZTSE4760A connected to vehicle harness and with
No: Repair Open or high
DPFOT sensor disconnected. Use a DMM to measure resistance
resistance in SIG GND circuit
from Breakout Box pin C1-10 and Breakout Harness pin-1.
between ECM pin C1-10 and
Is resistance less than 5 ohms? DPFOT sensor pin-1. After
repairs are complete, retest for
SPN 3246 FMI 3.

NOTE: After performing all diagnostic steps, if

SPN 3246 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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539
 536 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3246 FMI 4 - DPFOT signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Particulate Filter DPFOT signal ≤ 0.05 volt Key-On Engine-Running 0.5 seconds
Outlet Temperature (KOER)
(DPFOT) circuit short to
ground.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects the Diesel Particulate Filter Outlet
Temperature (DPFOT) sensor signal voltage is less
than 0.05 volts for more than 0.5 seconds. Active
and parked regeneration of the DPF will be disabled.
Engine torque will be reduced if the engine is operated
for an extended period of time with this fault active.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

DPFOT circuit

ECM 58 - Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
sensor
1--WD~P:..!.::F~O~T_ _ _7 5 ~-------i 2 2
Pin C1 - 27

Pin C1 - 10 )-~S~IG~G~N~D_ _ _7 6~-1

~
1
5 ['' 11 .!!JI II I]
10 I II fEj\ II ii 6
L'>

Exhaust sensor
connector (end view)
0000047994

Figure 225 DPFOT sensor circuit diagram

Possible Causes • SIG GND circuit shorted to DPFOT circuit

• Short to GND in DPFOT circuit • Failed DPFOT sensor

540
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 537

Step Action Decision

1 Inspect connections at Diesel Particulate Filter Outlet Temperature Yes: Go to step 2.
(DPFOT) sensor. Key OFF, disconnect DPFOT sensor connector.
No: Repair connector, harness,
Check DPFOT sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3246 FMI 4.
Are the DOCOT sensor, connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check DPFOT circuit for short to GND. Connect Breakout Yes: Go to step 3.
Harness ZTSE4760A to vehicle harness and leave DPFOT sensor
No: Repair short to GND in
disconnected. Key-On Engine-Off (KOEO) measure voltage
DPFOT circuit between ECM pin
between Breakout Harness pin-2 and a known good ground.
C1-27 and DPFOT sensor pin-2.
Is voltage within 0.5 volts of 5 volts? After repairs are complete, retest
for SPN 3246 FMI 4.

Step Action Decision

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3 Inspect connections at Engine Control Module (ECM). Key OFF, Yes: Go to step 4.
disconnect ECM connector. Check ECM and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM connector, harness, and terminals clean and SPN 3246 FMI 4.
undamaged?

Step Action Decision

4 Check for short between DPFOT and SIG GND circuits. Connect Yes: Replace DPFOT sensor.
Breakout Harness ZTSE4760A and leave DPFOT sensor After repairs are complete, retest
disconnected. Key OFF, disconnect ECM and measure resistance for SPN 3246 FMI 4.
between Breakout Harness pin-1 and pin-2.
No: Repair short between
Is resistance greater than 1000 ohms? DPFOT and SIG GND circuits.
After repairs are complete, retest
for SPN 3246 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 3246 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

541
 538 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3246 FMI 20 - DPFOT signal drifted HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Particulate Filter DPFOT > 932°F (500°C) Time after successful regen 10 seconds
Output Temperature 10 to 20 minutes after complete > 20 minutes
(DPFOT) is above regen
Timer after Key On > 0 seconds
932°F (500°C) ten
to twenty minutes Battery voltage > 10.7 volts
after Regeneration
Battery voltage < 15 volts
completes.

Fault Overview
Fault code sets when the Diesel Particulate Filter
Outlet Temperature (DPFOT) reaches above 932°F
(500°C) within a predetermined time frame by the
Engine Control Module (ECM).

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

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Associated Faults
SPN’s 94, 157, 3055, 3246, 3251, 3480, 4077, 4765,
5456, and 5541.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

DPFOT circuit

ECM 58- Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
sensor
1------~D~P~F~O~T---1 5'------,2 2
Pin C1 - 27

Pin C1 - 10 }-~S~IG~G~N~D_ _ _7 6 ' - - - 1

~ 1
5 [e"• ii11.U..,11 "]
ffJl ii II 6
10
L'S

Exhaust sensor
connector (end view)
0000047994

Figure 226 DPFOT sensor circuit diagram

542
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 539

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3246 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 3246 FMI 20.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 3246 FMI 20.
of restrictions, leaks, and physical damage?

Step Action Decision

3 Inspect connections at Diesel Particulate Filter Outlet Temperature Yes: Go to step 4.
(DPFOT) sensor. Key OFF, disconnect DPFOT. Check DPFOT
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After

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corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 3246 FMI 20.
Are the DPFOT sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

4 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 5.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 3246 FMI 20.

Step Action Decision

5 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 3246 FMI 20.
Does engine have excessive crankcase pressure?
No: Go to step 6.

Step Action Decision

6 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 7.
Cylinder Cutout Test (page 182).
No: Go to step 8.
Did one or more cylinders have significant speed difference(s)
than the others?

543
 540 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 3246 FMI 20.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 3246
FMI 20.

1 2

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4 3
0000047001

Figure 227 Down Stream Injection (DSI) Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

8 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 9.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 3246 FMI 20.

544
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 541

Step Action Decision

9 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 3246 FMI 20.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 3246
FMI 20.
AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 3246 FMI 20.
AFTFP1 signal value drops

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and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step
10.

Step Action Decision

10 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 11.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

545
 542 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

11 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification:
Go to step 12.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3246 FMI 20.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3246 FMI 20.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3246 FMI 20.
pressure.

546
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 543

Step Action Decision

12 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Inspect for oil
Pressure (DPFDP) signal measure below 0.5 psi at high idle? contamination of exhaust
system. See Lube Oil to
Exhaust (page 96). After repairs
are complete, retest for SPN
3246 FMI 20.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3246
FMI 20.

NOTE: After doing all diagnostic steps, if SPN

3246 FMI 20 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 544 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3246 FMI 21 - DPFOT signal drifted LOW

Condition /
Description
Diesel Particulate Filter DPFOT < 392°F (200°C)
Output Temperature
(DPFOT) is below
392°F (200°C) with
enable conditions met.
Setting Criteria Enable Conditions / Values Time Required
Injection Quantity > 115 mg / 10 seconds
stroke
IMP > 120 kPa
Engine speed > 1400 rpm
In above conditions > 45
seconds
Timer after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Fault Overview Associated Faults

Fault code sets when the Diesel Particulate Filter SPN’s 94, 157, 3055, 3251, 3480, 4077, 4765, 5456,
Outlet Temperature (DPFOT) is below 392°F (200°C) and 5541.
within a predetermined time frame by the Engine

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Control Module (ECM). Drive Cycle to Determine Fault Status
See 2013 HD-OBD Diagnostic Reference Manual.
Malfunction Indicator Lamp (MIL) Reaction
When fault is active, MIL will not illuminate.

548
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 545

DPFOT circuit

ECM 58- Pin DPFOT

C1 connector (6018) DPFOT
connector
connector DPFOT
(end view)
2 sensor
Pin C1 - 27

Pin C1 - 10

~ 1

10
5 [e"• iiIIJQI II il
ffjl I Iii 6
L'>

Exhaust sensor
connector (end view)
0000047994

Figure 228 DPFOT sensor circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.

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check for other fault codes.
No: Repair other fault code(s).
Is SPN 3246 FMI 21 the only fault code active? After repairs are complete, retest
for SPN 3246 FMI 21.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Inspect the fuel system
No: Repair restrictions, air leaks,
from fuel tank to Aftertreatment Fuel Injector (AFI) valve for leaks
fuel leaks or physical damage.
or physical damage.
After repairs are complete, retest
Is air intake system, exhaust system, fuel system and air filter free for SPN 3246 FMI 21.
of restrictions, leaks, and physical damage?

Step Action Decision

3 Inspect connections at Diesel Particulate Filter Outlet Temperature Yes: Go to step 4.
(DPFOT) sensor. Key OFF, disconnect DPFOT. Check DPFOT
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 3246 FMI 21.
Are the DPFOT sensor connector, harness, and terminals clean
and undamaged?

549
 546 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Determine if Fuel Delivery Pressure (FDP) is within specification. Yes: Go to step 5.
Using Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Do Fuel Delivery Pressure
Key-On Engine-Running (KOER) monitor FDP sensor. FDP
(FDP) Test (page 167). After
should be at a steady pressure of 90 psi or more.
repairs are complete, retest for
Is FDP between 85 – 120 psi? SPN 3246 FMI 21.

1 2

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4 3
0000047001

Figure 229 Down Stream Injection (DSI) Unit

1. Aftertreatment Fuel Shutoff 3. Aftertreatment Fuel Doser
Valve (AFTFSV) (WHITE) (AFTFD) (BLACK)
2. Aftertreatment Fuel Inlet Sensor 4. Aftertreatment Fuel Pressure 2
(AFTFIS) (AFTFP2) sensor

Step Action Decision

5 Check AFTFSV and Aftertreatment Fuel Doser (AFTFD) harness Yes: Go to step 6.
connectors are connected to the correct location? (AFTFSV and
No: Connect harness
AFTFD harness connectors can be swapped.)
connectors to correct location.
Are AFTFSV and AFTFD harness connectors connected to the After repairs are complete, retest
correct sensors? for SPN 3246 FMI 21.

550
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 547

Step Action Decision

6 Verify correct Down Stream Injection (DSI) unit and Aftertreatment AFTFP1 signal value does not
Fuel Injector (AFI) operation. Using Electronic Service Tool (EST) drop: Replace DSI unit. After
with ServiceMaxx™ software, KOER, run DSI De-Aeration test. repairs are complete, retest for
Actuate AFTFSV and AFTFD. Monitor AFTFP1 and AFTFP2 SPN 3246 FMI 21.
signal values during activation.
AFTFP2 signal value does not
• Does AFTFP1 signal value drop when AFTFD is actuated? rise properly then drop when
AFI opens: Clean Aftertreatment
• Does AFTFP2 signal value rise then drop when AFI opens?
Fuel Injector (AFI), AFI housing,
and bore. After repairs are
complete, retest for SPN 3246
FMI 21.
AFTFP2 signal value rises
but does not drop. Clean
Aftertreatment Fuel Injector
(AFI), AFI housing, and bore.
Inspect for kinked AFI supply
line. After repairs are complete,
retest for SPN 3246 FMI 21.
AFTFP1 signal value drops

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and AFTFP2 signal value rises,
then drops when AFI is opened
(correct operation): Go to step 7.

Step Action Decision

7 Using EST with ServiceMaxx software, start an On Board Filter Yes: Go to step 8.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

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 548 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

8 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification:
Go to step 9.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3246 FMI 21.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3246 FMI 21.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3246 FMI 21.
pressure.

Step Action Decision

9 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Verify each step was
Pressure (DPFDP) signal measure below 0.5 psi at high idle? completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3246
FMI 21.

NOTE: After doing all diagnostic steps, if SPN

3246 FMI 21 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

552
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 549

DPF System (Diesel Particulate Filter)

SPN FMI Condition Possible Causes Actions

3719 0 DPF Soot Load - • Engine performance problem Step-Based
Highest (level 3/3) Diagnostics (page
• Engine mechanical
552)
• Regen inhibited
• Failed DPFDP sensor module
• Restricted DPFDP sensor
hose(s)
3719 15 DPF Soot Load - • Engine performance problem Step-Based
Lowest (level 1/3) Diagnostics (page
• Engine mechanical
556)
• Regen inhibited
• Failed DPFDP sensor module
• Restricted DPFDP sensor
hose(s)
3719 16 DPF Soot Load - • Engine performance problem Step-Based

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Moderate (level 2/3)
3720 0 DPF Ash load at
maximum limit
Diagnostics (page
• Engine mechanical
560)
• Regen inhibited
• Failed DPFDP sensor module
• Restricted DPFDP sensor
hose(s)
• High DPF ash level Step-Based
Diagnostics (page
• Low Fuel Delivery Pressure
564)
• Restricted AFI unit
• Parked Regen Inhibited
• Exhaust leak(s)
• Biased DPFDP sensor
• Biased IMP sensor
• Low boost pressure

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 550 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3936 10 DPF Thermal • Engine Throttle Valve (ETV) Step-based

management mode or circuit fault Diagnostics (page
failed to raise DOC-In 569)
• Exhaust Gas Recirculation
Temp as expected
Valve (EGRV) or circuit fault
• Exhaust Back Pressure Valve
(EBPV) or circuit fault
• Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) sensor
or circuit fault
• Ambient Air Temperature
(AAT) sensor or circuit fault
• Exhaust leaks
• Restricted air filter
3936 20 High Regen Frequency • Biased Intake Manifold Step-based
Pressure (IMP) sensor or Diagnostics (page
circuit 572)
• Turbocharger 1 Turbine Outlet
Pressure (TC1TOP) sensor or

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circuit
• Diesel Particulate Filter
Differential Pressure (DPFDP)
sensor or circuit. DPFDP
hoses restricted or leaking.
• Diesel Oxidation Catalyst Inlet
Temperature (DOCIT), DOC
Outlet Temperature (DOCOT),
or DPF Outlet Temperature
(DPFOT) sensor or circuit
• Oxygen (O2) sensor or circuit
• Restricted Aftertreatment Fuel
Injector (AFI) or AFI housing
• Down Stream Injection (DSI)
failure or system leak
• Failed DOC
• Restricted air filter
• Exhaust or boost leaks
• Exhaust Gas Recirculation
Valve (EGRV) or circuit failure
• Turbocharger 2 Wastegate
Control failure
• Excessive forced parked
regenerations (with Electronic
Service Tool [EST]) in a short
amount of time

554
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 551

Overview
The Diesel Particulate Filter (DPF) system is used to
reduce soot released into the exhaust aftertreatment
system. The DPF is used in conjunction with the
Diesel Oxidation Catalyst (DOC) to reduce soot. The
process of reducing soot to ash is called regeneration
(regen). Regen can be active, stationary, or passive.
Passive regen needs no input from the ECM to work.
Active happens when the ECM commands the truck
to regen, and the truck goes into a regen strategy.
Stationary regen is used when an operator manually
tells the ECM to begin the regen process. This can
be accomplished by either manually pushing an
override button inside the cab, or through the use of
ServiceMaxx. The DOC and DPF can be serviced
separately.
Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

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2
0000046718

Figure 230 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

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 552 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3719 FMI 0- DPF Soot Load - Highest (level 3/3)

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Diesel Particulate Filter DPFDP sensor Key-ON Engine-Running 1 event
Differential Pressure has exceeded the (KOER)
(DPFDP) sensor data recommended pressure
Engine Speed > 500 rpm
valid, but above normal limits.
operating range (most
severe level).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 25 then 1 in 2013 HD-OBD Diagnostic
(ECM) detects the soot load of the Diesel Particulate Reference Manual.
Filter (DPF) has exceeded the maximum operating
limits. Torque output of the engine will be reduced as Fault Facts
soot load increases. Active and parked regeneration
This fault code may indicate exhaust temperature
of the aftertreatment system will be disabled. See
exiting the turbocharger are not high enough to
AFT System Overview for additional information.
actively regenerate the aftertreatment system.
Driving the vehicle with long-term increased load
Malfunction Indicator Lamp (MIL) Reaction

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may increase exhaust temperatures and decrease
When fault is active, MIL will not illuminate. aftertreatment regeneration frequency.
Possible Causes
Associated Faults
• Engine performance problem
SPN 94 (FDP); SPN 102 (IMP); SPN 157 (FRP);
SPN 651-656 (INJ/CYL); SPN 3246 FMI 2, 3, and 4 • Engine mechanical
(DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV);
• Regen inhibited
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT);
SPN 4766 (DOCOT); SPN 5541 (TC1TOP) • Failed DPFDP sensor
• Restricted DPFDP sensor hose(s)

556
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 553

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 2,
No: Repair SPN 3246 FMI 2, 3,
3, and 4 (DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV);
and 4; SPN 3480; SPN 3482;
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT); and SPN
SPN 3556; SPN 4765 FMI 2,
4766 FMI 2, 3, and 4 (DOCOT).
3, and 4; and SPN 4766 FMI
Is EST DTC list free of SPN 3246 FMI 2, 3, and 4; SPN 3480; 2, 3, and 4. After repairs are
SPN 3482; SPN 3556; SPN 4765 FMI 2, 3, and 4; and SPN 4766 complete, retest for SPN 3719
FMI 2, 3, and 4? FMI 0.

Step Action Decision

2 Check for engine performance problems. Using EST with Yes: Go to step 3.
ServiceMaxx™ software, check DTC list for SPN 94 (FDP), SPN
No: Repair SPN 94, SPN 102,
102 (IMP), SPN 157 (FRP), SPN 651-656 (INJ / CYL), and SPN
SPN 157, SPN 651-656, and
5541 (TC1TOP).
SPN 5541. After repairs are
Is EST DTC list free of SPN 94, SPN 102, SPN 157, SPN complete, retest for SPN 3719
651-656, and SPN 5541? FMI 0.

Step Action Decision

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3 Determine if a regen inhibitor is inhibiting regeneration of the Yes: Retest for SPN 3719 FMI
aftertreatment system. Using EST with ServiceMaxx software, go 0. Go to step 4.
to Procedures > KOER Aftertreatment Procedures > DPF Filter
No: Correct active regen
Regeneration > Inhibitors > and click Begin Test.
inhibitors ((page 319) and
Does DPF Filter Regeneration procedure run without any active ServiceMaxx Aftertreatment
Inhibitors? DPF Filter Regeneration
Inhibitors tab). After repairs are
complete, retest for SPN 3719
FMI 0.

Step Action Decision

4 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 5.
Pressure (DPFDP) sensor. Key OFF, disconnect DPFDP sensor.
No: Repair connector, harness,
Check DPFDP sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3719 FMI 0.
Are the DPFDP sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

5 Monitor DPFDP sensor signal. Key-On Engine-Running (KOER), Yes: Go to step 7.
using EST with ServiceMaxx software, load the Signals session
No: Go to step 6.
and monitor DPFDP.
Is DPFDP below 0.5 psi (normal operation)?

557
 554 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

BetterManuals.net
0000046718

Figure 231 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

6 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Replace DPFDP sensor.
Inspect the DPFDP sensor hoses for improper routing, restrictions, After repairs are complete, retest
or damage. for SPN 3719 FMI 0.
Are the DPFDP sensor hoses routed correctly, free of damage, No: Repair or replace DPFDP
and unrestricted? sensor hose(s). After repairs are
complete, retest for SPN 3719
FMI 0.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 3719 FMI 0.
Does engine have excessive crankcase pressure?
No: Go to step 8

558
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 555

Step Action Decision

8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Go to step 10.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 3719 FMI 0.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 3719
FMI 0.

Step Action Decision

10 Determine if vehicle has an engine performance related driveability Yes: Perform Engine

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problem. Test drive the vehicle. Performance Diagnostics.
After repairs are complete, retest
Does engine have a performance problem.
for SPN 3719 FMI 0.

NOTE: After performing all diagnostic steps, if

SPN 3719 FMI 0 remains, verify each step was
completed correctly, and the proper decision was
made. Notify supervisor for further action.

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 556 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3719 FMI 15- DPF Soot Load - Lowest (level 1/3)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
DPF Differential DPFDP sensor Key-On Engine-Running 1 event
Pressure (DPFDP) has exceeded the (KOER)
sensor data valid, but recommended limits.
Engine Speed > 500 rpm
above normal operating
range (least severe
level).

Fault Overview Fault Facts

Fault code sets when the Engine Control Module
(ECM) detects the soot load of the Diesel Particulate
Filter (DPF) has exceeded operating limits. Torque
output of the engine will be reduced as soot load
increases. See AFT System Overview for additional
information.
Malfunction Indicator Lamp (MIL) Reaction
This fault code may indicate exhaust temperature
exiting the turbocharger are not high enough to
actively regenerate the aftertreatment system.
Driving the vehicle with long-term increased load
may increase exhaust temperatures and decrease
aftertreatment regeneration frequency.
Possible Causes
• Engine performance problem

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When fault is active, MIL will not illuminate.
• Engine mechanical
Associated Faults
• Regen inhibited
SPN 94 (FDP); SPN 102 (IMP); SPN 157 (FRP);
• Failed DPFDP sensor
SPN 651-656 (INJ/CYL); SPN 3246 FMI 2, 3, and 4
(DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV); • Restricted DPFDP sensor hose(s)
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT);
SPN 4766 (DOCOT); SPN 5541 (TC1TOP)

Drive Cycle to Determine Fault Status

Drive Cycle 1 in 2013 HD-OBD Diagnostic Reference
Manual.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 557

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 2,
No: Repair SPN 3246 FMI 2, 3,
3, and 4 (DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV);
and 4; SPN 3480; SPN 3482;
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT); and SPN
SPN 3556; SPN 4765 FMI 2,
4766 FMI 2, 3, and 4 (DOCOT).
3, and 4; and SPN 4766 FMI
Is EST DTC list free of SPN 3246 FMI 2, 3, and 4; SPN 3480; 2, 3, and 4. After repairs are
SPN 3482; SPN 3556; SPN 4765 FMI 2, 3, and 4; and SPN 4766 complete, retest for SPN 3719
FMI 2, 3, and 4? FMI 15.

Step Action Decision

2 Check for engine performance problems. Using EST with Yes: Go to step 3.
ServiceMaxx™ software, check DTC list for SPN 94 (FDP), SPN
No: Repair SPN 94, SPN 102,
102 (IMP), SPN 157 (FRP), SPN 651-656 (INJ / CYL), and SPN
SPN 157, SPN 651-656, and
5541 (TC1TOP).
SPN 5541. After repairs are
Is EST DTC list free of SPN 94, SPN 102, SPN 157, SPN complete, retest for SPN 3719
651-656, and SPN 5541? FMI 15.

Step Action Decision

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3 Determine if a regen inhibitor is inhibiting regeneration of the Yes: Retest for SPN 3719 FMI
aftertreatment system. Using EST with ServiceMaxx software, go 15. Go to step 4.
to Procedures > KOER Aftertreatment Procedures > DPF Filter
No: Correct active regen
Regeneration > Inhibitors > and click Begin Test.
inhibitors ((page 319) and
Does DPF Filter Regeneration procedure run without any active ServiceMaxx Aftertreatment
Inhibitors? DPF Filter Regeneration
Inhibitors tab). After repairs are
complete, retest for SPN 3719
FMI 15.

Step Action Decision

4 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 5.
Pressure (DPFDP) sensor. Key OFF, disconnect DPFDP sensor.
No: Repair connector, harness,
Check DPFDP sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3719 FMI 15.
Are the DPFDP sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

5 Monitor DPFDP sensor signal. Key-On Engine-Running, using Yes: Go to step 7.
EST with ServiceMaxx software, load the Signals session and
No: Go to step 6.
monitor DPFDP.
Is DPFDP below 0.5 psi (normal operation)?

561
 558 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

BetterManuals.net
0000046718

Figure 232 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

6 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Replace DPFDP sensor.
Inspect the DPFDP sensor hoses for improper routing, restrictions, After repairs are complete, retest
or damage. for SPN 3719 FMI 15.
Are the DPFDP sensor hoses routed correctly, free of damage, No: Repair or replace DPFDP
and unrestricted? sensor hose(s). After repairs are
complete, retest for SPN 3719
FMI 15.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 3719 FMI 15.
Does engine have excessive crankcase pressure?
No: Go to step 8

562
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 559

Step Action Decision

8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Go to step 10.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 3719 FMI 15.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 3719
FMI 15.

Step Action Decision

10 Determine if vehicle has an engine performance related driveability Yes: Perform Engine

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problem. Test drive the vehicle. Performance Diagnostics.
After repairs are complete, retest
Does engine have a performance problem.
for SPN 3719 FMI 15.

NOTE: After performing all diagnostic steps, if

SPN 3719 FMI 15 remains, verify each step was
completed correctly, and the proper decision was
made. Notify supervisor for further action.

563
 560 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3719 FMI 16- DPF Soot Load - Moderate (level 2/3)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
DPF Differential DPFDP sensor Key-On Engine-Running 1 event
Pressure (DPFDP) has exceeded the (KOER)
sensor data valid, but recommended limits.
Engine Speed > 500 rpm
above normal operating
range (moderately
severe level).

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
(ECM) detects the soot load of the Diesel Particulate Manual.
Filter (DPF) has exceeded operating limits. Torque
output of the engine will be reduced as soot load Fault Facts
increases. Active and parked regeneration of the
This fault code may indicate exhaust temperature
aftertreatment system will be disabled. See AFT
exiting the turbocharger are not high enough to
System Overview for additional information.
actively regenerate the aftertreatment system.
Driving the vehicle with long-term increased load
Malfunction Indicator Lamp (MIL) Reaction

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may increase exhaust temperatures and decrease
This fault does not illuminate the MIL when active. aftertreatment regeneration frequency.
Possible Causes
Associated Faults
• Engine performance problem
SPN 94 (FDP); SPN 102 (IMP); SPN 157 (FRP);
SPN 651-656 (INJ/CYL); SPN 3246 FMI 2, 3, and 4 • Engine mechanical
(DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV);
• Regen inhibited
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT);
SPN 4766 (DOCOT); SPN 5541 (TC1TOP) • Failed DPFDP sensor
• Restricted DPFDP sensor hose(s)

564
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 561

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 3246 FMI 2,
No: Repair SPN 3246 FMI 2, 3,
3, and 4 (DPFOT); SPN 3480 (AFTFP1); SPN 3482 (AFTFSV);
and 4; SPN 3480; SPN 3482;
SPN 3556 (AFT); SPN 4765 FMI 2, 3, and 4 (DOCIT); and SPN
SPN 3556; SPN 4765 FMI 2,
4766 FMI 2, 3, and 4 (DOCOT).
3, and 4; and SPN 4766 FMI
Is EST DTC list free of SPN 3246 FMI 2, 3, and 4; SPN 3480; 2, 3, and 4. After repairs are
SPN 3482; SPN 3556; SPN 4765 FMI 2, 3, and 4; and SPN 4766 complete, retest for SPN 3719
FMI 2, 3, and 4? FMI 16.

Step Action Decision

2 Check for engine performance problems. Using EST with Yes: Go to step 3.
ServiceMaxx™ software, check DTC list for SPN 94 (FDP), SPN
No: Repair SPN 94, SPN 102,
102 (IMP), SPN 157 (FRP), SPN 651-656 (INJ / CYL), and SPN
SPN 157, SPN 651-656, and
5541 (TC1TOP).
SPN 5541. After repairs are
Is EST DTC list free of SPN 94, SPN 102, SPN 157, SPN complete, retest for SPN 3719
651-656, and SPN 5541? FMI 16.

Step Action Decision

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3 Determine if a regen inhibitor is inhibiting regeneration of the Yes: Retest for SPN 3719 FMI
aftertreatment system. Using EST with ServiceMaxx software, go 15. Go to step 4.
to Procedures > KOER Aftertreatment Procedures > DPF Filter
No: Correct active regen
Regeneration > Inhibitors > and click Begin Test.
inhibitors ((page 319) and
Does DPF Filter Regeneration procedure run without any active ServiceMaxx Aftertreatment
Inhibitors? DPF Filter Regeneration
Inhibitors tab). After repairs are
complete, retest for SPN 3719
FMI 16.

Step Action Decision

4 Inspect connections at Diesel Particulate Filter Differential Yes: Go to step 5.
Pressure (DPFDP) sensor. Key OFF, disconnect DPFDP sensor.
No: Repair connector, harness,
Check DPFDP sensor and connector terminals for: damaged or
or terminal damage. After
pinched wires; corroded terminals; loose, bent, or broken pins;
repairs are complete, retest for
or broken connector housing.
SPN 3719 FMI 16.
Are the DPFDP sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

5 Monitor DPFDP sensor signal. Key-On Engine-Running, using Yes: Go to step 7.
EST with ServiceMaxx software, load the Signals session and
No: Go to step 6.
monitor DPFDP.
Is DPFDP below 0.5 psi (normal operation)?

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 562 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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0000046718

Figure 233 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

6 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Replace DPFDP sensor.
Inspect the DPFDP sensor hoses for improper routing, restrictions, After repairs are complete, retest
or damage. for SPN 3719 FMI 16.
Are the DPFDP sensor hoses routed correctly, free of damage, No: Repair or replace DPFDP
and unrestricted? sensor hose(s). After repairs are
complete, retest for SPN 3719
FMI 16.

Step Action Decision

7 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 3719 FMI 16.
Does engine have excessive crankcase pressure?
No: Go to step 8

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 563

Step Action Decision

8 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 9.
Cylinder Cutout Test (page 182).
No: Go to step 10.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

9 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 3719 FMI 16.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 3719
FMI 16.

Step Action Decision

10 Determine if vehicle has an engine performance related driveability Yes: Perform Engine

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problem. Test drive the vehicle. Performance Diagnostics.
After repairs are complete, retest
Does engine have a performance problem.
for SPN 3719 FMI 16.

NOTE: After performing all diagnostic steps, if

SPN 3719 FMI 16 remains, verify each step was
completed correctly, and the proper decision was
made. Notify supervisor for further action.

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 564 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3720 FMI 0 - DPF Ash load at maximum limit

Fault Overview
The Diesel Particulate Filter (DPF) must be at soot
level 3, when the DPF lamp is flashing and the buzzer
sounding. This notifies operator the soot level has
reached a critical level and the engine is de-rated
further.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Associated Faults
SPN’s 27, 102, 1189, 2791, 3251, 3480, 4077, 5456,
and 5541.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

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2
0000046718

Figure 234 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 565

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3720 FMI 0 the only fault code active? After repairs are complete, retest
for SPN 3720 FMI 0.

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 4.
monitor Diesel Particulate Filter Differential Pressure (DPFDP)
No: Go to step 3.
signal with Key-On Engine-Off (KOEO). See "Appendix A (page
953)" for DPFDP specifications.
Is DPFDP within specifications?

Step Action Decision

3 Check for biased DPFDP sensor. Do DPFDP sensor biased Yes: Go to step 5.
check (page 514).
No: Repair DPFDP sensor or
Are DPFDP sensor and circuits within specifications? circuits. After DPFDP circuits
are repaired, go to step 5.

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Step Action Decision
4 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Go to step 5.
Inspect the DPFDP hoses for kinks, improper hose routing,
No: Repair DPFDP hoses. After
reversed hoses or damage. See DPFDP sensor locator for correct
repairs are complete, go to step
routing of hoses.
5.
Are the DPFDP hoses routed correctly and free of damage?

Step Action Decision

5 Start an Onboard Filter Cleanliness Test (OBFCT). Yes: Go to Step 6.
Is OBFCT running without an Abort message in ServiceMaxx? No: Correct Parked Regen
Inhibitors (page 319) and restart
OBFCT.

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 566 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 7.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3720 FMI 0.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3720 FMI 0.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3720 FMI 0.
pressure.

Step Action Decision

7 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 8.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3720
FMI 0.

Step Action Decision

8 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 9.
out of specifications. Using EST with ServiceMaxx software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 3720 FMI 0.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 567

Step Action Decision

9 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal change only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.
After repairs are complete, retest
Does IMP sensor signal change:
for SPN 3720 FMI 0.
• When TC2WC is commanded On?
IMP signal change only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN
3720 FMI 0.
Neither change IMP signal when
commanded On: Go to step 10.
Both change IMP signal when
commanded On: Go to step 11.

Step Action Decision

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10 Verify IMP sensor and bore are not restricted due to carbon Yes: Go to step 11.
buildup. Remove and inspect IMP sensor and bore for carbon
No: Clean IMP sensor bore of
buildup.
carbon deposits. After repairs
Is IMP sensor and bore free of carbon buildup? are complete, retest for SPN
3720 FMI 0.

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 568 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

11 Do Road Test (Full load to highway speed) (page 161), 100% Both TC1TOP and DPFDP
engine load (when safe to do so). Record a snapshot of the signals are above specification:
following signals: After doing all diagnostic steps,
verify each step was completed
• Diesel Particulate Filter Differential Pressure (DPFDP) = 0.5
correctly and the proper decision
to 0.8 psi
was made. Notify supervisor for
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP) = 2 to 3 psi further action.
• Soot load < 40% Only TC1TOP signal above
specification: Remove Pre
Are DPFDP and TC1TOP signals within specifications?
Diesel Oxidation Catalyst
NOTE: DPFDP and TC1TOP specifications only apply with soot (PREDOC) and Diesel Oxidation
load < 40%. Catalyst (DOC) for inspection
and clean or replace as
necessary. After repairs are
complete, retest for SPN 3720
FMI 0.
Neither signal above
specification: Retest for SPN
3720 FMI 0.

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NOTE: After doing all diagnostic steps, if
SPN 3720 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 569

SPN 3936 FMI 10 - DPF Thermal Management Mode Failed to Raise DOC-In Temp as Expected
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Hydrocarbon Injection HCI fuel quantity less Regeneration Active 0.05 Seconds
(HCI) quantity does not then expected within
Time after Key On > 0 seconds
exceed a calibrated 17.5 minutes after regen
threshold within a request. Ambient pressure > 10 psi (75
certain time after kPa)
regeneration request
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Engine operating in monitoring
region: Function of engine
speed > 600 rpm and load >
50%
DOCIT > –58°F (–50°C) and <
932°F (500°C)
DOCOT > –58°F (–50°C) and <
1166°F (630°C)

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DPFOT > –58°F (–50°C) and <
1250°F (675°C)
Exhaust gas mass flow >= 0
kg/h

Fault Overview
This fault sets when the Diesel Oxidation Catalyst
Inlet Temperature (DOCIT) sensor temperature can
not be reached during dosing of fuel into the exhaust
stream to establish full regeneration mode. Time is
determined from calculations and AAT sensor input.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, no lamp will illuminate.

Associated Faults
SPN’s 27, 51, 2791, 3464, 5542, and 5543.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3936 FMI 10 the only fault code active? After repairs are complete, retest
for SPN 3936 FMI 10.

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 570 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air leaks,
system from fuel tank to AFI valve for leaks or physical damage.
fuel leaks, or physical damage.
Is air intake system, exhaust system, fuel system and air filter free After repairs are complete, retest
of restrictions, leaks, and physical damage? for SPN 3936 FMI 10.

Step Action Decision

3 Determine if DOCIT sensor or circuit is out of specification. Yes: Go to step 4.
Key-On Engine-Off, using EST with ServiceMaxx software, open
No: Do DOCIT Circuit Checks
Sessions / Aftertreatment / Temperature. Key-On, Engine-On.
(page 487). After repairs are
Run engine at 1400 — 1500 rpm for 10 minutes (No load and
complete, retest for SPN 3936
stationary). Compare DPFOT, Diesel Oxidation Catalyst Inlet
FMI 10.
Temperature (DOCIT), and DOC Outlet Temperature (DOCOT).
Sensor temperatures should be within 15°C (25°F) of each other.
Is DOCIT sensor within 15°C (25°F) of DOC and DOCOT sensors?

Step Action Decision

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4 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 5.
session and determin if AAT sensor (page 207) is biased (best
No: Do AAT Circuit Checks
results if checked after cold soak).
(page 207) After repairs are
Is the sensor within specifications? (Wiggle test may be necessary complete, retest for SPN 3936
if code is inactive or pending.) FMI 10.

Step Action Decision

5 Using EST with ServiceMaxx™ software, do KOEO Actuator Test Yes: Go to step 6.
and actuate the EGRV (page 622), ETV (page 643), and EBPV
No: Diagnose and repair
(page 579).
malfunctioning actuator as
Did all of the actuators respond properly? necessary. After repairs are
complete, retest for SPN 3936
FMI 10.

Step Action Decision

6 Using EST with ServiceMaxx software, start an Onboard Filter Yes: Go to step 7.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx? Inhibitors (page 319) and restart
OBFCT.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 571

Step Action Decision

7 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 8.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 3936 FMI 10.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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3936 FMI 10.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3936 FMI 10.
pressure.

Step Action Decision

8 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: After doing all diagnostic
Pressure (DPFDP) signal measure below 0.5 psi at high idle? steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3936
FMI 10.

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 572 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3936 FMI 20 - High Regen Frequency

Fault Overview
Fault sets when the ECM determines the number of
exhaust regenerations has been exceeded within a
predetermined time.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

Associated Faults
SPN’s 102, 1189, 3246, 3251, 4765, 4766, and 5541.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

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2
0000046718

Figure 235 DPFDP Sensor Location (Typical)

1. DPFDP sensor 2. DPFDP sensor hoses

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3936 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 3936 FMI 20.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 573

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air
system from fuel tank to AFI valve for leaks or physical damage.
leaks, fuel leaks or physical
Is air intake system, exhaust system, fuel system and air filter free damage. After repairs are
of restrictions, leaks, and physical damage? complete, retest for SPN 3936
FMI 20.

Step Action Decision

3 Using EST with ServiceMaxx™ software, with the Key-On Yes: Go to step 4.
Engine-Off (KOEO), monitor Intake Manifold Pressure (IMP) (page
No: Repair IMP sensor circuit.
717). Use the KOEO values found in “Appendix A:Performance
After repairs are complete, retest
Specifications”.
for SPN 3936 FMI 20.
Is IMP sensor within specifications?

Step Action Decision

4 Using EST with ServiceMaxx™ software, KOEO, monitor Yes: Go to step 5.
Turbocharger 1 Turbine Outlet Pressure (TC1TOP) (page 832).
No: Repair TC1TOP sensor

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Use the KOEO values found in “Appendix A:Performance
circuit. After repairs are
Specifications”.
complete, retest for SPN 3936
Is TC1TOP sensor within specifications? FMI 20.

Step Action Decision

5 Using EST with ServiceMaxx™ software, KOEO, monitor Diesel Yes: Go to step 6.
Particulate Filter Differential (DPFDP) (page 514). Use the KOEO
No: Repair DPFDP sensor
values found in “Appendix A: Performance Specifications.”
circuit. After repairs are
Is DPFDP sensor within specifications? complete, retest for SPN 3936
FMI 20.

Step Action Decision

6 Using EST with ServiceMaxx™ software KOEO, monitor Diesel Yes: Go to step 7.
Oxidation Catalyst Inlet Temperature (DOCIT) sensor. Using
No: Repair DOCIT sensor circuit
the Component Specification values found in “Appendix A:
(page 487). After repairs are
Performance Specifications (page 956).”
complete, retest for SPN 3936
Is DOCIT sensor within specifications? FMI 20.

Step Action Decision

7 Using EST with ServiceMaxx™ software KOEO, monitor Yes: Go to step 8.
Diesel Oxidation Catalyst Outlet Temperature (DOCOT) sensor.
No: Repair DOCOT sensor
Using the Component Specification values found in “Appendix
circuit (page 503). After repairs
A:Performance Specifications (page 956).”
are complete, retest for SPN
Is the DOCOT sensor within specifications? 3936 FMI 20.

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Step Action Decision

8 Using EST with ServiceMaxx™ software KOEO, monitor Yes: Go to step 9.
Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.
No: Repair DPFOT sensor
Using the Component Specification values found in “Appendix
circuit (page 514). After repairs
A:Performance Specifications (page 956).”
are complete, retest for SPN
Is the DPFOT sensor within specifications? 3936 FMI 20.

Step Action Decision

9 Using EST with ServiceMaxx™ software, run the Continuous Yes: Go to step 10.
Monitor session and determine if the O2 sensor is biased (page
No: Repair O2 sensor circuit
819).
(page 819) and then retest for
Is the O2 sensor within specifications? SPN 3936 FMI 20.

Step Action Decision

10 Check for biased DPFDP sensor. Do DPFDP sensor biased Yes: Go to step 11.
check (page 514).
No: Repair DPFDP sensor
Are DPFDP sensor and circuits within specification? or circuits. After repairs are
complete, retest for SPN 3936

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FMI 20.

Step Action Decision

11 Check DPFDP sensor hoses for correct routing and restrictions. Yes: Go to step 12.
Inspect the DPFDP hoses for kinks, improper hose routing,
No: Repair DPFDP hoses. After
reversed hoses or damage. See DPFDP sensor locator for correct
repairs are complete, retest for
routing of hoses.
SPN 3936 FMI 20.
Are the DPFDP hoses routed correctly and free of damage?

Step Action Decision

12 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 13.
out of specifications. Using EST with ServiceMaxx™ software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor or Circuit Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 3936 FMI 20.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 575

Step Action Decision

13 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal change only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.
After repairs are complete, retest
Does IMP sensor signal change:
for SPN 3936 FMI 20.
• When TC2WC is commanded On?
IMP signal change only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN
3936 FMI 20.
Neither change IMP signal when
commanded On: Go to step 14.
Both change IMP signal when
commanded On: Go to step 15.

Step Action Decision

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14 Verify IMP sensor and bore are not restricted due to carbon Yes: Go to step 15.
buildup. Remove and inspect IMP sensor and bore for carbon
No: Clean IMP sensor bore of
buildup.
carbon deposits. After repairs
Is IMP sensor and bore free of carbon buildup? are complete, retest for SPN
3936 FMI 20.

Step Action Decision

15 Do Road Test (Full load to highway speed) (page 161), 100% Both TC1TOP and DPFDP
engine load (when safe to do so). Record a snapshot of the signals are above specification:
following signals: Go to step 16.
• Only TC1TOP signal above
Diesel Particulate Filter Differential Pressure (DPFDP) = 0.5
to 0.8 psi specification: Remove Pre
Diesel Oxidation Catalyst
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP) = 2 to 3 psi
(Pre-DOC) and Diesel Oxidation
• Soot load < 40% Catalyst (DOC) for inspection
and clean or replace as
Are DPFDP and TC1TOP signals within specifications?
necessary. After repairs are
NOTE: DPFDP and TC1TOP specifications only apply with soot complete, retest for SPN 3936
load < 40%. FMI 20.
Neither signal is high, go to step
17.

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Step Action Decision

16 Using EST with ServiceMaxx software, start an Onboard Filter Yes: Go to step 17.
Cleanliness Test (OBFCT). Is OBFCT running without an Abort
No: Correct Parked Regen
Message in ServiceMaxx™?
Inhibitors (page 319) and restart
OBFCT.

Step Action Decision

17 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 18.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for

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SPN 3936 FMI 20.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN
3936 FMI 20.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 3936 FMI 20.
pressure.

Step Action Decision

18 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 19.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 3936
FMI 20.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 577

Step Action Decision

19 Is the vehicle being operated outside torque curve creating Yes: Check application of
excessive soot? vehicle and rear axle gear ratio
for correct RPM range during
vehicle usage.
No: Verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.

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EBPV (Exhaust Back Pressure Valve)

SPN FMI Condition Possible Causes

5542 15 TC1TOP above desired • Restricted Exhaust
• Stuck or sticking closed EBPV
5542 17 TC1TOP below desired • EBPV not closing when commanded
5543 3 EBPC short to PWR • EBPV circuit short to PWR
• Failed EBPV
5543 4 EBPC short to GND • EBPV circuit short to GND
• Failed EBPV
5543 5 EBPC open load/circuit • EBPC circuit OPEN
• Failed EBPV

EBPV circuit

EBPV ACV
ECM 96-Pin
connector (EBPV)
E1 connector
EBPV

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ECM PWROUT2
Pin E1 - 54 connector
(end view)
EBPV 1
Pin E1 - 04 2
VREF3
Pin E1 - 89 8
2
SIG GND
Pin E1 - 20 10 0

V00061

Figure 236 EBPV circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE6003 (EBPV)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
NOTE: The EBPV, TC1TOP, TC1WC, and TC2WC
circuits share the same connector to the ACV
assembly.

582
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 579

Connector Voltage Check – EBPV Disconnected

NOTE: Excessive backpressure in the exhaust system, such as a plugged Diesel Oxidation Catalyst
(DOC), could set this fault. Check for exhaust system damage and proper aftertreatment system
operation before performing electrical checks.
Connect Breakout Harness ZTSE6003 to EBPV engine harness, and leave EBPV disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check (page 580).
2 to GND 3.5 V ± 1.0 V If < 2.5 V, check for OPEN circuit, Do Harness Resistance
Check (page 580).
8 to GND 5 V ± 0.5 V If > 5.5 V, check VREF for short to PWR.
If < 4.5 V, check VREF for OPEN or short to GND. Do
Harness Resistance Check (page 580).
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

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NOTE: Ensure air tanks have at least 90 psi (621 kPa) of pressure.
1. Connect Breakout Harness ZTSE6003 between EBPV and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Exhaust Back Pressure Valve from the drop-down menu.
3. Command Exhaust Back Pressure Valve to 5%.
4. Use DMM to measure voltage.
5. Command Exhaust Back Pressure Valve to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND 5% = 12 V ± 2.0 V If < 10 V, check for OPEN circuit.
2 to GND 95% = 0.5 V ± 0.5 V If > 1 V, check for OPEN circuit or failed EBPV.

Actuator Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE6003 to EBPV and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment
1 to 2 4 Ω to 8 Ω If not within specification, replace the EBPV.
If measurements are within specifications, go to Harness Resistance Check.

583
 580 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with Breakout Harness 00-01468-00 to ECM E1
connector and leave ECM disconnected. Connect Breakout Harness ZTSE6003 to vehicle harness and
leave EBPV disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-54 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-04 <5Ω If > 5 Ω, check for OPEN circuit.
8 to GND > 1k Ω If < 1k Ω, check for short circuit.
8 to E1-89 <5Ω If > 5 Ω, check for OPEN circuit.
10 to GND > 1k Ω If < 1k Ω, check for short circuit.
10 to E1-20 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If DTC returns, replace EBPV.

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584
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 581

ECB1 (Engine Compression Brake 1)

SPN FMI Condition Possible Causes

1072 3 ECB1 Control short to PWR • ECB1 control circuit short to PWR
• Failed ECB1 solenoid
1072 4 ECB1 Control short to GND • ECB1 control circuit short to GND
• Failed ECB1 solenoid
1072 5 ECB1 Control open load/circuit • ECB1 control OPEN circuit
• Failed ECB1 solenoid

ECB1 circuit

ECM 96-Pin ECB1

1ji]
E1 connector ECB1 connector
connector
ECM PWROUT2
Pin E1 - 05 1

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ECB1 I
Pin E1 -47 2
2

V00064

Figure 237 ECB1 circuit diagram

Tools Required • Electronic Service Tool (EST) with ServiceMaxx™

software
• 00-00956-08 – 180-Pin Breakout Box
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness WARNING: To prevent personal injury or
• ZTSE4899 – Big Bore Terminal Test Probe Kit death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
• Breakout Harness ZTSE6004 (ECB)
• Digital Multimeter (DMM)

585
 582 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check – ECB1 Disconnected

Connect Breakout Harness ZTSE6004 to ECB1 engine harness, and leave ECB1 disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check.
2 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE6004 between ECB1 and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Engine Compression Brake 1 from the drop-down menu.
3. Command ECB1 to 5%.

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4. Use DMM to measure voltage.
5. Command ECB1 to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND 5% = 12 V ± 2.0 V If < 10 V, check for OPEN circuit.
2 to GND 95% = 2.5 V ± 0.5 V If > 3 V, check for OPEN circuit or failed ECB1.

Actuator Resistance Check

Turn ignition switch to OFF. Connect Breakout Harness ZTSE6004 to ECB1 and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Specifications Comment
1 to 2 9Ω If not within specification, replace the ECB1.
If measurements are within specifications, go to Harness Resistance Check.

586
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 583

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE6004 to ECB1 engine harness,
and leave ECB1 disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1–05 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-47 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If DTC returns, replace ECB1.

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587
 584 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

ECB2 (Engine Compression Brake 2)

SPN FMI Condition Possible Causes

1073 3 ECB2 Control short to PWR • ECB2 control circuit short to PWR
• Failed ECB2 solenoid
1073 4 ECB2 Control short to GND • ECB2 control circuit short to GND
• Failed ECB2 solenoid
1073 5 ECB2 Control open load/circuit • ECB2 control circuit OPEN
• Failed ECB2 solenoid

ECB2 circuit

ECB2
ECM 96-Pin ECB2
E1 connector ECB2 connector
connector

lii:Pin E1 - 50
ECB2 12V
---------+-+----I 3

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ECB2
-----------t-t-----1 4
Pin E1 - 49

V00065

Figure 238 ECB2 circuit diagram

Tools Required • Breakout Harness ZTSE6004 (ECB)

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

588
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 585

Connector Voltage Check – ECB2 Disconnected

Connect Breakout Harness ZTSE6004 to ECB2 engine harness, and leave ECB2 disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
3 to GND 1 V ± 0.5 V If < 1 V, check for OPEN circuit. Do Harness Resistance
Check.
4 to GND 1 V ± 0.5 V If < 1 V, check for OPEN circuit. Do Harness Resistance
Check.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE6004 between ECB2 and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Engine Compression Brake 2 from the drop-down menu.
3. Command ECB2 to 5%.

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4. Use DMM to measure voltage.
5. Command ECB2 to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
4 to GND 5% = 1 V ± 0.5 V If < 0.5 V, check for OPEN circuit.
4 to GND 95% = 2.5 V ± 0.5 V If < 2 V, check for OPEN circuit or failed ECB1.

Actuator Resistance Check

Turn ignition switch OFF. Connect Breakout Harness ZTSE6004 to ECB2 and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Spec Comment
3 to 4 9Ω If not within specification, replace the ECB2.
If measurements are within specifications, go to Harness Resistance Check.

589
 586 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch OFF. Connect 180-Pin Breakout Box with Breakout Harness 00-01468-00 with ECM E1
and E2 harness to ECM E1 connector, and leave ECM disconnected. Connect Breakout Harness ZTSE6004
to ECB2 engine harness and leave ECB2 disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1–50 <5Ω If > 5 Ω, check for OPEN circuit.
4 to GND > 1k Ω If < 1k Ω, check for short circuit.
4 to E1-49 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If DTC returns, replace the ECB1.

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590
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 587

ECL Switch (Engine Coolant Level)

SPN FMI Condition Possible Causes

111 1 Low Engine Coolant level • Low coolant level
• Checks for leaks or boiling out

ECL circuit

ECL
ECM 58-Pin ECL ECL switch
C2 connector connector connector
(end view)
Pin C2 - 49

ECM PWR OUT 2

Pin C1 - 42 ~t-=-.:::.!.:.!...!.....!.~~~_J 2

ECM 58-Pin 2
C1 connector
V00046

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Figure 239 ECL switch circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

Software
• ZTSE4899 – Big Bore Terminal Test Probe Kit
1. Using Electronic Service Tool (EST) with
• Digital Multimeter (DMM)
ServiceMaxx™ software, verify DTC is active
• Electronic Service Tool (EST) with ServiceMaxx™ for this sensor.
software
• If code is previously active, wiggle the
• J1939 and J1708 RP1210B Compliant Device harness of the suspect sensor. If the
circuit is interrupted, the DTC will go
WARNING: To prevent personal injury or active.
death, stay clear of rotating parts (belts and fan) • If code is active, proceed to Pinpoint ECL
and hot engine surfaces. System Fault.
NOTE: Inspect connectors for damaged,
corrosion, or loose pins. Repair if necessary.

591
 588 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 111 FMI 1 – Low Engine Coolant level

Pinpoint ECL System Fault
1. Check for low coolant level. If coolant is not low, go to Connector Voltage Check.

Connector Voltage Check

Disconnect ECL switch. Using Big Bore Terminal Test Probe Kit ZTSE4899 insert proper terminal into ECL
engine harness connector. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 0V If > 0.5 V, check for short to PWR.
2 to GND 12 V ± 2.0 V If < 10.0 V, check for OPEN circuit.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 connectors, and leave ECM disconnected. Using Big Bore Terminal Test Probe Kit ZTSE4899 insert
proper terminal into ECL engine harness connector. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.

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1 to C2-49 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to C1-42 <5Ω If > 5 Ω, check for OPEN circuit.

592
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 589

ECM Power (Engine Control Module)

SPN FMI Condition Possible Causes

158 15 ECM Switched voltage too HIGH • Jump start using more than system voltage
• Batteries wired incorrectly
158 17 ECM Switched voltage too LOW • Low discharged batteries
• Charging system failure
• High resistance in ECM powering circuits

ECM PWR circuit

ECM 58-Pin
C2 connector
B+ 10A
Pin C2-01

GND
ETV Pin C2-02

Ignition
switch Batteries
+

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3 r----
4 l_.,___....,!S:2JW~BA~TL.__ __J B+
GND 25A
CSR
GND Fuse 5

GND Link
21-Way On/Off Pin C1-04
Engine Harness GND
Interface connector Pin C1-06
SWBAT
Pin C1-17
B+
EGRV Pin C1-01
B+
Pin C1-03
B+
Pin C1-05
Timer
Pin C1-19

ECM 58-Pin
C1 connector V00052

Figure 240 ECM PWR (Input Power) circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box • Electronic Service Tool (EST) with ServiceMaxx™
software
• ZTSE4498 – 3-Banana Plug Harness
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit

593
 590 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 158 FMI 15- ECM Switched voltage too HIGH

Pin-point ECM System Fault
1. Turn engine OFF and measure battery voltage.
• If battery voltage is above 16 V, batteries are wired incorrectly. Repair circuitry.
2. Start engine and measure battery voltage.
• If battery voltage is above 16 V, repair charging system.

SPN 158 FMI 17- ECM Switched voltage too LOW

Pin-point ECM System Fault
1. Start engine and measure battery voltage.
• If battery voltage is below 10 V, repair charging system.
• If voltage is above 12 V, continue to next step.
2. Using ServiceMaxx™ software, monitor Switched Battery voltage.
• If battery voltage is below 10 V, continue pinpoint diagnostics.

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Voltage Checks at ECM
Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle harness
connectors, and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
C1-01 to GND B+ If < B+, check for OPEN in B+ circuit.
C1-03 to GND B+ If < B+, check for OPEN in B+ circuit.
C1-05 to GND B+ If < B+, check for OPEN in B+ circuit.
C2-01 to GND B+ If < B+, check for OPEN in B+ circuit.
C1-19 to GND B+ If < B+, check for OPEN in Timer circuit.
C1-17 to GND B+ If < B+, check for OPEN in SWBAT circuit.
C1-02 to B+ B+ If < B+, check for OPEN in ground circuit.
C1-04 to B+ B+ If < B+, check for OPEN in ground circuit.
C1-06 to B+ B+ If < B+, check for OPEN in ground circuit.
C2-02 to B+ B+ If < B+, check for OPEN in ground circuit.

594
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 591

ECM Power Output (Engine Control Module)

SPN FMI Condition Possible Causes

3597 4 ECM Power Output 1 below normal • ECM Power Output 1 circuit short to GND
ECM Pins: C1-31, C1-33, C1-54,
C2-51, E1-01 and E1-51
3598 4 ECM Power Output 2 below normal • ECM Power Output 2 circuit short to GND
ECM Pins: C1-42, C2-06, E1-05,
E1-28, E1-29 and E1-54
3599 4 ECM Power Output 3 below normal • ECM Power Output 3 circuit short to GND
ECM Pins: C1-30, C2-03, E1-24,
E1-26, and E1-27

ECM Power Output 1

E1-01 C1-31
ECM Power Output 2

E1-05 C1-42 E1 -24

----
ECM Power Output 3
C1-30
E1-51 C1-33 E1-28 E1 -26
C1-54 E1-29 C2-06 E1 -27 C2-03
E1-54

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C2-51
V00160

Figure 241 ECM PWR (Output Power) circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box • Electronic Service Tool (EST) with ServiceMaxx™
software
• ZTSE4498 – 3-Banana Plug Harness
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit

595
 592 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3597 FMI 4 – ECM Power Output 1

Voltage Check
Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle harness
connectors, and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
C1-31 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
C1-33 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
C1-54 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
C2-51 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine harness connectors,
and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than

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E1-01 to GND B+
E1-51 to GND B+
If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Harness Resistance Check

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-31 to GND > 1k Ω If < 1k Ω, check for short circuit.
C1-33 to GND > 1k Ω If < 1k Ω, check for short circuit.
C1-54 to GND > 1k Ω If < 1k Ω, check for short circuit.
C2-51 to GND > 1k Ω If < 1k Ω, check for short circuit.

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.

Turn ignition OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-01 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-51 to GND > 1k Ω If < 1k Ω, check for short circuit.

596
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 593

SPN 3598 FMI 4 – ECM Power Output 2

Voltage Check
Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle harness
connectors, and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
C1-42 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
C2-06 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine harness connectors,
and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
E1-05 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
E1-28 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

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E1-29 to GND B+
E1-54 to GND B+
If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Harness Resistance Check

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-42 to GND > 1k Ω If < 1k Ω, check for short circuit.
C2-06 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-05 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-28 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-29 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-54 to GND > 1k Ω If < 1k Ω, check for short circuit.

597
 594 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.

Turn ignition OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-05 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-28 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-29 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-54 to GND > 1k Ω If < 1k Ω, check for short circuit.

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598
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 595

SPN 3599 FMI 4 – ECM Power Output 3

Voltage Check
Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle harness
connectors, and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
C1-30 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
C2-03 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine harness connectors,
and leave ECM disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
E1-24 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.
E1-26 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

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E1-27 to GND B+ If < B+, check for short to GND or internally shorted component. Do
Harness Resistance Check.

Harness Resistance Check

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and C2 vehicle
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-30 to GND > 1k Ω If < 1k Ω, check for short circuit.
C2-03 to GND > 1k Ω If < 1k Ω, check for short circuit.

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.

Turn ignition OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2 engine
harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-24 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-26 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-27 to GND > 1k Ω If < 1k Ω, check for short circuit.

599
 596 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

ECM (Engine Control Module) Self-Diagnostics

Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

SPN FMI Condition Possible Causes

108 3 BARO signal Out of Range HIGH Internal ECM failure, replace ECM and perform
Crank Position (CKP) relearn procedure (page
598).
108 4 BARO signal Out of Range LOW Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)
628 12 ECM Memory Error Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)
629 2 ECM Error –Level 2 Monitoring Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)
629 8 Engine Off timer fault Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)

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629 12 ECM Internal chip Error Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)
629 14 ECM Internal component Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)
1110 31 ECM Internal component Internal ECM failure, replace ECM and perform
CKP relearn procedure (page 598)

NOTE: Ensure battery voltage is at or above 12 V,

before running the following procedures.

SPN 108 FMI 3- BARO signal Out of Range HIGH

Checks whether the signal from the Barometric Pressure (BARO) sensor is above the maximum threshold.
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 108 FMI 4 - BARO signal Out of Range LOW

Checks whether the signal from the BARO sensor is below the minimum threshold.
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

600
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 597

SPN 628 FMI 12 - ECM Memory Error

Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 629 FMI 2- ECM Error- Level 2 Monitoring

Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 629 FMI 8 - Engine Off timer fault

Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 629 FMI 12 - ECM Internal chip Error

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Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 629 FMI 14 - ECM Internal component

Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

SPN 1110 FMI 31 – ECM Detects Fueling Without Demand

1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM and perform CKP relearn procedure (page 598).

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 598 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Crank Sensor Relearn Procedure 3. Start ServiceMaxx™ software.

Tools Required 4. From sessions drop-down menu select
Programming.
• Electronic Service Tool (EST) with ServiceMaxx™
software 5. Search for parameter Crankshaft Position
Learning Reset Request (ID 95232).
• J1939 and J1708 RP1210B Compliant Device
6. Click in Value field and select Yes from drop-down
Function menu.
To perform Crankshaft Position (CKP) sensor relearn 7. Click on Program Engine button.
after replacing the ECM, CMP, or CKP sensor.
8. After programming is complete, the value will
1. Turn ignition switch to ON, engine OFF. switch back to No.
2. Connect EST to vehicle's Diagnostic Connector.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 599

ECS (Engine Coolant System)

Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

SPN FMI Condition Possible Causes Actions

110 17 Engine Coolant System below OBD • Low coolant level Step-Based Diagnostics
monitoring temperature (page 600)
• Failed Engine
Coolant
Temperature 1
(ECT1) sensor
• Failed engine
cooling fan (stuck
on)
• Failed thermostat
110 18 Engine coolant system below closed • Low coolant level Step-Based Diagnostics
loop minimum temperature (page 602)

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• Failed Engine
Coolant
Temperature 1
(ECT1) sensor
• Failed engine
cooling fan (stuck
on)
• Failed thermostat
1659 20 ECT1 below expected: Check • Failed thermostat Pin-Point Diagnostics
Thermostat (page 604)
4752 4 EGR Cooler Efficiency: EGR Outlet • Low coolant level Pin-Point Diagnostics
Temp above expected (page 604)
• EGR cooler failure

Overview • Interface cable (RP1210B compliant supporting

J1939 and J1708)
Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software

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 600 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 110 FMI 17- Engine Coolant System below OBD monitoring temperature
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Minimum Onboard Engine Coolant Expected Engine Coolant 60 seconds
Diagnostics (OBD) Temperature 1 (ECT1) < Temperature > 158°F (70°C)
coolant temperature not 158°F (70°C)
Limp home mode inactive
reached.
DPF regeneration inactive
Power Take Off (PTO) inactive
Barometric (BARO) pressure >
11 psi (75 kPa)
Engine running > 30 seconds
Ambient Air Temp (AAT) > -40°F
(-40°C)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the signal from Engine Coolant Drive Cycle 13 in 2013 HD-OBD Diagnostic Reference
Temperature 1 (ECT1) is not increasing as expected. Manual.

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Possible Causes
Malfunction Indicator Lamp (MIL) Reaction
• Low coolant level
MIL will illuminate when this fault is detected during
two consecutive drive cycles. • Failed Engine Coolant Temperature 1 (ECT1)
sensor
Associated Faults
• Failed engine cooling fan (stuck on)
SPN 110 FMI 3 and 4 (ECT1)
• Failed thermostat (stuck Open)
Fault Facts
In cold climates, operating the vehicle for extended
periods of time at idle, or Without a winter front, may
cause this fault to set.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 601

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 3,4
No: Repair SPN 110 FMI 3,4.
(ECT1).
After repairs are complete, retest
Is EST DTC list free of SPN 110 FMI 3,4? for SPN 110 FMI 17.

Step Action Decision

2 Inspect coolant level. Check the coolant for correct level and Yes: Go to step 3.
condition.
No: Perform Coolant Loss
Is coolant filled to correct level? (page 79) test. After repairs are
complete, retest for SPN 110
FMI 17.

Step Action Decision

3 Check for stuck on engine cooling fan. Using EST with Yes: Go to step 4.
ServiceMaxx™, go to Tests > KOER Tests > Engine Fan Test.
No: Repair or replace radiator
Determine fans ability to maintain desired speeds.
fan assembly. After repairs are
Is the fan operating properly? complete, retest for SPN 110

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FMI 17.

Step Action Decision

4 Check for a failed ECT1 sensor. Using EST, perform the Coolant Yes: Replace Thermostats.
Control Valve Test. Go to Tests > KOER Tests > Coolant Control After repairs are complete, retest
Valve Test. Set the Coolant Mixer Valve to On (95%) and run the for SPN 110 FMI 17.
engine at high idle.
No: Replace Engine Coolant
Are ECT1 and ECT2 within 10°F (6°C) of each other? Temperature 1 (ECT1) sensor.
After repairs are complete, retest
for SPN 110 FMI 17.

NOTE: After performing all diagnostic steps, if

SPN 110 FMI 17 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 602 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 110 FMI 18- Engine Coolant System below closed loop minimum temperature
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Minimum closed-loop ECT1 < 50°F (10°C) Calculated Engine Coolant 60 seconds
coolant temperature not Temperature > 50°F (10°C)
reached.
Limp home mode inactive
DPF regeneration inactive
Power Take Off (PTO) inactive
Barometric (BARO) pressure >
11 psi (75 kPa)
Engine running > 30 seconds
Ambient Air Temp (AAT) > -40°
F (-40°C)

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the signal from Engine Coolant Drive Cycle 13 in 2013 HD-OBD Diagnostic Reference
Temperature 1 (ECT1) does not allow for closed-loop Manual.

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operation.
Possible Causes
Malfunction Indicator Lamp (MIL) Reaction • Low coolant level
MIL will illuminate when this fault is detected during • Failed Engine Coolant Temperature 1 (ECT1)
two consecutive drive cycles. sensor
• Failed engine cooling fan (stuck on)
Associated Faults
• Failed thermostat (stuck Open)
SPN 110 FMI 3 and 4 (ECT1)

Fault Facts
In cold climates, operating the vehicle for extended
periods of time at idle, or Without a winter front, may
cause this fault to set.

606
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 603

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 3,4
No: Repair SPN 110 FMI 3,4.
(ECT1).
After repairs are complete, retest
Is EST DTC list free of SPN 110 FMI 3,4? for SPN 110 FMI 18.

Step Action Decision

2 Inspect coolant level. Check the coolant for correct level. Yes: Go to step 3.
Is coolant filled to correct level? No: Perform Coolant Loss
(page 79) test. After repairs are
complete, retest for SPN 110
FMI 18.

Step Action Decision

3 Check for a stuck on engine cooling fan. Using EST with Yes: Go to step 4.
ServiceMaxx™ go to Tests > KOER Tests > Engine Fan Test.
No: Repair or replace fan
Determine fans ability to maintain desired speeds.
assembly. After repairs are
Is the fan operating properly? complete, retest for SPN 110

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FMI 18.

Step Action Decision

4 Check for a failed ECT1 sensor. Using EST, perform the Coolant Yes: Replace Thermostats.
Control Valve Test. Go to Tests > KOER Tests > Coolant Control After repairs are complete, retest
Valve Test. Set the Coolant Mixer Valve to On (95%) and run the for SPN 110 FMI 18.
engine at high idle.
No: Replace Engine Coolant
Are ECT1 and ECT2 within 10°F (6°C) of each other? Temperature 1 (ECT1) sensor.
After repairs are complete, retest
for SPN 110 FMI 18.

NOTE: After performing all diagnostic steps, if

SPN 110 FMI 18 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 604 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Cold Soak Sensor Compare Check With ServiceMaxx™ Software

NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare Engine Coolant Temperature 1 (ECT1) to Engine Coolant Temperature 2 (ECT2). Sensor
temperatures should be within 10°F (6°C) of each other.
• If ECT1 is 10°F (6°C) or more above or below ECT2, check for poor circuitry going to the
ECT1 sensor.
4. Verify engine fan is not stuck ON. Using ServiceMaxx™ software, run the Engine Fan Procedure.
5. Remove thermostats using procedure in the Engine Service Manual.
• If the thermostat assemblies are stuck open, damaged, cracked, or not operating properly,
replace them.
• If engine fan or thermostat are not the cause, verify if code was set due to extended idle time in
very cold ambient temperatures while running a large cabin heater.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 605

ECT1 Sensor (Engine Coolant Temperature 1)

SPN FMI Condition Possible Causes

110 3 ECT1 signal Out of Range HIGH • ECT1 signal OPEN or short to PWR
• SIG GND circuit OPEN
• Failed ECT1 sensor
110 4 ECT1 signal Out of Range LOW • ECT1 signal circuit short to GND
• Failed ECT1 sensor

ECT1 circuit

ECM 96-Pin ECT1 ECT1

E1 connector ECT1 connector sensor
/ connector (end view)
' -

IJ 0
ECT1
PinE1-14 1

SIG GND
PinE1-68 3

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\.
'--- 2 4
~

V00016

Figure 242 ECT1 sensor circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4827 (ECT1)
• Digital Multimeter (DMM)
Software
WARNING: To prevent personal injury or
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.

• Electronic Service Tool (EST) with ServiceMaxx™ 2. Monitor sensor voltage and verify an active
software DTC for this sensor.

• J1939 and J1708 RP1210B Compliant Device • If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Sensor
Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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 606 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827 to ECT1 vehicle harness, and leave ECT1 sensor disconnected.
Connect 180-Pin Breakout Box with ECM E1 and E2 harness between ECM E1 and E2 connectors and
ECM. Turn ignition ON. Use a DMM to measure voltage.
Test Point Specification Comment– < Less than, > Greater than
Measure pin E1-71 to GND 4.5 V to 5 V If < 4.5 V, check ECT1 signal circuit for short to GND.
Measure pin E1-71 to GND 0V If > 0.25 V, check ECT1 signal circuit for OPEN. Do
Harness Resistance Check (page 606).
Short ECT1 pin-1 to GND
Measure pin E1-71 to GND 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check (page 606).
Short ECT1 pin-1 to pin-3
Measure pin E1-71 to GND < 1.0 V If > 1.0 V, check ECT1 signal circuit for short to PWR.
Short 500 Ω resistor between
ECT1 pin-1 and pin-3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace ECT1
sensor.

Connector Voltage Check Without ServiceMaxx™ Software

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Connect Breakout Harness ZTSE4827 to ECT1 engine harness, and leave ECT1 sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 4.5 V to 5 V If < 4.5 V, check for short to GND.
3 to B+ B+ If < B+, check for short to PWR.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4827 to ECT1
engine harness and leave ECT1 sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-14 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-68 <5Ω If > 5 Ω, check for OPEN circuit.

610
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 607

ECT2 Sensor (Engine Coolant Temperature 2)

SPN FMI Condition Possible Causes Actions

4076 2 ECT2 signal erratic, intermittent, or • Aftermarket block Step-Based Diagnostics
incorrect heater installed (page 609)
• Failed ECT2 sensor
• High resistance in
ECT2 circuit
• High resistance in
SIG GND circuit
4076 3 ECT2 signal Out of Range HIGH • ECT2 signal circuit Pin-Point Diagnostics
OPEN or short to (page 612)
PWR
• Failed ECT2 sensor
4076 4 ECT2 signal Out of Range LOW • ECT2 signal circuit Pin-Point Diagnostics
short to GND (page 612)
• Failed ECT2 sensor

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4076 17 ECT2 signal stuck low, not warming up • Failed Coolant Flow Pin-Point Diagnostics
Valve (CFV) or (page 612)
circuit
• Failed Coolant
Mixer Valve (CMV)
or circuit

ECT2 circuit

ECM 96-Pin ECT2

ECT2
E1 connector ECT2 connector
sensor
/ connector (end view)
' ECT2
-

II 0
PinE1-71 1

SIG GND
PinE1-44 3
2 4
\. ----
V00018

Figure 243 ECT2 sensor circuit diagram

NOTE: See latest version of Maxxforce 11 / 13

Engine and Aftertreatment Wiring Schematic
Form 0000002941 for additional circuit
information.

611
 608 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Overview
The ECT2 sensor is a thermistor that is supplied 5 V
VREF at pin-1 from ECM pin E1-71. The sensor is
grounded at pin-3 from ECM pin E1-44. As the coolant
temperature increases the resistance of the thermistor
decreases, causing the signal voltage to decrease.
Tools Required
• 180-Pin Breakout Box 00-00956-08
• ECM Breakout Harness 00-01468-00
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• Breakout Harness ZTSE4827
• 500 Ohm Resistor Harness ZTSE4497
• Big Bore Terminal Test Probe Kit ZTSE4899
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• Interface cable (RP1210B compliant supporting
J1939 and J1708)
612
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 609

SPN 4076 FMI 2 ECT2 signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine Coolant ECT2 difference from Key-On Immediate
Temperature 2 (ECT2) Inlet Air Temp (IAT) >
Engine is cold soaked
does not agree with 10°F (6°C)
other sensors. Difference between Engine
Coolant Temperature 1 (ECT1),
Ambient Air Temperature (AAT),
and Exhaust Gas Temperature 1
(EGT1) at Key on < 27°F (15°C)

Fault Overview
Fault code sets when Engine Coolant Temperature 2
(ECT2) differs from Inlet Air Temp (IAT) > 10°F (6°C)
after a cold soak.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during

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two consecutive drive cycles.

Fault Facts
Diagnostic runs at initial Key-On after a minimum of
an 8 hour cold soak.

Drive Cycle to Determine Fault Status

Drive Cycle 10 then 4 in 2013 HD-OBD Diagnostic
Reference Manual.

ECT2 circuit

ECM 96-Pin ECT2

ECT2
E1 connector ECT2 connector
sensor
/ connector (end view)
' -

IJ 0
ECT2
PinE1-71 1

SIG GND
Pin E1 -44 3
'--- 2 4
'"
V00018

Figure 244 ECT2 sensor circuit diagram

613
 610 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Possible Causes
• Aftermarket block heater installed
• Failed ECT2 sensor
• High resistance in ECT2 circuit
• High resistance in SIG GND circuit

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 105 FMI 3, 4
No: Repair SPN 105 FMI 3, 4
and SPN 4076 FMI 0, 3, 4, 15, 17(ECT2).
and SPN 4076 FMI 0, 3, 4, 15,
Is EST DTC list free of SPN 105 FMI 3, 4 and SPN 4076 FMI 17. After repairs are complete,
0, 3, 4, 15, 17? retest for SPN 4076 FMI 2.

Step Action Decision

2 Check ECT2 circuit for high resistance. Connect Breakout Yes: Go to step 3.
Harness ZTSE4827 to ECT2 harness and leave ECT2
No: Repair high resistance
disconnected. Connect 180-pin Breakout Box with ECM Breakout
between ECT2 connector pin-1
Harness 00-01468-00 to ECM E1 harness, and leave ECM

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and ECM connector pin E1-71.
disconnected. Key OFF, use a DMM to measure resistance from
After repairs are complete, retest
Breakout Harness ZTSE4827 pin-1 and 180-pin Breakout Box
for SPN 4076 FMI 2.
pin E1-71.
Is resistance less than 5 ohms?

Step Action Decision

3 Check SIG GND circuit for high resistance. Connect Breakout Yes: Go to step 4.
Harness ZTSE4827 to ECT2 harness and leave ECT2
No: Repair high resistance
disconnected. Connect 180-pin Breakout Box with ECM Breakout
between ECT2 connector pin-3
Harness 00-01468-00 to ECM E1 harness , and leave ECM
and ECM connector pin E1-44.
disconnected. Key OFF, use a DMM to measure resistance from
After repairs are complete, retest
Breakout Harness ZTSE4827 pin-3 and 180-pin Breakout Box
for SPN 4076 FMI 2.
pin E1-44.
Is resistance less than 5 ohms?

614
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 611

NOTE: An aftermarket block heater could set this

fault.

Step Action Decision

4 Check for a failed ECT2 sensor. If installed, disconnect Yes: Replace ECT2 sensor.
aftermarket block heater. After performing drive cycle 10, using After repairs are complete, retest
ServiceMaxx™ software, open the Continuous Monitor session. for SPN 4076 FMI 2.
Compare ECT2 with Inlet Air Temp (IAT).
No: Aftermarket block heater
Is the ECT2 difference greater than 10°F (6°C) of IAT value? causing fault code to set.

NOTE: After performing all diagnostic steps, if

SPN 4076 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 612 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Pinpoint Diagnostics With ServiceMaxx™

Software

ECT2 circuit

ECM 96-Pin ECT2

ECT2
E1 connector ECT2 connector
sensor
connector (end view)
I' '

IJ ~
~

ECT2
PinE1-71 1

SIG GND
Pin E1 -44 3
2 4
\. ----
V00018

Figure 245 ECT2 sensor circuit diagram

2. Monitor sensor voltage and verify an active

WARNING: To prevent personal injury or DTC for this sensor.

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death, stay clear of rotating parts (belts and fan)
and hot engine surfaces. • If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
1. Using Electronic Service Tool (EST) with If circuit is interrupted, signal will spike
ServiceMaxx™ software, run the Continuous and DTC will go active or pending.
Monitor test.
• If DTC is active, continue to Cold Soak
Sensor Compare Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

616
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 613

SPN 4076 FMI 16 – ECT2 signal does not agree with other sensors (Cold soak)
Cold Soak Sensor Compare Check With ServiceMaxx™ Software
NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare ECT2, Engine Coolant Temperature 1 (ECT1), and Engine Oil Temperature (EOT). Sensor
temperatures should be within 5 °C (10 °F) of each other.
• If ECT2 is 5 °C (10 °F) above or below the ECT1 or EOT, check for poor circuitry going to the
ECT2 sensor.
• If circuits are within specification, replace ECT2 sensor.

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827 to ECT2 connector and leave sensor disconnected. Connect 180-pin
Breakout Box with Breakout Harness 00-01468-00. Key ON, use a DMM to measure voltage.
Test Point Specification Comment– < Less than, > Greater than
Measure pin E1-14 to GND 4.5 V to 5 V If <4.5 V, check ECT2 signal circuit for short to GND.

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Measure pin E1-14 to GND 0V If > 0.25 V, check ECT2 signal circuit for OPEN. Do
Harness Resistance Check (page 614).
Short ECT2 pin-1 to GND
Measure pin E1-14 to GND 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check (page 614).
Short ECT2 pin-1 to pin-3
Measure pin E1-14 to GND < 1.0 V If > 1.0 V, check ECT2 signal circuit for short to PWR.
Short 500 Ω resistor between
ECT2 pin-1 and pin-3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace ECT2
sensor.

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827 to ECT2 engine harness, and leave ECT2 sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 4.5 V to 5 V If < 4.5 V, check for short to GND.
3 to B+ B+ If < B+, check for short to PWR.

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 614 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4827 to ECT2
engine harness, and leave ECT2 sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-71 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-44 <5Ω If > 5 Ω, check for OPEN circuit.

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618
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 615

EFC (Engine Fan Control) – Two Speed and

Variable

SPN FMI Condition Possible Causes

647 3 EFC short to PWR • EFC circuit short to PWR
647 4 EFC short to GND • EFC circuit short to GND
647 5 EFC open load/circuit • EFC circuit OPEN
• EFC failure

EFC Two-speed circuit

EFC
Two-speed
ECM 58-Pin connector EFC
C1 connector Connector (end view) Two-speed

Pin C1 - 18

Pin C1 - 30
EFC

ECM PWR OUT 3 B=w

A 3
1

3
~ 06
4
[fil]
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V00070

Figure 246 Two-Speed EFC circuit diagram

EFC Variable speed circuit

ECM 58-Pin EFC Variable

C1 connector
_ _ _ _ _ _ _ _ _,........, connector
speed 1
EFC
Pin C1 - 18 _ _ _ _ _ _ _ _ _,........, 3 3
ECM PWROUT 3 EFC Variable speed
Pin C1- 30
Pin C1- 49
Pin C1- 08
Pin C1- 58
VREF4
>--+-------------1 2
EFS GND
>--+-------------1 4
EFS
>--+-------------15
[fil]
4 EFC Variable 6
speed connector
(end view)
V00071

Figure 247 Variable EFC circuit diagram

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 616 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4844 (EFAN)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
Function Two-Speed EFC
The purpose of the engine fan is to force a higher
airflow through the radiator when the A/C is on or the
ECT goes above a set temperature.
The single-speed EFC is an air-actuated belt-driven
on-off design. When engaged the fan runs at input
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sheave speed, and when disengaged the fan speed
is close to zero.
The two-speed EFC is an air actuated belt-driven
two-speed drive. When engaged the fan runs at input
sheave speed, and when the air clutch releases, the
fan runs at a nominal speed driven by a magnetic
eddy current system that produces 300-400 rpm at
idle and 700-900 rpm at when the engine rpm is 1900.
This provides improved cooling and delays the fan
coming on in high ambient temperatures or at high
loads.
The difference between the single speed and
two-speed EFCs is internal to the fan hub; both fans
have identical external circuitry.
Function Variable EFC
The purpose of the variable electronic engine fan is
to force a higher airflow through the radiator when
the A/C is on or when the ECT goes above a set
temperature.
The variable EFC is a direct-driven electronically
controlled viscous fan drive. The fan has a number of
operating regions.
• From 300 to 1100 engine rpm it is an on-off drive.
Off is under 300 rpm, on is 99% of input speed.
• From 1100 to 1750 engine rpm it is a variable
speed drive with an effective range of 800 rpm to
99% of input speed.
• From 1750 to 2150 engine rpm it is on-off again.
• From 2150 to 2450 engine rpm it is either off or
2625 rpm.
• Above 2450 engine rpm it is off.
EFC – Two Speed Sensor Circuit Operation
The default state of the EFC is ON. B+ is needed to
turn the fan OFF.
ECM Pin C1-18 controls the EFC to shut off by
supplying PWR to the EFC deactivating it.
EFC – Variable Sensor Circuit Operation
The default state of the EFC is ON. B+ is needed to
turn the fan OFF.
ECM Pin C1-18 controls the EFC to shut off by
supplying B+ to the EFC, deactivating it.
ECM Pin C1-58 controls EFC speed by supplying a
Pulse Width Modulated (PWM) signal to the EFC.
620
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 617

Voltage Check at Single or Two-Speed EFC Connector - Actuator Test

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4844 to single or two-speed EFC 2-pin connector, and leave
EFC disconnected.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Engine Fan Control from the drop-down menu.
3. Command Engine Fan Control to 5%.
4. Use DMM to measure voltage.
5. Command Engine Fan Control to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
A to GND B+ If < B+, check for open in ECM PWR OUT 3.
B to GND 0 V to 0.25 V If > 0.25 V, check for short to PWR.
Actuator Test - at 5% state
B to GND 0 V to 0.25 V If > 0.25 V, check for short to PWR.

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Actuator Test - at 95% state
B to GND B+ If < B+, check EFC circuit for OPEN or short to GND. Do Harness
Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4484 to
EFC vehicle harness, and leave EFC disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-30 to A <5Ω If > 5 Ω, check for OPEN circuit between ECM pin C1-30 and EFC pin A.
C1-18 to B <5Ω If > 5 Ω, check for OPEN circuit between ECM pin C1-18 and EFC pin B.
If voltage and resistance measurements are within specification but DTC is still active, or EFC does not
work, replace the EFC.

621
 618 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

EGRT Sensor (Exhaust Gas Recirculation

Temperature)

SPN FMI Condition Possible Causes Actions

412 1 EGRT signal stuck low, not warming • Biased EGRT Pin-Point Diagnostics
up sensor or circuit (page 619)
412 2 EGRT signal does not agree with other • Biased EGRT Pin-Point Diagnostics
sensors sensor or circuit (page 619)
412 3 EGRT signal Out of Range HIGH • EGRT signal circuit Pin-Point Diagnostics
OPEN or shorted to (page 619)
PWR
• SIG GND circuit
OPEN
• Failed EGRT sensor
412 4 EGRT signal Out of Range LOW • EGRT signal circuit Pin-Point Diagnostics
short to GND (page 619)
• Failed EGRT sensor
or circuit

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EGRT circuit
EGRT
sensor
ECM 96- Pin EGRT
E 1 connector EGRT
connector
connector
(end view}

Pin E1 - 95 \..--l--=E~G~R~T_ _ _ _7

Pin E1 - 94 Cl----l---S2.!l~G~G~N.!.!:D~--~ 2
1

iO:
0000058114

Figure 248 EGRT sensor circuit diagram

Tools Required • Breakout Harness ZTSE4760A (EGRT)

• 180-Pin Breakout Box 00-00956-08 • Digital Multimeter (DMM)
• 2010 MaxxForce 11 & 13 Harness Kit • Electronic Service Tool (EST) with ServiceMaxx™
00-01462-00 software
• 3-Banana Plug Harness ZTSE4498 • Interface cable (RP1210B compliant supporting
J1939 and J1708)
• 500 Ohm Resistor Harness ZTSE4497
• Big Bore Terminal Test Probe Kit ZTSE4899

622
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 619

Pinpoint Diagnostics With ServiceMaxx™

Software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Cold Soak
Sensor Compare Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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SPN 412 FMI 2 – EGRT signal does not agree with other sensors
Cold Soak Sensor Compare Check With ServiceMaxx™ Software
NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare EGRT, Engine Coolant Temperature 1 (ECT1), and Engine Coolant Temperature 2
(ECT2). Sensor temperatures should be within 5 °C (10 °F) of each other.
• If EGRT is 5 °C (10 °F) above or below the ECT1 and ECT2, check for poor circuitry going
to the EGRT sensor.
• If circuits are within specification, replace EGRT sensor.

623
 620 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4760A to EGRT engine harness, and leave EGRT sensor disconnected.
Turn ignition ON.
Test Point Specification Comment– < Less than, > Greater than
EST – Monitor EGRTv 4.5 – 5 V If <4.5 V, check EGRT signal circuit for short to GND.
EST – Monitor EGRTv 0V If > 0.25 V, check EGRT signal circuit for OPEN. Do
Harness Resistance Check.
Short pin 1 to GND
EST – Monitor EGRTv 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check.
Short pin 1 to 2
EST – Monitor EGRTv < 1.0 V If > 1.0 V, check EGRT signal circuit for short to PWR.
Short 500 Ω resistor across pins
1 and 2
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace EGRT
sensor.

Connector Voltage Check Without ServiceMaxx™ Software

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Connect Breakout Harness ZTSE4760A to EGRT engine harness, and leave EGRT sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5V If < 4.5 V, check EGRT signal circuit for short to GND.
2 to B+ B+ If < B+, check SIG GND for OPEN circuit.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and
E2 vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4760A to
EGRT engine harness, and leave EGRT sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-95 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-94 <5Ω If > 5 Ω, check for OPEN circuit.

624
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 621

EGR (Exhaust Gas Recirculation) Valve

SPN FMI Condition Possible Causes

27 0 EGRP fault: over temperature • EGR overheated
• Low coolant flow through EGR
• Hot soaking after hard run and
shut down
• Low coolant level
• Failed Coolant Flow Valve (CFV)
27 3 EGRP signal Out of Range HIGH • EGRP circuit short to PWR
27 4 EGRP signal Out of Range LOW • EGRP Open circuit
• EGRP circuit short to GND
27 7 EGRP does not agree with • Sticking or failed EGR valve
commanded position
• EGRP circuit fault
• EGRC circuit fault
2791 3 EGRC short to PWR • EGRC circuit short to PWR

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2791 5 EGRC open load/circuit • EGRC circuit OPEN
• Failed EGR valve
• Sensor or connector terminals:
damaged or pinched wires;
corroded terminals; loose, bent, or
broken pins; or broken connector
housing.
2791 8 EGR valve not receiving ECM PWM • Broken return spring in EGR valve
signal
• Sensor or connector terminals:
damaged or pinched wires;
corroded terminals; loose, bent, or
broken pins; or broken connector
housing.

625
 622 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

EGRV circuit EGRV

ECM 96-Pin E1 connector connector
EGRC EGRV
Pin E1 - 77 1 connector
1 (end view) EGRV
ECM 58-Pin C2 connector 4
EGRP
Pin C2 - 16 14 2

SWBAT 2
B+ ______./ 4 3
lgn Switch
2 4
- 21-Way On/Off 3
GND Engine Harness
Interface connector V00063

Figure 249 EGR Valve circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

Software
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness WARNING: To prevent personal injury or

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• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE6016 (EGR Valve)
• Digital Multimeter (DMM)
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, load the 2010
Actuator session.

• Electronic Service Tool (EST) with ServiceMaxx™ 2. Select EGR Position from the Actuator
software drop-down menu on the right side.

• J1939 and J1708 RP1210B Compliant Device
3. Command actuator movement by clicking on
the Start Test button. Monitor EGR Position
(EGRP) and EGR Valve CTL (EGRC).
• If EGRP does not closely match EGRC,
check EGR valve for mechanical
problem.
• If EGR valve does not move, continue to
Connector Voltage Check.

626
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 623

SPN 27 FMI 7 – EGRP does not agree with commanded position

1. Check coolant level. Low coolant level will cause coolant flow problems through the EGR cooler
and valve.
2. Use ServiceMaxx™ software to run KOER Coolant Valve Test. Verify Coolant Flow Valve (CFV)
and Coolant Mixer Valve (CMV) are working and interstage cooler is sending cooled coolant to
the EGR valve.
3. Interview the driver. Ask the driver if they shut the engine down right after a hard run. Instruct them
to let the engine idle for 5 minutes before shutting down. This will give the coolant a chance to
cool the EGR valve.

Connector Voltage Check — EGR Valve Disconnected

Connect Breakout Harness ZTSE6016 to EGR valve engine harness, and leave EGR valve disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
4 to battery positive B+ If < B+, check for OPEN in GND circuit. Do Harness
Resistance Check (page 624).
3 to GND B+ If < B+, check for OPEN in SWBAT circuit or blown fuse.

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2 to GND 5.0 V ± 1.0 V If > 6 V, check for short to PWR.
If < 4 V, check for OPEN or short to GND. Do Harness
Resistance Check (page 624).
1 to GND 0 V to 1 V If > 1 V, check for short to PWR.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE6016 between EGR valve and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select EGR Position from the drop-down menu.
3. Command EGRP to 5%.
4. Use DMM to measure voltage.
5. Command EGRP to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND 5% = 3.0 V ± 1.0 V If > 4.0 V, check for OPEN or short to PWR.
If < 2.0 V, check for short circuit or failed EGR valve.
2 to GND 95% = 0.8 V ± 0.5 V If > 1.3 V, check for OPEN or short to PWR.
1 to GND 5% = 7.5 V ± 1.0 V If > 8.5 V, check for short to PWR.
If < 6.5 V, check for short circuit.
1 to GND 95% = 0.5 V ± 0.5 V If > 1.0 V, check for OPEN circuit or failed EGR valve.

627
 624 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE6016 to EGR
engine harness, and leave EGR valve disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1–77 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to C2-16 <5Ω If >5 Ω, check for OPEN circuit.
4 to GND <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If the DTC returns, replace the
EGR valve.

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628
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 625

Exhaust Gas Recirculation (EGR) System Monitor

SPN FMI Condition Possible Causes Actions

3058 0 Engine did not go into Open • Biased Oxygen (O2) Step-Based Diagnostics
loop EGR control when sensor or circuit (page 626)
expected
• Biased Engine Coolant
Temperature 1 (ECT1)
sensor or circuit
• Biased Barometric
Pressure (BARO) sensor
or circuit
• Biased Diesel
Oxidation Catalyst Inlet
Temperature (DOCIT)
sensor or circuit
• Exhaust Gas
Recirculation Valve
(EGRV) or circuit failure
• Engine Throttle Valve

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(ETV) or circuit failure
• Exhaust Back Pressure
Valve (EBPV) or circuit
failure
3058 10 Engine did not go into Closed • Biased O2 sensor or Step-Based Diagnostics
loop EGR control when circuit (page 629)
expected
• O2 heater or circuit
• Biased BARO sensor or
circuit
• EGR valve or circuit
failure
• Intake Throttle Valve
(ITV) or circuit failure

Tools Required • J1939 and J1708 RP1210B Compliant Device

• Electronic Service Tool (EST) with ServiceMaxx™
software

629
 626 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3058 FMI 0 - Engine Did Not Go Into Open Loop EGR Control When Expected
Condition / Setting Criteria
Description
Monitors the time it Function of initialized
takes for EGR to enter Engine Coolant
open loop control Temperature 1 (ECT1)
sensor at engine start x
barometric pressure.
Enable Conditions / Values Time Required
Cold Ambient Protection (CAP) 0.05 Seconds
inactive
Time after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Engine Compression brake
inactive

Fault Overview
Fault code sets when O2 sensor is unable to reach
required operating temperature or EGR valve failed
to react to enter open loop operation. Open loop
operation occurs when the engine operates the
EGRV based on calculations rather than on feedback
from the O2. Operating the EGRV before the engine

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reaches operating temperature and establishes open
loop operation could cause performance issues.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Associated Faults
SPN’s 27, 51, 108, 110, 724, 2791, 3223, 3464, 4765,
5542, and 5543.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3058 FMI 0 the only fault code active? After repairs are complete, retest
for SPN 3058 FMI 0.

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air
system from fuel tank to AFI valve for leaks or physical damage.
leaks, fuel leaks or physical
Is air intake system, exhaust system, fuel system and air filter free damage. After repairs are
of restrictions, leaks, and physical damage? complete, retest for SPN 3058
FMI 0.

630
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 627

Step Action Decision

3 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 4.
session and monitor Diesel Oxidation Catalyst Inlet Temperature
No: Do Hot Run Sensor
(DOCIT) sensor (Wiggle test may be necessary if code is inactive
Comparison Test (page 72).
or pending.).
After repairs are complete, retest
Is DOCIT sensor within specifications? for SPN 3058 FMI 0.

Step Action Decision

4 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 5.
2
session and monitor Oxygen (O S) sensor (Wiggle test may be 2
No: Do O S Biased Sensor or
necessary if code is inactive or pending.).
Circuit Check (page 819). After
2
Is O S sensor within specifications? repairs are complete, retest for
SPN 3058 FMI 0.

Step Action Decision

5 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 6.
session and monitor Barometric Pressure (BARO) sensor. See
No: Do ECM Self-Diagnostics
Key-On Engine-Off Barometric Pressure (page 953) for sensor
(page 596). After repairs are

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value (Wiggle test may be necessary if code is inactive or
complete, retest for SPN 3058
pending.).
FMI 0.
Is the BARO sensor within specifications?

Step Action Decision

6 Using EST with ServiceMaxx™ software, run Continuous Yes: Go to step 7.
Monitor session and monitor Engine Coolant Temperature 1
No: Do ECT1 sensor Circuit
(ECT1) sensor. See Component Specification in “Appendix A:
Checks (page 606). After repairs
Performance Specifications” (page 956) for sensor value (Wiggle
are complete, retest for SPN
test may be necessary if code is inactive or pending.).
3058 FMI 0.
Is the ECT1 sensor within specifications?

Step Action Decision

7 Using EST with ServiceMaxx™ software, see Exhaust Gas Yes: Go to step 8.
Recirculation (EGR) Valve Pinpoint Diagnostics (page 622) for
No: Correct EGR Valve issues
EGR Valve Actuator command test.
and retest for SPN 3058 FMI.
Is EGR Valve within specifications?

Step Action Decision

8 Using EST with ServiceMaxx™ software, see Engine Throttle Yes: Go to step 9.
Valve (ETV) Pinpoint Diagnostics (page 642) for ETV Valve
No: Correct ETV issues and
Actuator command test.
retest for SPN 3058 FMI 0.
Is ETV Valve within specifications?

631
 628 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

9 Using EST with ServiceMaxx™ software, do Exhaust Back Yes: Verify each step was
Pressure Valve (EBPV) test (page 163) for EBPV Actuator test. completed correctly and the
proper decision was made.
Is EBPV within specifications?
Notify supervisor for further
action.
No: Correct EBPV issues and
retest for SPN 3058 FMI 0.

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632
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 629

SPN 3058 FMI 10 - Engine Did Not Go Into Closed Loop EGR Control When Expected
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Monitor the time it takes ECM not entering closed Cold Ambient Protection (CAP) 0.05 Seconds
for EGR to enter closed loop operation within inactive
loop control 61 minutes after engine
Time after Key On > 0 seconds
starts.
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Engine Compression brake
inactive
Engine in required speed > 1000
rpm and load > 40% enable
region.

Fault Overview
Fault code sets when O2 sensor is unable to reach
required operating temperature or EGR valve failed

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to react to enter open loop operation. Open loop
operation occurs when the engine operates the
EGRV based on calculations rather than on feedback
from the O2. Operating the EGRV before the engine
reaches operating temperature and establishes open
loop operation could cause performance issues.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Associated Faults
SPN’s 27, 51, 108, 724, 2791, 3223, 3464, 4765,
5542, and 5543.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 3058 FMI 10 the only fault code active? After repairs are complete, retest
for SPN 3058 FMI 10.

633
 630 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air
system from fuel tank to AFI valve for leaks or physical damage.
leaks, fuel leaks or physical
Is air intake system, exhaust system, fuel system and air filter free damage. After repairs are
of restrictions, leaks, and physical damage? complete, retest for SPN 3058
FMI 10.

Step Action Decision

3 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 4.
session and monitor Diesel Oxidation Catalyst Inlet Temperature
No: Do Hot Run Sensor
(DOCIT) sensor (Wiggle test may be necessary if code is inactive
Comparison Test (page 72).
or pending.).
After repairs are complete, retest
Is DOCIT sensor within specifications? for SPN 3058 FMI 10.

Step Action Decision

4 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 5.

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2
session and monitor Oxygen (O S) sensor (Wiggle test may be 2
No: Do O S Biased Sensor or
necessary if code is inactive or pending.).
Circuit Check (page 819) and
2
Is O S sensor within specifications? retest for SPN 3058 FMI 10.

Step Action Decision

5 Using EST with ServiceMaxx™ software, run Continuous Monitor Yes: Go to step 6.
session and monitor Barometric Pressure (BARO) sensor. See
No: Do ECM Self-Diagnostics
Key-On Engine-Off Barometric Pressure (page 953) for sensor
(page 596) and retest for SPN
value (Wiggle test may be necessary if code is inactive or
3058 FMI 10.
pending.).
Is the BARO sensor within specifications?

Step Action Decision

Yes: Go to step 7.
6 Using EST with ServiceMaxx™ software, see Exhaust Gas No: Correct EGR Valve issues
Recirculation (EGR) Valve Pinpoint Diagnostics (page 622) for and retest for SPN 3058 FMI 10.
EGR Valve Actuator command test.
Is EGR Valve within specifications?

Step Action Decision

7 Using EST with ServiceMaxx™ software, see Engine Throttle Yes: Go to step 8.
Valve (ETV) Pinpoint Diagnostics (page 642) for ETV Valve
No: Correct ETV issues and
Actuator command test.
retest for SPN 3058 FMI 10.
Is ETV Valve within specifications?

634
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 631

Step Action Decision

8 Using EST with ServiceMaxx™ software, do Exhaust Back Yes: Verify each step was
Pressure Valve (EBPV) test (page 163) for EBPV Actuator test. completed correctly and the
proper decision was made.
Is EBPV within specifications?
Notify supervisor for further
action.
No: Correct EBPV issues and
retest for SPN 3058 FMI 10.

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635
 632 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

EOL Sensor (Engine Oil Level)

SPN FMI Condition Possible Causes

98 3 EOL signal Out of Range HIGH • EOL signal circuit OPEN or short to PWR
• SIG GND circuit OPEN
• Failed EOL sensor
98 4 EOL signal Out of Range LOW • EOL signal circuit short to GND
• Failed EOL sensor
1135 3 EOT2 signal Out of Range HIGH • EOT2 signal circuit OPEN or short to PWR
• SIG GND circuit OPEN
• Failed EOL sensor
1135 4 EOT2 signal Out-of-Range LOW • EOL signal circuit short to GND
• Failed EOL sensor

EOL circuit
EOL
ECM 96-Pin EOL
sensor

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E1 connector connector EOL
PinE1 -64
PinE1 -45
EOL
SIGGND
1
2
connector
(end view) I I

SIGGND
PinE1 -46 4
3
EOT2
PinC1 - 15 5 3
21-Way On/Off
ECM 58-Pin 4 2
Engine Harness
C1 connector Interface connector V00037

Figure 250 EOL sensor circuit diagram

Tools Required • Breakout Harness ZTSE4827 (EOL)

• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

636
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 633

Pinpoint Diagnostics With ServiceMaxx™

Software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor session.
2. Monitor sensor voltage. Verify an active DTC
for the sensor.
• If DTC is inactive, monitor the signal
while wiggling the connector and all wires
at suspected location. If the circuit is
interrupted, the signal will spike and the
DTC will go active.
• If DTC is active, continue to Sensor
Circuit Check.
NOTE: Inspect connectors for damaged pins,

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corrosion, loose pins. Repair if necessary.

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827 to EOL vehicle harness, and leave EOL sensor disconnected.
Turn ignition ON..
Test Point Specification Comment– < Less than, > Greater than
EST – Monitor EOLv 4.5 V – 5 V If < 4.5 V, check EOL circuit for short to GND.

EST – Monitor EOT2v 4.5 V – 5 V If < 4.5 V, check EOT2 circuit for short to GND.
EST – Monitor EOLv 0V If > 0.5 V, check EOL circuit for OPEN. Do Harness
Resistance Check.
Short pin 1 to GND
EST – Monitor EOLv 0V If > 0.5 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check.
Short pin 1 to 4
EST – Monitor EOT2v 0V If > 0.5 V, check EOT2 circuit for OPEN. Do Harness
Resistance Check.
Short pin 3 to GND
EST – Monitor EOT2v 0V If > 0.5 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check.
Short pin 2 to 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace EOL
sensor.

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 634 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827. Leave EOL sensor disconnected. Turn ignition switch ON. Use
DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5V±5V If > 5.5 V, check EOL for short to PWR.
If < 4.5 V, check EOL for OPEN or short to GND. Do
Harness Resistance Check.
3 to GND 5V If > 5.5 V, check EOT2 for short to PWR.
If < 4.5 V, check EOT2 for OPEN or short to GND. Do
Harness Resistance Check.
2 to B+ B+ If < B+, check SIG GND for OPEN circuit.
4 to B+ B+ If < B+, check SIG GND for OPEN circuit.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4827 to EOL
vehicle harness, and leave EOL sensor disconnected. Use DMM to measure resistance.

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Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short GND in EOL circuit.
1 to E1-64 <5Ω If > 5 Ω, check for OPEN in EOL circuit.
2 to E1-45 <5Ω If > 5 Ω, check for OPEN in SIG GND circuit.
3 to GND >1k Ω If < 1k Ω, check for short to GND in EOT2 circuit.
3 to C1-15 <5Ω If > 5 Ω, check for OPEN in EOT2 circuit.
4 to E1-46 <5Ω If > 5 Ω, check for OPEN in SIG GND circuit.

638
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 635

EOP Sensor (Engine Oil Pressure)

SPN FMI Condition Possible Causes Actions

100 3 EOP signal Out of Range HIGH • EOP signal circuit Pin-Point Diagnostics
OPEN or short to (page 635)
PWR
• SIG GND circuit
OPEN
• Failed EOP sensor
100 4 EOP signal Out of Range LOW • EOP signal circuit Pin-Point Diagnostics
short to GND (page 635)
• VREF5 circuit
OPEN
• Failed EOP sensor

EOP circuit

EOP

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EOP
ECM 96-Pin connector
sensor
E1 connector EOP (end view)
connector

~
VREF-5
Pin E1 - 82 1
SIG GND
PinE1-19 2
EOP
Pin E1 - 10 3

V00014

Figure 251 EOP sensor circuit diagram

Tools Required • J1939 and J1708 RP1210B Compliant Device

• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness
00-01462-00
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4882 (EOP)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
Pinpoint Diagnostics With ServiceMaxx™
Kit Software
WARNING: To prevent personal injury or
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.

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 636 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2. Monitor sensor voltage and verify an active

DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Sensor
Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

Sensor Circuit Check

Connect Breakout Harness ZTSE4882 to EOP engine harness, and leave EOP sensor disconnected.
Turn ignition ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor EOPv 5.0 V ± 0.5 V If < 4.5 V, check EOP signal circuit for short to GND
DMM – Measure volts 5.0 V ± 0.5 V If > 5.5 V, check VREF5 circuit for short to PWR.
1 to GND If < 4.5 V, check VREF5 circuit for OPEN or short to GND.

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Do Harness Resistance Check (page 637).
DMM – Measure 5 V ± 0.5 V If < 4.5 V, check SIG GND circuit for OPEN. Do Harness
voltage Resistance Check (page 637).
1 to 2
EST – Monitor EOPv 0V If > 0.5 V, check EOP signal circuit for OPEN. Do Harness
Resistance Check (page 637).
Short across Breakout
Harness ZTSE4882
pins 2 and 3
If checks are within specification, connect sensor and clear DTCs. If active DTC remains, replace EOP
sensor.

Connector Voltage Check

Connect Breakout Harness ZTSE4882 to EOP engine harness, and leave EOP sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5 V ± 0.5 V If > 5.5 V, check VREF5 circuit for short to PWR.
If < 4.5 V, check VREF5 circuit for OPEN or short to GND.
Do Harness Resistance Check (page 637).
2 to GND 0V If > 0.25V, check SIG GND circuit for short to PWR.
3 to GND 5 V ± 0.5 V If < 4.5 V, check EOP signal circuit for short to GND.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 637

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4882 to EOP
engine harness, and leave EOP sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
1 to E1-82 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short to GND.
2 to E1-19 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short to GND.
3 to E1-10 <5Ω If > 5 Ω, check for OPEN circuit.

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 638 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

EOT Sensor (Engine Oil Temperature)

SPN FMI Condition Possible Causes Action

175 3 EOT signal Out of Range High • EOT signal circuit Pin-Point Diagnostics
OPEN or short to (page 638)
PWR
• SIG GND circuit
OPEN
• Failed EOT sensor
175 4 EOT signal Out of Range LOW • EOT signal circuit Pin-Point Diagnostics
short to GND (page 638)
• Failed EOT sensor

EQT circuit

EQT
ECM 96-Pin EQT
sensor
E1 connector EQT connector

~
connector (end view)
/
' -

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~
EQT
PinE1-36 1

SIG GND
PinE1-63 3
'---
\..

V00011

Figure 252 EOT sensor circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

Software
• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness Kit WARNING: To prevent personal injury or
00-01462-00 death, stay clear of rotating parts (belts and fan)
• ZTSE4498 – 3-Banana Plug Harness and hot engine surfaces.

• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4827 (EOT)
• Digital Multimeter (DMM)
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.

• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Sensor
Circuit Check.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 639

NOTE: Inspect connectors for damaged pins,

corrosion, or loose pins. Repair if necessary.

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4827 to EOT engine harness, and leave EOT sensor disconnected.
Turn ignition ON.
Test Point Specification Comment– < Less than, > Greater than
EST – Monitor EOTv 4.5 V to 5 V If < 4.5 V, check EOT signal circuit for short to GND.
EST – Monitor EOTv 0V If > 0.25 V, check EOT signal circuit for OPEN. Do
Harness Resistance Check (page 639).
Short pin 1 to GND
EST – Monitor EOTv 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check (page 639).
Short pin 1 to 3
EST – Monitor EOTv < 1.0 V If > 1.0 V, check EOT signal circuit for short to PWR.
Short 500 Ω resistor across pins
1 and 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace EOT
sensor.

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Pinpoint Diagnostics Without ServiceMaxx™ Software
Connect Breakout Harness ZTSE4827 to EOT engine harness, and leave EOT sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 4.5 V to 5 V If < 4.5 V, check for short to GND.
3 to B+ B+ If < B+, check for short to PWR.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4827 to EOT
engine harness, and leave EOT sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-36 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-63 <5Ω If > 5 Ω, check for OPEN circuit.

643
 640 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

ETV (Engine Throttle Valve)

SPN FMI Condition Possible Causes Actions

51 0 ETP fault: over temperature • ETV internal failure
51 3 ETP signal Out of Range HIGH • ETP circuit short to
PWR
51 4 ETP signal Out of Range LOW • ETP Open Circuit
• ETP circuit short to
GND
51 7 ETP does not agree with commanded • Sticking or failed
position ETV
• ETP circuit fault
• ETC circuit fault
3464 3 ETC short to PWR • ETC circuit short to
PWR
• Failed ETV
Pin-Point Diagnostics
(page 642)
Pin-Point Diagnostics
(page 642)
Pin-Point Diagnostics
(page 642)
Step-Based Diagnostics
(page 645)
Pin-Point Diagnostics
(page 642)

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3464 5 ETC open load/circuit • ETC circuit OPEN Pin-Point Diagnostics
(page 642)
• Failed ETV
3464 8 ETC not receiving command from • ETC circuit fault Pin-Point Diagnostics
ECM (page 642)

ETV
ETV
ECM 96-Pin E1 connector ETV
connector
ETC connector
Pin E1 - 75 1 1 (end view) ETV
4
ETP
Pin E1 - 57 2

2
B+ ........... SWBAT
3 3
lgn Switch
1 4
21-Way On/Off 3
GND
Engine Harness
Interface connector V00058

Figure 253 ETV valve circuit diagram

Tools Required • ZTSE4497 – 500 Ohm Resistor Harness

• 00-00956-08 – 180-Pin Breakout Box • ZTSE4899 – Big Bore Terminal Test Probe Kit
• 2010 MaxxForce 11 & 13 Harness Kit • Breakout Harness ZTSE6016 (ETV)
00-01462-00
• Digital Multimeter (DMM)
• ZTSE4498 – 3-Banana Plug Harness

644
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 641

• Electronic Service Tool (EST) with ServiceMaxx™

software
• J1939 and J1708 RP1210B Compliant Device

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Figure 254
1.
ETV Location
Engine Throttle Valve (ETV)
0000048972

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 642 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

ETV
ETV
ECM 96-Pin E1 connector ETV
connector
ETC connector
Pin E1 - 75 1 1 (end view) ETV
4
ETP
Pin E1 - 57 2

B+
.--
lgn Switch
SWBAT
3
1
3
4
2

- 21-Way On/Off 3
GND
Engine Harness
Interface connector V00058

Figure 255 ETV valve circuit diagram

Pinpoint Diagnostics With ServiceMaxx™ 3. Command actuator movement by clicking

Software on the Start Test button. Monitor Engine
Throttle Position (ETP) and Engine Throttle
WARNING: To prevent personal injury or CTL (ETC).

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death, stay clear of rotating parts (belts and fan) • If ETP does not closely match ETC, check
and hot engine surfaces. ETV for mechanical problem.
1. Using Electronic Service Tool (EST) with • If ETV does not move, continue to
ServiceMaxx™ software, go to Tests > KOEO Connector Voltage Check.
Tests > Actuator Test.
2. Select ETV Position from the Actuator
drop-down menu on the right side.

646
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 643

Connector Voltage Check — ETV Disconnected

Connect Breakout Harness ZTSE6016 to ETV engine harness, and leave ETV disconnected. Turn ignition
ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
4 to battery positive B+ If < B+, check for OPEN in GND circuit. Do Harness
Resistance Check (page 644).
3 to GND B+ If < B+, check for OPEN in SWBAT circuit or blown fuse.
2 to GND 12 V ± 2.0 V If < 10 V, check for OPEN or short to GND. Do Harness
Resistance Check (page 644).
1 to GND 0 V to 1 V If > 1 V, check for short to power.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE6016 between ETV and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select ETV Position from the drop-down menu.

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3. Command ETVP to 5%.
4. Use DMM to measure voltage.
5. Command ETVP to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND 5% = 3.0 V ± 1.0 V If > 4.0 V, check for OPEN or short to PWR.
If < 2.0 V, check for short circuit or failed ETV.
2 to GND 95% = 0.8 V ± 0.5 V If > 1.3 V, check for OPEN or short to PWR.
1 to GND 5% = 7.5 V ± 1.0 V If > 8.5 V, check for short to PWR.
If < 6.5 V, check for short circuit.
1 to GND 95% = 0.5 V ± 0.5 V If > 1.0 V, check for OPEN circuit or failed ETV.

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 644 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

ETV
ETV
ECM 96-Pin E1 connector ETV
connector
ETC connector
Pin E1 - 75 1 1 (end view) ETV
4
ETP
Pin E1 - 57 2

B+
.--
lgn Switch
SWBAT
3
1
3
4
2

- 21-Way On/Off 3
GND
Engine Harness
Interface connector V00058

Figure 256 ETV valve circuit diagram

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE6016 to ETV
engine harness, and leave APP sensor disconnected. Use DMM to measure resistance.

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Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-75 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-57 <5Ω If > 5 Ω, check for OPEN circuit.
4 to GND <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If the DTC returns, replace
the ETV.

648
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 645

SPN 51 FMI 10 - ETP sensor feedback deviation during CSER

Condition /
Description
Engine Throttle Position
(ETP) sensor does
not a agree with ECM
commanded position
Setting Criteria Enable Conditions / Values Time Required
Engine Throttle Valve Key ON 8 seconds
(ETV) position > 10%
from commanded position

Fault Overview
Fault code sets when feedback from the Engine
Throttle Position (ETP) sensor does not agree with the
Engine Control Module (ECM) commanded position
during Cold Start Emission Reduction (CSER).

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults

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SPN 51 FMI 7.

Drive Cycle to Determine Fault Status

Drive Cycle 18 then 4 in 2013 HD-OBD Diagnostic
Reference Manual.

ETV
ETV
ECM 96-Pin E1 connector ETV
connector
ETC connector
Pin E1 - 75 1 1 (end view) ETV
4

.~
ETP
Pin E1 - 57 2

SWBAT 2
B+ 3 3
lgn Switch
1 4
21-Way On/Off 3
GND
Engine Harness
Interface connector V00058

Figure 257 ETV valve circuit diagram

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 646 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Do Operational Voltage
check Diagnostic Trouble Code (DTC) list for SPN 51 FMI 3, SPN Check (page 643). After repairs
51 FMI 4, SPN 3464 FMI 3, and SPN 3464 FMI 5. are complete, retest for SPN 51
FMI 10.
Is SPN 51 FMI 10 the only fault code active?
No: Repair other fault code(s).
After repairs are complete, retest
for SPN 51 FMI 10.

NOTE: After doing all diagnostic steps, if SPN 51

FMI 10 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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650
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 647

EWPS (Engine Warning Protection System)

SPN FMI Condition Possible Causes Actions

100 1 Engine Oil System below • Biased EOP sensor or circuit EWPS
critical pressure Programmable
• Engine oil system mechanical
Parameters (page
failure
651)
100 11 Engine oil pressure below • Lubrication system suction side EWPS
dealer programmed engine leak (pickup tube) Programmable
RPM value Parameters (page
• Engine oil system mechanical
651)
failure
• Biased EOP sensor or circuit
100 17 Low Oil Pressure vehicle event • Oil pressure regulator stuck open EWPS
fault Programmable
• Biased EOP sensor or circuit
Parameters (page
• Engine oil system mechanical 651)
failure
100 18 Engine Oil System below • Biased EOP sensor or circuit EWPS
Warning Pressure Programmable

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• Engine oil system mechanical
Parameters (page
failure
651)
110 0 Engine Coolant System above • Biased ECT1 sensor or circuit Step-Based
Critical Temperature Diagnostics (page
• Low coolant level
654)
• Engine cooling system
mechanical failure
110 11 Event Logger, Coolant Temp • Incorrect value in Programmable Step-Based
Hot, Extreme Parameter (PP) 8332 Diagnostics (page
656)
• Blockage between radiator and
Charge Air Cooler (CAC) or Low
Temperature Radiator (LTR)
• Cooling system overheating
• Degraded coolant

651
 648 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

110 15 Engine Coolant System above • Incorrect value in Programmable Step-Based

Warning Temperature
110 16 Engine Coolant System above
OBD maximum temperature
111 1 Low Engine Coolant Level
Parameter (PP) 77012 Diagnostics (page
656)
• Failed Thermostat
• Low Temperature Radiator (LTR)
Plugged
• Blockage between Charge Air
Cooler (CAC) and Radiator
• Degraded Coolant
• Failed Water pump
• Failed CCV
• Low coolant level EWPS
Programmable
• Check for leaks or boiling out
Parameters (page
651)
• Biased ECT1 sensor or circuit EWPS
Programmable
• Low coolant level
Parameters (page
• Engine cooling system 651)

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mechanical failure
175 0 Engine Coolant System above • Biased EOT sensor or circuit EWPS
critical temperature Programmable
• Failed Engine oil cooler
Parameters (page
651)
175 11 Engine Oil System above • Biased EOT sensor or circuit EWPS
critical temperature Programmable
• Failed engine oil cooler
Parameters (page
651)
175 15 Engine Coolant System above • Biased EOT sensor or circuit EWPS
warning temperature Programmable
Parameters (page
651)
188 0 Engine unable to achieve • Engine over-fueling Step-Based
desired idle speed (too high) Diagnostics (page
• External fuel source
658)
• Lube oil leak to intake
• Fuel leak to intake
• Contaminated fuel

652
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 649

188 1 Engine unable to achieve • Low Fuel Rail Pressure (FRP) Step-Based
desired idle speed (too low) Diagnostics (page
• Low Fuel Delivery Pressure (FDP)
660)
• Low cylinder compression
• Clutch or Power Take Off (PTO)
engagement without command
• Injector or injector circuit fault
190 0 Engine overspeed most severe • Failed Turbocharger Step-based
level Diagnostics (page
• Contaminated fuel
663)
• Failed fuel injector
• Air born combustibles
190 11 Engine overspeed vehicle • Transmission in too low of a gear EWPS
event fault at high vehicle speed Programmable
Parameters (page
651)
190 15 Engine overspeed detected • Transmission in too low of a gear EWPS
at high vehicle speed Programmable
Parameters (page

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651)
190 16 Engine above 2250 rpm • Transmission in too low of a gear EWPS
at high vehicle speed Programmable
Parameters (page
651)
2588 0 Vehicle overspeed 1, event • Vehicle speed has exceeded the Step-Based
log, extreme value in PP 77232 Diagnostics (page
665)
2588 15 Vehicle overspeed 1, event • Vehicle speed has exceeded the Step-Based
log, non extreme value in PP 77232 Diagnostics (page
666)
2589 0 Vehicle overspeed 2, event • Vehicle speed has exceeded the Step-Based
log, extreme value in PP 77242 Diagnostics (page
667)
2589 15 Vehicle overspeed 2, event • Vehicle speed has exceeded the Step-Based
log, non extreme value in PP 77242 Diagnostics (page
668)
4076 0 ECT2 above Critical (EWPS • Biased ECT2 sensor or circuit EWPS
programmable limit) Programmable
• Low coolant level
Parameters (page
• Engine cooling system 651)
mechanical failure

653
 650 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

4076 15 ECT2 above Warning (EWPS • Biased ECT2 sensor or circuit EWPS
programmable limit) Programmable
• Low coolant level
Parameters (page
• Engine cooling system 651)
mechanical failure
5395 0 Engine unable to achieve • Failed fuel injector Step-Based
desired idle torque (too high) Diagnostics (page
• Aftermarket PTO system not
669)
installed correctly
• Aftermarket PTO system not
programmed correctly
5395 1 Engine unable to achieve • Engine mechanical failure Step-Based
desired idle torque (too low) Diagnostics (page
• Failed cylinder
671)
• External fuel source
• Lube oil leak to intake
• Fuel leak to intake
• Contaminated fuel

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Input Output
CKP
Triangle
ECT
--------l Warning
CMP J1939 Light

Red Exclamation
EOP Stop Engine Light
Calibration
EQT Reduce Power
Engine Shutdown

ECL

V00012

Figure 258 Functional diagram for the EWPS

Function The following optional features to this base system

The EWPS warns the operator of conditions that can
damage the engine.
The Standard Warning System is the base system in
which all engines are equipped. If one of these faults
are detected, the ECM illuminates the red engine lamp
and sets a corresponding DTC.
provide added warning or protection.
Standard Warning – No engine shutdown available.
• ECT - Engine overheat warning
• EOP - Low engine oil pressure warning
3-way Warning – No engine shutdown available.
• ECT - Engine overheat warning

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS
• EOP - Low engine oil pressure warning
• ECL - Low engine coolant level warning
3-way Protection – Engine shutdown is available if
critical condition is detected.
• ECT, EOP, ECL - Same as 3-way Warning
• ECT - Engine overheat critical protection
• EOP - Low engine oil pressure critical protection
• ECL - Low engine coolant level critical protection
Warning (Amber Triangle Light) – Temperature
above specific threshold sounds a buzzer, illuminates
the red OIL/WATER (OWL) lamp and sets a DTC.
Critical (Exclamation Mark Stop Lamp) –
Temperature above specific threshold shuts down the
engine and sets a DTC.
Event log (NOTE: Don't have yet but is supposed
to be in the software) – This feature logs occurrences
of the event according to the engine hours and
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odometer readings.
EWPS Programmable Parameters
• 1 = 3-way Warning
• 2 = 3-way Protection
• 3 = Standard Warning
ECT Warning Temperature – Specifies temperature
threshold where the Triangle Warning light and
warning buzzer is turned on.
ECT Critical Temperature – Specifies temperature
threshold where an engine shutdown is commanded
(Exclamation Engine Stop lamp).
EOP Engine Speed Region Boundary 1 (600 RPM)
– Specifies at what RPM a specified oil pressure (EOP
Critical Pressure for Region 1) should be detected.
EOP Engine Speed Region Boundary 2 (800 RPM)
– Specifies at what RPM a specified oil pressure (EOP
Critical Pressure for Region 2) should be detected.
EOP Engine Speed Region Boundary 3 (1000 RPM)
– Specifies at what RPM a specified oil pressure (EOP
Critical Pressure for Region 3) should be detected.
651
EOP Warning Pressure for Region 1 (10 psi / 69
kPa) – Specifies the minimum oil pressure with engine
speed greater than (EOP Engine Speed Region
Boundary 1). Failure to meet set point turns on the
OIL/WATER lamp and warning buzzer.
EOP Warning pressure for Region 2 (16 psi /
110 kPa) – Specifies the minimum oil pressure with
engine speed greater than (EOP Engine Speed
Region Boundary 1), but less than (EOP Engine
Speed Region Boundary 2). Failure to meet set point
turns on the OIL/WATER lamp and warning buzzer.
EOP Warning Pressure for Region 3 (20 psi /
138 kPa) – Specifies the minimum oil pressure with
engine speed greater than (EOP Engine Speed
Region Boundary 2), but less than (EOP Engine
Speed Region Boundary 3). Failure to meet set point
turns on the OIL/WATER lamp and warning buzzer.
EOP Critical Pressure for Region 1 (7.5 psi / 52
kPa) – Specifies the minimum oil pressure with engine
speed greater than (EOP Engine Speed Region
Boundary 1). Failure to meet set point commands an
engine shut down.
EOP Critical Pressure for Region 2 (12 psi / 83
kPa) – Specifies the minimum oil pressure with
engine speed greater than (EOP Engine Speed
Region Boundary 1), but less than (EOP Engine
Speed Region Boundary 2). Failure to meet set point
commands an engine shutdown.
EOP Critical Pressure for Region 3. (15 psi /
103 kPa) – Specifies the minimum oil pressure with
engine speed greater than (EOP Engine Speed
Region Boundary 2), but less than (EOP Engine
Speed Region Boundary 3). Failure to meet set point
commands an engine shutdown.
Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
655
 652 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 110 FMI 0 - Engine Coolant System above Critical Temperature

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine Coolant ECT1 > value Key-On Engine-Running Immediate
Temperature 1 programmed into
(ECT1) above critical Programmable
temperature Parameter (PP) 77022

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that Engine Coolant Temperature
1 (ECT1) is above Programmable Parameter (PP)
77022.

Malfunction Indicator Lamp (MIL) Reaction

Engine shutdown is commanded and Red Stop Lamp
(RSL) active.

Associated Faults

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SPN 110 FMI 2, 3, 4 (ECT1)

Fault Facts
Air pockets in the cooling system can interfere with
coolant flow or prevent the thermostats from opening
when needed, resulting in this fault.

Drive Cycle to Determine Fault Status

Drive cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Incorrect value in Programmable Parameter (PP)
77022
• Blockage between radiator and Charge Air Cooler
(CAC) or Low Temperature Radiator (LTR)
• Cooling system overheating
• Degraded coolant

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 2, 3,
No: Repair SPN 110 FMI 2,
4 (ECT1).
3, 4 (ECT1). After repairs are
Is EST DTC list free of SPN 110 FMI 2, 3, 4? complete, retest SPN 110 FMI 0.

656
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 653

Step Action Decision

2 Check for blockage between radiator and Charge-Air Cooler Yes: Clean blockage between
(CAC) or Low Temperature Radiator (LTR). Inspect the between the CAC and LTR. After repairs
the radiator and CAC / LTR for blockage. are complete, retest for SPN 110
FMI 11.
Is there any blockage between the radiator and CAC or LTR?
No: Go to step 3.

Step Action Decision

3 Check Programmable Parameter (PP) 77022. Using EST with Yes: Go to step 4.
ServiceMaxx™ software, go to Sessions > Programming > Engine
No: Program PP 77022 to
Warn Protection System. Check value, verify with customer
correct value. After repairs are
desired temperature limit and compare to normal operating
complete, retest for SPN 110
temperature.
FMI 0.
Is PP 77022 programmed correctly?

Step Action Decision

4 Check for degraded coolant. Using Coolant And Battery Yes: Go to step 5.
Refractometer ZTSE4796, determine condition of coolant.
No: Perform coolant flush and

BetterManuals.net
Is coolant filled to spec, clean, and Not degraded? fill coolant to spec. After repairs
are complete, retest for SPN 110
FMI 0.

Step Action Decision

5 Determine coolant over temperature condition. Perform Coolant Yes: Retest for SPN 110 FMI 0.
Over-Temperature tests (page 87).
No: Repair engine cooling
Is cooling system free from physical damage and Not leaking? system. After repairs are
complete, retest for SPN 110
FMI 0.

NOTE: After doing all diagnostic steps, if SPN 110

FMI 0 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

657
 654 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 110 FMI 11 - Event Logger, Coolant Temp Hot, Extreme

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine coolant at ECT1 > value Key-On Engine-Running Immediate
Engine Coolant programmed into
Temperature 1 (ECT1) Programmable
is above critical Parameter (PP) 8332
temperature

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that engine coolant at Engine Coolant
Temperature 1 (ECT1) is above Programmable
Parameter (PP) 8332.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Associated Faults
SPN 110 FMI 2, 3, 4 (ECT1)

Fault Facts
Air pockets in the cooling system can interfere with
coolant flow or prevent the thermostats from opening
when needed, resulting in this fault.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
• Incorrect value in Programmable Parameter (PP)
8332
• Blockage between radiator and Charge Air Cooler
(CAC) or Low Temperature Radiator (LTR)
• Cooling system overheating
• Degraded coolant

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 2, 3,
No: Repair SPN 110 FMI 2, 3,
4 (ECT1).
4. After repairs are complete,
Is EST DTC list free of SPN 110 FMI 2, 3, 4? retest SPN 110 FMI 11.

658
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 655

Step Action Decision

2 Check for blockage between radiator and Charge-Air Cooler Yes: Clean blockage between
(CAC) or Low Temperature Radiator (LTR). Inspect the between the CAC and LTR. After repairs
the radiator and CAC / LTR for blockage. are complete, retest for SPN 110
FMI 11.
Is there any blockage between the radiator and CAC or LTR?
No: Go to step 3.

Step Action Decision

3 Check Programmable Parameter (PP) 8332. Using EST with Yes: Go to step 4.
ServiceMaxx™ software, go to Sessions > Programming > Engine
No: Program PP 8332 to
Warn Protection System. Check value, verify with customer
correct value. After repairs are
desired temperature limit and compare to normal operating
complete, retest for SPN 110
temperature.
FMI 11.
Is PP 8332 programmed correctly?

Step Action Decision

4 Check for degraded and low coolant. Using Coolant And Battery Yes: Go to step 5.
Refractometer ZTSE4796, determine condition of coolant.
No: Perform coolant flush and

BetterManuals.net
Is coolant filled to spec, clean, and Not degraded? fill coolant to spec. After repairs
are complete, retest for SPN 110
FMI 11.

Step Action Decision

5 Determine coolant over temperature condition. Perform Coolant Yes: Retest for SPN 110 FMI 11.
Over-Temperature (page 87).
No: Repair engine cooling
Is cooling system free from physical damage and Not leaking? system. After repairs are
complete, retest for SPN 110
FMI 11.

NOTE: After doing all diagnostic steps, if SPN 110

FMI 11 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 656 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 110 FMI 15 - Engine Coolant System above Warning Temperature

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine coolant at ECT1 > value Key-On Engine-Running (KOER) Immediate
Engine Coolant programmed into
Temperature 1 (ECT1) Programmable
is above Warning Parameter (PP) 77012
temperature.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects that engine coolant at Engine Coolant
Temperature 1 (ECT1) is above Programmable
Parameter (PP) 77012.

Malfunction Indicator Lamp (MIL) Reaction

Warning Lamp set and Warning buzzer turned ON.

Associated Faults

BetterManuals.net
SPN 110 FMI 2, 3, 4 (ECT1)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Incorrect value in Programmable Parameter (PP)
77012
• Failed Thermostat
• Low Temperature Radiator (LTR) Plugged
• Blockage between Charge Air Cooler (CAC) and
Radiator
• Degraded Coolant
• Failed Water pump
• Failed CCV

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 2, 3,
No: Repair SPN 110 FMI 2, 3,
4 (ECT1).
4. After repairs are complete,
Is EST DTC list free of SPN 110 FMI 2, 3, 4? retest SPN 110 FMI 15.

660
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 657

Step Action Decision

2 Check for blockage stuck between Charge-Air Cooler (CAC) and Yes: Go to step 3.
Low Temperature Radiator (LTR). Inspect the between the CAC
No: Clean blockage between
and LTR for blockage.
the CAC and LTR. After repairs
Is there a blockage between the CAC and LTR? are complete, retest for SPN 110
FMI 15.

Step Action Decision

3 Check Programmable Parameter (PP) 77012. Using EST with Yes: Go to step 4.
ServiceMaxx™ software, go to Sessions > Programming > Engine
No: Program PP 77012 to
Warn Protection System. Check value, verify with customer
correct value. After repairs are
desired temperature limit and compare to normal operating
complete, retest for SPN 110
temperature.
FMI 15.
Is PP 77012 programmed correctly?

Step Action Decision

4 Check for degraded and low coolant. Using Coolant And Battery Yes: Go to step 5.
Refractometer ZTSE4796, determine condition of coolant.
No: Perform coolant flush and

BetterManuals.net
Is coolant filled to spec, clean, and Not degraded? fill coolant to spec. After repairs
are complete, retest for SPN 110
FMI 15.

Step Action Decision

5 Determine coolant over temperature condition. Perform Coolant Yes: Go to step 6.
Over- Temperature (page 87).
No: Repair engine cooling
Is cooling system free from physical damage and Not leaking? system. After repairs are
complete, retest for SPN 110
FMI 15.

Step Action Decision

6 Check for Failed Coolant Control Valve (CCV). Perform CCV Test Yes: Retest for SPN 110 FMI 15.
(page 93).
No: Replace Coolant Control
Is the CCV working correctly? Valve assembly. (CCV) . After
repairs are complete, retest for
SPN 110 FMI 15.

NOTE: After doing all diagnostic steps, if SPN 110

FMI 15 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

661
 658 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 188 FMI 0 - Engine speed unable to achieve desired idle speed (too high)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine idle speed too Engine speed > 106.7% Key ON 10 seconds
high of desired idle speed
Engine Coolant Temperature 1
(ECT1) between 16°F (-9°C) and
248°F (120°C)
Vehicle speed < 0.62 mph
PTO not engaged
Accelerator pedal position 0%

Fault Overview
Fault sets when vehicle is stationary and engine
speed is greater than what is requested by the Engine
Control Module (ECM).

Malfunction Indicator Lamp (MIL) Reaction

BetterManuals.net
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 110 FMI 2 (ECT1); SPN 5395 FMI 0 (EWPS)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Cause
• Engine over-fueling
• External fuel source
• Lube oil leak to intake
• Fuel leak to intake
• Contaminated fuel

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 110 FMI 2
No: Repair SPN 110 FMI 2; SPN
(ECT1); SPN 5395 FMI 0 (EWPS).
5395 FMI 0. After repairs are
Is EST DTC list free of SPN 110 FMI 2; SPN 5395 FMI 0? complete, retest for SPN 188
FMI 0.

662
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 659

Step Action Decision

2 Inspect for airborne combustibles (such as propane saturated air, Yes: Go to step 3.
ether) near engine. Inspect air filter and intake system for stains,
No: Repair source of
concentrations of contaminants, odors / smells from external fuel
combustibles. After repairs
sources, and modifications.
are complete, retest for SPN 188
Is the engine intake system intact and free from any external FMI 0.
fuel sources?

Step Action Decision

3 Inspect for a lube oil leak to intake. Perform Lube Oil to Intake Yes: Go to step 4.
leak test (page 96).
No: Repair lube oil leak to intake.
Is lube oil leaking to intake? After repairs are complete, retest
for SPN 188 FMI 0.

Step Action Decision

4 Inspect for a fuel leak to intake. Perform Fuel to Intake leak test Yes: Go to step 5.
(page 103).
No: Repair fuel leak to intake.
Is fuel leaking to intake? After repairs are complete, retest

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for SPN 188 FMI 0.

Step Action Decision

5 Inspect for contaminated fuel (alternate fuels other than Diesel Yes: Go to step 6.
fuel). Perform Fuel Quality Check (page 154).
No: Drain fuel tank, and fill with
Is diesel fuel in good condition and Not contaminated? clean and / or known good diesel
fuel. After repairs are complete,
retest for SPN 188 FMI 0.

Step Action Decision

6 Determine if engine has a fuel injector problem. Perform Multiple Yes: Replace fuel injector on
Cylinder Cutout Test (page 182). suspected cylinder. After repairs
are complete retest for SPN 188
Did one or more cylinders have significant speed difference(s)
FMI 0.
than the others?
No: Retest for SPN 188 FMI 0.

NOTE: After doing all diagnostic steps, if SPN 188

FMI 0 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

663
 660 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 188 FMI 1 - Engine speed unable to achieve desired idle speed (too low)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine idle speed too Engine speed < 93.3% of Key ON 10 seconds
low desired idle speed
Engine Coolant Temperature 1
(ECT1) between 16°F (-9°C) and
248°F (120°C)
Vehicle speed < 0.62 mph
PTO not engaged
Accelerator pedal position 0%

Fault Overview
Fault sets when vehicle is stationary and engine
speed is less than what is requested by the Engine
Control Module (ECM).

Malfunction Indicator Lamp (MIL) Reaction

BetterManuals.net
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 651, 652, 653, 654, 655, 656 (INJ); SPN 5395
FMI 1 (EWPS)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Low Fuel Rail Pressure (FRP)
• Low Fuel Delivery Pressure (FDP)
• Low cylinder compression
• Clutch or Power Take Off (PTO) engagement
without command
• Injector or injector circuit fault

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 651, 652, 653,
No: Repair SPN 651, 652, 653,
654, 655, 656 (INJ); SPN 5395 FMI 1 (EWPS).
654, 655, 656; SPN 5395 FMI
Is EST DTC list free of SPN 651, 652, 653, 654, 655, 656; SPN 1. After repairs are complete,
5395 FMI 0? retest for SPN 188 FMI 1.

664
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 661

Step Action Decision

2 Verify Fuel Delivery Pressure (FDP) is within specification. Using Yes: Go to step 3.
Electronic Service Tool (EST) with ServiceMaxx™ software,
No: Perform Fuel Delivery
Key-On Engine-Running (KOER) monitor FDP sensor.
Pressure Test (page 167). After
Is FDP between 60 and 120 psi? repairs are complete, retest for
SPN 188 FMI 1.

Step Action Decision

3 Determine if Fuel Rail Pressure (FRP) is within specification. Yes: Go to step 4.
Using EST with ServiceMaxx software, KOER monitor FRP
No: Perform High-pressure
sensor.
Pump Inlet Test (High-pressure
Is FRP greater than 10,500 psi? Pump Inlet Pressure Test, page
175). After repairs are complete,
retest for SPN 188 FMI 1.

Step Action Decision

4 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After

BetterManuals.net
(page 179). repairs are complete, retest for
SPN 188 FMI 1.
Does engine have excessive crankcase pressure?
No: Go to step 5.

Step Action Decision

5 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 6.
Cylinder Cutout Test (page 182).
No: Go to step 7.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

6 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 188 FMI 1.
Is valve train free of failed valve train components?
No: Repair failed valve train
components. After repairs are
complete retest for SPN 188 FMI
1.

665
 662 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 Check for Power Take Off (PTO) engagement without command. Yes: Repair PTO unit. After
KOER, monitor PTO output shaft rotation. repairs are complete, retest for
SPN 188 FMI 1.
Is PTO output shaft rotating without throttle?
No: Retest for SPN 188 FMI 1.

NOTE: After doing all diagnostic steps, if SPN 188

FMI 1 remains, verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

BetterManuals.net

666
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 663

SPN 190 - FMI 0 - Engine Overspeed Most Severe level

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine speed reaches Engine speed exceeds Vehicle speed < 0.1 mph 1 event
most severe level 2600 rpm with no fuel
APP < 0.1%
with Accelerator Pedal being requested
Position (APP) and RAPP < 0.1%
Vehicle Speed Sensor
Engine speed > 2600 rpm
(VSS) at 0% or 0.

Fault Overview Malfunction Indicator Lamp (MIL) Reaction

Fault sets only when a vehicle is stationary and The Malfunction Indicator Lamp and Red Stop Lamp
engine speed reaches 2600 rpm with no fuel being will illuminate when this fault is detected.
requested by the Engine Control Module (ECM).
CAUTION: To prevent engine damage, do not attempt
Once conditions are met, the ECM will initiate a
to start engine until a full engine analysis and all
protection strategy. The Engine Throttle Valve (ETV)
diagnostic steps have been completed.
and Exhaust Gas Recirculation (EGR) valve will be
closed and fuel injectors disabled. The Fuel Pressure NOTE:
Control Valve (FPCV) will open to relieve fuel rail
Before beginning diagnosis:
pressure in case of injector tip damage. A complete

BetterManuals.net
full engine analysis needs to be completed to asses • Take pictures of all damage / failure evidence
damage due from excessive engine speed before the
• Do not replace any parts till complete
engine can be started.
inspection has been done

667
 664 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect for signs of an alternative fuel source that could be After inspection is complete,
induced into the intake manifold with no fuel being requested by notify supervisor with results for
the ECM or driver inputs causing the engine to exceed 2600 RPM further action.
from the list below:
• Engine oil consumption. See Engine Symptom Diagnostics,
Lubrication System (page 95), for procedures to inspect for
lube oil leaking into intake or exhaust system.
• Air born combustibles (ex. propane saturated air, ether).
Inspect air filter and intake system for stains, concentrations
of contaminants, odors / smells from alternative fuel sources.
• Fuel contamination (alternate fuels other than diesel fuel). See
Hard Start and No Start Diagnostics, Fuel Quality Check (page
120) for procedures to inspect quality of vehicle’s diesel fuel.
• Operator error.
Was an alternative fuel source found to be induced into the intake
manifold or operator error causing the engine to exceed 2600
rpm?

BetterManuals.net

668
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 665

SPN 2588 FMI 0 - Vehicle overspeed 1, event log, extreme

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Vehicle over-speed level Vehicle speed is greater Key-On Engine-Running
1: This occurs when than the value of PP (KOER)
vehicle speed is above 77232
value in Programmable
Parameter (PP) 77232.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects vehicle speed exceeds the value set
in Programmable Parameter (PP) 77232.

Malfunction Indicator Lamp (MIL) Reaction

9 - Special error class for VETS faults

Associated Faults
SPN 191 (VSS).

BetterManuals.net
Fault Facts
This fault indicates vehicle speed has exceeded the
value programmed in PP 77232, and does not indicate
a vehicle problem.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Vehicle speed has exceeded the value set in PP
77232

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Verify PP 77232 is set to
check Diagnostic Trouble Code (DTC) list for SPN 191 (VSS). appropriate speed value.
Is EST DTC list free of SPN 191? No: Repair SPN 191. After
repairs are complete, retest for
SPN 2588 FMI 0.

NOTE: After doing all diagnostic steps, if SPN

2588 FMI 0 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

669
 666 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 2588 FMI 15 - Vehicle overspeed 1, event log, non extreme

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Vehicle over-speed level Vehicle speed is greater Key-On Engine-Running
1: This occurs when than the value of PP (KOER)
vehicle speed is above 77232
value in Programmable
Parameter (PP) 77232.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects vehicle speed exceeds the value set
in Programmable Parameter (PP) 77232.

Malfunction Indicator Lamp (MIL) Reaction

9 - Special error class for VETS faults

Associated Faults
SPN 191 (VSS).

BetterManuals.net
Fault Facts
This fault indicates vehicle speed has exceeded the
value programmed in PP 77232, and does not indicate
a vehicle problem.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Vehicle speed has exceeded the value set in PP
77232

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Yes: Verify PP 77232 is set
check Diagnostic Trouble Code (DTC) list for SPN 191 (VSS). to appropriate speed value.
Is EST DTC list free of SPN 191? No: Repair SPN 191. After
repairs are complete, retest for
SPN 2588 FMI 15.

NOTE: After doing all diagnostic steps, if SPN

2588 FMI 15 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

670
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 667

SPN 2589 FMI 0 - Vehicle overspeed 2, event log, extreme

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Vehicle over-speed level Vehicle speed is greater Key-On Engine-Running
2: This occurs when than the value of PP (KOER)
vehicle speed is above 77242
value in Programmable
Parameter (PP) 77242.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects vehicle speed exceeds the value set
in Programmable Parameter (PP) 77242.

Malfunction Indicator Lamp (MIL) Reaction

9 - Special error class for VETS faults

Associated Faults
SPN 191 (VSS).

BetterManuals.net
Fault Facts
This fault indicates vehicle speed has exceeded the
value programmed in PP 77242, and does not indicate
a vehicle problem.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Vehicle speed has exceeded the value set in PP
77242

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Verify PP 77242 is set to
check Diagnostic Trouble Code (DTC) list for SPN 191 (VSS). appropriate speed value.
Is EST DTC list free of SPN 191? No: Repair SPN 191. After
repairs are complete, retest for
SPN 2589 FMI 0.

NOTE: After doing all diagnostic steps, if SPN

2589 FMI 0 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

671
 668 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 2589 FMI 15 - Vehicle overspeed 2, event log, non extreme

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Vehicle over-speed level Vehicle speed is greater Key-On Engine-Running
2: This occurs when than the value of PP (KOER)
vehicle speed is above 77242
value in Programmable
Parameter (PP) 77242.

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects vehicle speed exceeds the value set
in Programmable Parameter (PP) 77242.

Malfunction Indicator Lamp (MIL) Reaction

9 - Special error class for VETS faults

Associated Faults
SPN 191 (VSS).

BetterManuals.net
Fault Facts
This fault indicates vehicle speed has exceeded the
value programmed in PP 77242, and does not indicate
a vehicle problem.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Vehicle speed has exceeded the value set in PP
77242

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Verify PP 77242 is set to
check Diagnostic Trouble Code (DTC) list for SPN 191 (VSS). appropriate speed value.
Is EST DTC list free of SPN 191? No: Repair SPN 191. After
repairs are complete, retest for
SPN 2589 FMI 15.

NOTE: After doing all diagnostic steps, if SPN

2589 FMI 15 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

672
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 669

SPN 5395 FMI 0 - Engine Unable to Achieve Desired Idle Torque (Too High)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine idle fuel quantity Engine speed and fuel Vehicle speed <0.62 mph 10 Seconds
too high, engine unable quantity greater than
Key ON
to achieve desired idle expected.
torque. Engine coolant temperature <
239°F (115°C)
Engine coolant temperature >
16°F (–9°C)
Engine speed > 560 rpm

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects fuel quantity is and engine speed is
greater than expected.

Malfunction Indicator Lamp (MIL) Reaction

BetterManuals.net
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 188 FMI 1 (EWPS).

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Failed fuel injector
• Aftermarket PTO system not installed correctly
• Aftermarket PTO system not programmed
correctly

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 188 FMI 1
No: Repair SPN 188 FMI 1.
(EWPS).
After repairs are complete, retest
Is EST DTC list free of SPN 188 FMI 1? for SPN 5395 FMI 0.

673
 670 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

2 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 5395 FMI 0.
Does engine have excessive crankcase pressure?
No: Go to step 3

Step Action Decision

3 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 4.
Cylinder Cutout Test (page 182).
No: Go to step 5.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

4 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 5395 FMI 0.
Is valve train free of failed valve train components?

BetterManuals.net
No: Repair failed valve train
components. After repairs are
complete retest for SPN 5395
FMI 0.

Step Action Decision

5 Inspect for installation of aftermarket PTO system. Yes: Do Harness Resistance
Check (page 827). After repairs
Was an aftermarket PTO system installed and programmed
are complete, retest for SPN
correctly?
5395 FMI 0.
No: After inspection is complete,
notify supervisor with results for
further action.

NOTE: After doing all diagnostic steps, if SPN

5395 FMI 0 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 671

SPN 5395 FMI 1 - Engine Unable to Achieve Desired Idle Torque (Too Low)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Engine idle fuel quantity engine speed and Vehicle speed <0.62 mph 10 Seconds
too low, engine unable fuel quantity less than
Key ON
to achieve desired idle expected.
torque. Engine coolant temperature <
239°F (115°C)
Engine coolant temperature >
16°F (–9°C)
Engine speed > 560 rpm

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects an un-commanded load being placed
on the engine at idle or detects fuel quantity is less
than expected.

Malfunction Indicator Lamp (MIL) Reaction

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MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 188 FMI 0 (EWPS).

Drive Cycle to Determine Fault Status

Drive Cycle 22 in 2013 HD-OBD Diagnostic Reference
Manual.
• Engine mechanical failure
• Failed cylinder
• External fuel source
• Lube oil leak to intake
• Fuel leak to intake
• Contaminated fuel

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 188 FMI 0
No: Repair SPN 188 FMI 0.
(EWPS).
After repairs are complete, retest
Is EST DTC list free of SPN 188 FMI 0? for SPN 5395 FMI 1.

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 672 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

2 Determine if the engine has a mechanical cylinder balance Yes: Repair base engine
problem (compression loss). Perform Crankcase Pressure Test compression imbalance. After
(page 179). repairs are complete, retest for
SPN 5395 FMI 1.
Does engine have excessive crankcase pressure?
No: Go to step 3

Step Action Decision

3 Determine if engine has a fuel injector problem. Perform Multiple Yes: Go to step 4.
Cylinder Cutout Test (page 182).
No: Go to step 5.
Did one or more cylinders have significant speed difference(s)
than the others?

Step Action Decision

4 Inspect for failed valve train components. Remove upper valve Yes: Replace injector suspected
cover (see Engine Service Manual). Inspect for bent valves, fallen by Multiple Cylinder Cutout Test.
bridges, and valves out of adjustment. After repairs are complete, retest
for SPN 5395 FMI 1.
Is valve train free of failed valve train components?

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No: Repair failed valve train
components. After repairs are
complete retest for SPN 5395
FMI 1.

Step Action Decision

5 Inspect for airborne combustibles (ex. propane saturated air, Yes: Go to step 6.
ether, etc.) near engine. Inspect air filter and intake system
No: Repair source of
for stains, concentrations of contaminants, odors / smells from
combustibles. After repairs
external fuel sources, and modifications.
are complete, retest for SPN
Is the engine intake system intact and free from any external 5395 FMI 1.
fuel sources?

Step Action Decision

6 Inspect for a lube oil leak to intake. Perform Lube Oil to Intake Yes: Go to step 7.
leak test (page 96).
No: Repair lube oil leak to intake.
Is lube oil leaking to intake? After repairs are complete, retest
for SPN 5395 FMI 1.

Step Action Decision

7 Inspect for a fuel leak to intake. Perform Fuel to Intake leak test Yes: Go to step 8.
(page 103).
No: Repair fuel leak to intake.
Is fuel leaking to intake? After repairs are complete, retest
for SPN 5395 FMI 1.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 673

Step Action Decision

8 Inspect for contaminated fuel (alternate fuels other than Diesel Yes: Retest for SPN 5395 FMI 1.
fuel). Perform Fuel Quality Check (page 154).
No: Drain fuel tank, and fill with
Is diesel fuel in good condition and Not contaminated? clean and / or known good diesel
fuel. After repairs are complete,
retest for SPN 5395 FMI 1.

NOTE: After doing all diagnostic steps, if SPN

5395 FMI 1 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 674 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

FDP Sensor (Fuel Delivery Pressure)

SPN FMI Condition Possible Causes Actions

94 0 Fuel pressure above • VREF5 circuit Open or high resistance Step-Based
critical Diagnostics (page
• SIG GND circuit Open or high
676)
resistance
• FDP circuit Open or high resistance
• Restricted engine fuel filter
• Restriction in return line to fuel tank
• Failed Fuel Delivery Pressure (FDP)
sensor
94 3 FDP signal Out of • FDP signal circuit OPEN or short to Pin-Point Diagnostics
Range HIGH PWR (page 679)
• SIG GND circuit OPEN
• Failed FDP sensor
94 4 FDP signal Out of • FDP signal circuit short to GND Pin-Point Diagnostics
Range LOW (page 679)

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• VREF5 circuit OPEN
• Failed FDP sensor

FOP circuit

FOP FOP
ECM 96-Pin
connector sensor
FOP

g
E1 connector
(end view)
/ "I connector
Pin E1 - 81
VREF-5 -1
Pin E1 - 22 ___,
Pin E1 - 35
SIG GNO
FOP
2 4~ '@'
\.
-3 2 ""' 3

V00020

Figure 259 FDP sensor circuit diagram

Tools Required • ZTSE4905 – Fuel Block Off Tool

• 00-00956-08 – 180-Pin Breakout Box • ZTSE4906 – Fuel Line Coupler
• ZTSE4498 – 3-Banana Plug Harness • ZTSE4760A – Breakout Harness 4760A (DOCIT,
DOCOT, DPFOT, and EGRT)
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4906 – Breakout Harness 4881 (FDP)
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• ZTSE4681 – Fuel Pressure Gauge
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 675

• Electronic Service Tool (EST) with ServiceMaxx™

software
• J1939 and J1708 RP1210B Compliant Device

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0000063154

Figure 260 FDP Sensor Location

1. Fuel Delivery Pressure (FDP)
sensor

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 676 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 94 FMI 0 - Fuel Delivery Pressure above Critical

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Signal from Fuel Fuel Delivery Pressure Key-On Engine-Running 0 seconds
Delivery Pressure > 145 psi (1000 kPa) or (KOER)
(FDP) sensor above (130 psi [900 kPa] at idle)
expected (in-range, but
not rational).

Fault Overview
Fault code sets when Engine Control Module (ECM)
detects that Fuel Delivery Pressure (FDP) is over 130
psi (900 kPa) at idle, or over 145 psi (1000 kPa) when
engine speed is above idle.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

Drive Cycle to Determine Fault Status

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Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

FOP circuit

FOP FOP
ECM 96-Pin
connector sensor
E1 connector FOP
(end view)

e
/ connector
Pin E1 - 81
VREF-5 -1
'@' Pin E1 - 22
SIG GNO
FOP
2 4~
Pin E1 - 35
~
-3 2 ""' 3
'"
V00020

Figure 261 FDP Sensor Circuit Diagram

Possible Causes • Restricted secondary (engine) fuel filter

• VREF5 circuit Open or high resistance • Restriction in return line to fuel tank
• SIG GND circuit Open or high resistance • Failed Fuel Delivery Pressure (FDP) sensor
• FDP circuit Open or high resistance

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 677

Step Action Decision

1 Inspect connections at Fuel Delivery Pressure (FDP) sensor. Key Yes: Go to step 2.
OFF, disconnect FDP sensor. Check FDP sensor and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the FDP sensor connector, harness, and terminals clean and SPN 94 FMI 0.
undamaged?

Step Action Decision

2 Check for a failed FDP sensor. Connect Fuel Inlet Restriction / Yes: Go to step 3.
Aeration Tool ZTSE4886 between low side pressure line and the
No: Go to step 5.
inlet to the secondary (engine) mounted fuel filter. Connect Fuel
Pressure Gauge ZTSE4681 to Fuel Inlet Restriction / Aeration
Tool ZTSE4886. Run engine at idle and high idle, compare gauge
with the ServiceMaxx value. (Note: ServiceMaxx reads 15 psi
below gauge pressure).
Do idle and high idle fuel pressure values stay within 2 psi each
other?

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Step Action Decision
3 Check for a restricted secondary (engine mounted) fuel filter. Yes: Go to step 4.
Perform the High-pressure Pump Inlet Pressure Test (page 175).
No: Replace secondary fuel
Is fuel pressure constantly between 85 and 120 psi at low and filter. After repairs are complete,
high idle? retest for SPN 94 FMI 0.

Step Action Decision

4 Check for restriction in return line to fuel tank. Perform the HP Yes: Replace the FDP sensor.
Pump Fuel Return Pressure Test (page 178). After repairs are complete, retest
for SPN 94 FMI 0.
Is fuel pressure < 13 psi?
No: Repair restriction in return
line to fuel tank. After repairs
are complete, retest for SPN 94
FMI 0.

Step Action Decision

5 Check for Open or high resistance in VREF5 circuit. Connect Yes: Go to step 6.
180-pin Breakout Box with Breakout Harness 00-01468-00
No: Repair Open or high
to vehicle harness and leave Engine Control Module (ECM)
resistance between FDP
disconnected. Connect Breakout Harness ZTSE4881 to vehicle
connector pin-1 and ECM
harness and leave FDP sensor disconnected. Key OFF, use a
pin E1-81. After repairs are
DMM to measure resistance from Breakout Harness pin-1 to
complete, retest for SPN 94 FMI
180-pin Breakout Box pin E1-81.
0.
Is resistance less than 5 ohms?

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 678 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Check for Open or high resistance in SIG GND circuit. Connect Yes: Go to step 7.
180-pin Breakout Box with Breakout Harness 00-01468-00 to
No: Repair Open or high
vehicle harness and leave ECM disconnected. Connect Breakout
resistance between FDP
Harness ZTSE4881 to vehicle harness and leave FDP sensor
connector pin-2 and ECM
disconnected. Key OFF, use a DMM to measure resistance from
pin E1-22. After repairs are
Breakout Harness ZTSE4881 pin-2 to 180-pin Breakout Box pin
complete, retest for SPN 94 FMI
E1-22.
0.
Is resistance less than 5 ohms?

Step Action Decision

7 Check for Open or high resistance in FDP circuit. Connect No: Replace the FDP sensor.
180-pin Breakout Box with Breakout Harness 00-01468-00 to After repairs are complete, retest
vehicle harness and leave ECM disconnected. Connect Breakout for SPN 94 FMI 0.
Harness ZTSE4881 to vehicle harness and leave FDP sensor
No: Repair Open or high
disconnected. Key OFF, use a DMM to measure resistance from
resistance between FDP
Breakout Harness pin-3 to 180-pin Breakout Box pin E1-35.
connector pin-3 and ECM
Is resistance less than 5 ohms? pin E1-35. After repairs are
complete, retest for SPN 94 FMI

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0.

NOTE: After performing all diagnostic steps,

if SPN 94 FMI 0 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 679

Pinpoint Diagnostics With ServiceMaxx™

Software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Biased
Sensor or Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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Sensor Circuit Check With ServiceMaxx™ Software
Connect Breakout Harness ZTSE4881 to FDP engine harness, and leave FDP sensor disconnected.
Turn ignition ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor FDPv 5.0 V ± 0.5 V If > 4.5 V, check FDP signal circuit for short to GND

DMM — Measure 5.0 V ± 0.5 V If > 5.5 V, check VREF5 for short to PWR.
voltage
If < 4.5 V, check VREF5 for OPEN or short to GND. Do
1 to GND Harness Resistance Check (page 680).
DMM — Measure 5 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
voltage Resistance Check (page 680).
1 and 2
EST – Monitor FDPv 5 V ± 0.5 V If > 0.5 V, check FDP signal circuit for OPEN. Do Harness
Resistance Check (page 680).
Short across Breakout
Harness ZTSE4881
pins 2 to 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace FDP
sensor.

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 680 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4881 to FDP engine harness, and leave FDP sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5 V ± 0.5 V If > 5.5 V, check VREF5 for short to PWR.
If < 4.5 V, check VREF5 for OPEN or short to GND. Do
Harness Resistance Check (page 680).
2 to GND 0V If > 0.25 V, check SIG GND circuit for short to PWR.
2 to GND 0V If > 5.5 V, check VREF5 for short to PWR.
If < 4.5 V, check VREF5 for OPEN or short to GND. Do
Harness Resistance Check (page 680).
3 to GND 5.0 V If <, 4.5 V, check FDP signal circuit for short to GND.
3 to GND 5 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
Resistance Check (page 680).

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2

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engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4881 to FDP
engine harness, and leave FDP sensor disconnected. Use DMM to measure resistance.

Test Point Specifications Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
1 to E1–81 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short to GND.
2 to E1–22 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short to GND.
3 to E1–35 <5Ω If > 5 Ω, check for OPEN circuit.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 681

FPCV (Fuel Pressure Control Valve)

SPN FMI Condition Possible Causes Actions

633 3 FPCV short to PWR • FPCV circuit short Pin-Point Diagnostics
to PWR (page 681)
• Failed FPCV valve
633 4 FPCV short to GND • FPCV circuit short Pin-Point Diagnostics
to GND (page 681)
• Failed FPCV valve
633 5 FPCV open load/circuit • FPCV circuit OPEN Pin-Point Diagnostics
(page 681)
• Failed FPCV

FPCV circuit

FPCV FPCV
ECM 96-Pin FPCV
connector
, E1 connector f - connector
FPCV

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1 High
PinE1-73
1~2 pressure
FPCV 12V fuel pump
PinE1-25 2
'-. ~
V ----

V00067

Figure 262 FPCV circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

Software
• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness Kit WARNING: To prevent personal injury or
00-01462-00 death, stay clear of rotating parts (belts and fan)
• ZTSE4498 – 3-Banana Plug Harness and hot engine surfaces.

• ZTSE4497 – 500 Ohm Resistor Harness 1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, select Tests >
• ZTSE4899 – Big Bore Terminal Test Probe Kit KOER Tests > High Pressure Pump Test.
• Breakout Harness ZTSE4828 (FPCV) 2. Run High Pressure Pump Test.
• Digital Multimeter (DMM) • If High Pressure Pump Test fails, check
• Electronic Service Tool (EST) with ServiceMaxx™ FPCV valve for mechanical problem.
software • If FPCV valve does not move, continue
• J1939 and J1708 RP1210B Compliant Device with pinpoint diagnostics.

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 682 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check – FPCV Disconnected

Connect Breakout Harness ZTSE4828 to FPCV engine harness, and leave FPCV sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
2 to GND B+ If < B+, OPEN circuit. Do Harness Resistance Check
1 to GND 0.8 V If >1.3 V, Check for OPEN circuit. Do Harness Resistance
Checks
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure battery voltage is at or above 12 V, before running this procedure.
1. Connect Breakout Harness ZTSE4828 between FPCV and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select Fuel Pressure Control Valve from the drop-down menu.
3. Command FPCV to 5%.
4. Use DMM to measure voltage.

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5. Command FPCV to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5% = 8.5 V ± 1.0 V If < 7.5 V, check for OPEN circuit. Do Harness Resistance
Check.
1 to GND 95% = 1.5 V ± 0.5 V If > 2.0 V, check for OPEN circuit or failed actuator.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4828 to FPCV
engine harness, and leave FPCV sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
1 to E1-73 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for OPEN circuit.
2 to E1-25 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, the FPCV is working correctly. See High Pressure
Fuel System (page 135) in “HARD START AND NO START DIAGNOSTICS."

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 683

FRP Sensor (Fuel Rail Pressure)

SPN FMI Condition Possible Causes Actions

157 3 FRP signal Out of • FRP signal circuit short to PWR Circuit Checks (page
Range HIGH 685)
• SIG GND circuit high resistance or
Open
• Failed FRP sensor
157 4 FRP signal Out of • FRP signal circuit short to GND Circuit Checks (page
Range LOW 685)
• FRP signal circuit high resistance or
Open
• Failed FRP sensor
• VREF6 circuit high resistance or
Open
157 20 FRP signal Drifted • FRP signal circuit short to PWR Step-based Diagnostics
HIGH (page 688)
• SIG GND circuit high resistance or
Open
• Failed FRP sensor

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157 21 FRP signal Drifted • FRP signal circuit short to GND Step-based Diagnostics
LOW (page 690)
• FRP signal circuit high resistance or
Open
• Failed FRP sensor
• VREF6 circuit high resistance or
Open

FRP circuit

FRP FRP
ECM 96-Pin
connector sensor
E1 connector FRP
(end view)
connector
SIG GND

M
Pin E1 - 21 1
FRP
Pin E1 - 34 2
VREF6 D
Pin E1 - 88 3
1 3
V00162

Figure 263 FRP sensor circuit diagram

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 684 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Overview
The FRP sensor is a variable-capacitance sensor
that measures fuel rail pressure at the high-pressure
common fuel rail. As pressure increases, sensor
capacitance changes causing the voltage sent to
Engine Control Module (ECM) to change. The ECM
adjusts the Fuel Pressure Control Valve (FPCV)
duty cycle to match engine requirements for starting,
engine load, speed, and temperature.
Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4829 (FRP)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™

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0000041032
software
• J1939 and J1708 RP1210B Compliant Device Figure 264 FRP Sensor Location
1. Fuel Rail Pressure (FRP) sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 685

FRP circuit

FRP FRP
ECM 96-Pin
connector sensor
E1 connector FRP
(end view)
connector
SIG GND

~
Pin E1 - 21 1
FRP
Pin E1 - 34 2
VREF6
Pin E1 - 88 3
1 3

V00162

Figure 265 FRP sensor circuit diagram

Pinpoint Diagnostics With ServiceMaxx™ 2. Monitor sensor voltage and verify an active
Software DTC for this sensor.
• If DTC is previously active, monitor signal
WARNING: To prevent personal injury or while wiggling harness of suspect sensor.

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death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
If circuit is interrupted, signal will spike.
• If DTC is active or pending, continue to
Sensor Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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 686 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4829 to FRP engine harness, and leave FRP sensor disconnected.
Turn ignition ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor FRPv 5.0 V ± 0.5 V If < 4.5 V, check FRP signal circuit for short to GND.

DMM — Measure volts 5.0 V ± 0.5 V If > 5.5 V, check VREF6 for short to PWR.
3 to GND If < 4.5 V, check VREF6 for OPEN or short to GND. Do
Harness Resistance Check (page 687).
DMM — Measure 5 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
voltage Resistance Check (page 687).
1 to 3
EST – Monitor FRPv 4.5 V to 5.5 V If < 4.5 V, check FRP signal circuit for OPEN. Do Harness
Resistance Check (page 687).
Short across Breakout
Harness ZTSE4829
pins 2 to 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace FRP

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sensor.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 687

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4829 to FRP engine harness, and leave FRP sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
3 to GND 5.0 V ± 0.5 V If > 5.5 V, check VREF6 for short to PWR.
If < 4.5 V, check VREF6 for OPEN or short to GND. Do
Harness Resistance Check (page 687).
1 to GND 0V If > 0.25 V, check SIG GND circuit for short to PWR.
2 to GND 0V If < 4.5 V, check FRP signal circuit for short to GND.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4829 to FRP
engine harness, and leave FRP sensor disconnected. Use DMM to measure resistance.

Test Point Specifications Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.

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1 to E1-21 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-34 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-88 <5Ω If > 5 Ω, check for OPEN circuit.

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 688 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 157 - FMI 20 FRP signal Drifted HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure Fuel Rail Pressure (FRP) Engine coolant temp. > 138°F 3 Events
rationality offset high greater than 0.609 volts (60°C)
(during after run)
Time after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts
ECM in After Run (“house
keeping”)
Injector blank shot cycle
complete

Fault Overview
After shutdown, with enable conditions met, the
Engine Control Module (ECM) operates after run cycle
(for 30 to 45 seconds) to do needed "house keeping"

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operations. The after run cycle is the process the
ECM goes through to save memory and shutdown.

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

Associated Faults
If SPN 3514 FMI 14 is active, correct and then retest
for SPN 157 FMI 20.

Drive Cycle
See 2013 HD-OBD Diagnostic Reference Manual.

FRP circuit

FRP FRP
ECM 96-Pin
connector sensor
E1 connector FRP
(end view)
connector
SIG GND

~
Pin E1 - 21 1
FRP
Pin E1 - 34 2
VREF6
Pin E1 - 88 3
1 3
V00162

Figure 266 FRP sensor circuit diagram

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 689

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 157 FMI 20 the only fault code active? After repairs are complete, retest
for SPN 157 FMI 20.

Step Action Decision

2 Inspect connections at FRP sensor. Key OFF, disconnect FRP Yes: Go to step 3.
sensor. Check FRP sensor and connector terminals for: damaged
No: Repair connector, harness,
or pinched wires; corroded terminals; loose, bent, or broken pins;
or terminal damage. After
or broken connector housing.
repairs are complete, retest for
Are the FRP sensor connector, harness, and terminals clean and SPN 157 FMI 20.
undamaged?

Step Action Decision

3 Check FRP circuit for short to power. Using EST with Yes: Go to step 4.
ServiceMaxx™, run Continuous Monitor session. Key-On
No: Repair short to power from
Engine-Off, FRP sensor connected.
FRP sensor connector pin 2 to

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Does ServiceMaxx™ software show FRP sensor voltage less ECM 96–pin connector E1 pin
than 5.0 volts? 34. After repairs are complete,
retest for SPN 157 FMI 20.

Step Action Decision

4 Check SIG GND circuit for high resistance. With FRP sensor Yes: Replace FRP sensor. See
disconnected, connect Breakout Harness 4829. Measure Engine Service Manual.
resistance between FRP sensor connector pin 1 and a known
No: Repair high resistance
good ground.
between FRP sensor connector
Is resistance less than 5 ohms? pin 1 and ECM 96–pin connector
E1 pin 21. After repairs are
complete, retest for SPN 157
FMI 20.

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 690 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

NOTE: After doing all diagnostic steps, if SPN 157

FMI 20 remains verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

SPN 157 - FMI 21 FRP signal Drifted LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure Fuel Rail Pressure (FRP) Engine coolant temp. > 138°F 3 Events
rationality offset low less than 0.424 volts (60°C)
(during after run)
Time after Key On > 0 seconds
Battery voltage > 10.7 volts
Battery voltage < 15 volts
ECM in After Run (“house
keeping”)
Injector blank shot cycle
complete

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Fault Overview Associated Faults
After shutdown, with enable conditions met, the If SPN 3514 FMI 14 is active, correct and then retest
Engine Control Module (ECM) operates after run cycle for SPN 157 FMI 21.
(for 30 to 45 seconds) to do needed "house keeping"
operations. The after run cycle is the process the Drive Cycle
ECM goes through to save memory and shutdown.
See 2013 HD-OBD Diagnostic Reference Manual.
Malfunction Indicator Lamp (MIL) Reaction
When fault is active, MIL will not illuminate.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 691

FRP circuit

FRP FRP
ECM 96-Pin
connector sensor
E1 connector FRP
(end view)
connector
SIG GND

~
Pin E1 - 21 1
FRP
Pin E1 - 34 2
VREF6
Pin E1 - 88 3
1 3

V00162

Figure 267 FRP sensor circuit diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 157 FMI 21 the only fault code active? After repairs are complete, retest

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for SPN 157 FMI 21.

Step Action Decision

2 Inspect connections at FRP sensor. Key OFF, disconnect FRP Yes: Go to step 3.
sensor. Check FRP sensor and connector terminals for: damaged
No: Repair connector, harness,
or pinched wires; corroded terminals; loose, bent, or broken pins;
or terminal damage. After
or broken connector housing.
repairs are complete, retest for
Are the FRP sensor connector, harness, and terminals clean and SPN 157 FMI 21.
undamaged?

Step Action Decision

3 Check FRP circuit for short to ground. Connect Breakout Yes: Go to step 4.
Harness 4829 to FRP sensor connector and leave FRP sensor
No: Repair short to ground
disconnected. Use a DMM to measure resistance between
between FRP connector pin
Breakout harness 4829 test point 2 and a known, good ground.
2 and ECM 96–pin connector
Is resistance greater than 1000 ohms? E1 pin 34. After repairs are
complete, retest for SPN 157
FMI 21.

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 692 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Check VREF6 circuit for Open or high resistance. Key-On Yes: Go to step 5.
Engine-Off, with Breakout Harness 4829 connected to FRP sensor
No: Repair high resistance
connector, use a DMM to measure voltage between FRP sensor
between FRP sensor connector
connector pin 3 and a known good ground.
pin 3 and ECM 96–pin connector
Is voltage 4.5 volts or greater? E1 pin 88. After repairs are
complete, retest for SPN 157
FMI 21.

Step Action Decision

5 Check FRP circuit for high resistance or Open. Using EST Yes: Replace FRP sensor. See
with ServiceMaxx™ software, run Continuous Monitor session. Engine Service Manual.
Key-On Engine-Off, with Breakout Harness 4829 connected, short
No: Repair high resistance
FRP sensor connector pin 3 to pin 2.
between FRP sensor connector
Does ServiceMaxx™ software show FRP sensor voltage 4.5 volts pin 2 and ECM 96–pin connector
or more? E1 pin 34. After repairs are
complete, retest for SPN 157
FMI 21.

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NOTE: After doing all diagnostic steps, if SPN 157
FMI 21 remains verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 693

FRP (Fuel Rail Pressure) System

SPN FMI Condition Possible Causes Actions

157 0 FRP relief valve opening fault • Outdated ECM Calibration out-of-date
calibration (page 696)
157 14 FRP Relief Valve failure • Outdated ECM Calibration out-of-date
calibration (page 696)
3055 0 FRP exceeded maximum • Restricted Step-Based
high-pressure pump Diagnostics (page
fuel return line 697)
• Failed Fuel Pressure
Control Valve (FPCV)
(sticking)
3055 1 Low Fuel Pressure at start • Fuel Rail Pressure Step-Based
(FRP) sensor or Diagnostics (page
circuit fault 699)
• Low fuel level
• Low-pressure fuel

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system leaks
• Restricted engine
mounted secondary
fuel filter
• Aerated fuel delivery
• Restricted low
pressure fuel system
• Internal leak in
high-pressure fuel
system
• Leaking fuel pressure
relief valve
• Leaking Piston
Overflow Valve
(KUEV) valve
• Stuck or sticking
FPCV
• Failed low-pressure
fuel pump
• Failed high-pressure
fuel pump

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 694 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3055 15 FRP below minimum with maximum • Low fuel level Step-Based
command Diagnostics (page
• Fuel pressure fuel
703)
system leaks
• Restricted engine
mounted secondary
fuel filter
• Aerated fuel delivery
• Restricted fuel supply
• Internal leak in
high-pressure fuel
system
• Leaking fuel pressure
relief valve
• Leaking Piston
Overflow Valve
(KUEV) valve
• Stuck or sticking

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FPCV
• Failed low-pressure
fuel pump
• Failed high-pressure
fuel pump
3055 17 FRP above maximum with minimum • Restricted Step-Based
command high-pressure pump Diagnostics (page
fuel return line 707)
• Fuel Pressure Control
Valve (FPCV) or
circuit fault

FRP circuit

FRP FRP
ECM 96-Pin
connector sensor
E1 connector FRP
(end view)
connector
SIG GND

~
Pin E1 - 21 1
FRP
Pin E1 - 34 2
VREF6
Pin E1 - 88 3
1 3
V00162

Figure 268 FRP Sensor Circuit Diagram

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 695

NOTE: See latest version of Maxxforce 11 / 13 • Fuel Inlet Restriction / Aeration Tool ZTSE4886
Engine and Aftertreatment Wiring Schematic
• Fuel Pressure Gauge ZTSE4681
Form 0000002941 for additional circuit
information. • Fuel Line Coupler ZTSE4906
• ZTSE4526 - Compucheck Fitting
Overview
• Clean Fuel Source Tool 15-637-01
The Fuel Rail Pressure (FRP) sensor is a
variable-capacitance sensor that measures pressure • Pressure Test Kit ZTSE4409
at the high-pressure common fuel rail. As pressure
• High Pressure Return Line Tester ZTSE4887
increases, sensor capacitance changes causing
voltage to Engine Control Module (ECM) to change. • High Pressure Rail Plug ZTSE6098
The ECM adjusts the Fuel Pressure Control Valve
• Electronic Service Tool (EST) with ServiceMaxx™
(FPCV) duty cycle to control fuel pressure for
software
starting and for changing engine load, speed, and
temperature. • Interface cable (RP1210B compliant supporting
J1939 and J1708)
Tools Required
• Breakout Harness ZTSE4828 (FPCV)
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00

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 696 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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0000041032

Figure 269 FRP Sensor Location

1. Fuel Rail Pressure (FRP) sensor

Pinpoint Diagnostics With ServiceMaxx™

Software

WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.

SPN 157 FMI 0 - FRP relief valve opening fault

Re-flash Engine Control Module (ECM) software.

SPN 157 FMI 14 - FRP Relief Valve failure

Re-flash ECM software.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 697

SPN 3055 FMI 0 - FRP Exceeded Maximum

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure FRP greater than 34,000 Key ON 0.25 seconds
(FRP) above maximum psi (235,000 kpa)
Closed loop FRP control
pressure.

Fault Overview
Fault code sets when signal from the Fuel Rail
Pressure (FRP) sensor indicates FRP exceeds
34,000 psi (235,000 kPa).

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 94 FMI 0 (FDP); SPN 157 FMI 3, 4, 20, and 21
(FRP); and SPN 633 FMI 3, 4, and 5 (FPCV)

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Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Restricted high-pressure pump fuel return line
• Failed Fuel Pressure Control Valve (FPCV)
(sticking)

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 FMI 0
No: Repair SPN 94 FMI 0; SPN
(FDP); SPN 157 FMI 3, 4, 20, and 21 (FRP); and SPN 633 FMI 3,
157 FMI 3, 4, 20, and 21; and
4, and 5 (FPCV).
SPN 633 FMI 3, 4, and 5. After
Is the EST DTC list free of SPN 94 FMI 0; SPN 157 FMI 3, 4, 20, repairs are complete, retest for
and 21 and SPN 633 FMI 3, 4, and 5? SPN 3055 FMI 0.

Step Action Decision

2 Check for restricted fuel return line. Perform HP Pump Fuel Yes: Go to step 3.
Return Pressure Test (page 178).
No: Repair restriction in
Is pressure < 13 psi? fuel return line between
high-pressure fuel pump and
fuel tank. After repairs are
complete, retest for SPN 3055
FMI 0.

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 698 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Check for a failed Fuel Pressure Control Valve (FPCV). Key Yes: Go to step 4.
OFF, connect Breakout Harness ZTSE4828 to FPCV and leave
No: Replace FPCV. After repairs
vehicle harness disconnected. Using a DMM, measure resistance
are complete, retest for SPN
between ZTSE4828 pin-1 and pin-2.
3055 FMI 0.
Is resistance between 2.6 and 3.2 ohms?

Step Action Decision

4 Check for a sticking FPCV. Run engine at idle. Using EST, monitor Yes: Retest for SPN 3055 FMI 0.
the difference between the desired and actual fuel rail pressure
No: Replace FPCV. After repairs
for 5 minutes.
are complete, retest for SPN
Does pressure difference remain < 1160 psi (80 Bar) throughout 3055 FMI 0.
the test?

NOTE: After performing all diagnostic steps, if

SPN 3055 FMI 0 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 699

SPN 3055 FMI 1 - Low Fuel Pressure at Start

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure FRP less than 1,450 psi Engine Speed > 70 rpm 0.5 seconds
(FRP) below minimum (10,000 kpa)
Ambient Pressure > 12 psi (83
pressure.
kPa)
Ambient Temp > 19°F (-7°C)
Battery Voltage (before crank) >
11 Volts

Fault Overview
Fault code sets when the Engine Control Module
(ECM) detects Fuel Rail Pressure (FRP) does not
build within a predetermined time while the engine is
cranking.

Malfunction Indicator Lamp (MIL) Reaction

MIL may illuminate when this fault is detected during

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one drive cycle.

Associated Faults
SPN 94 FMI 0 (FDP); SPN 157 FMI 3, 4, 20, and 21
(FRP); and SPN 633 FMI 3, 4, and 5 (FPCV)

Fault Facts
The Piston Overflow Valve (KUEV) valve is a flow
control valve that allows return fuel to lubricate the
internal components of the high-pressure fuel pump
when the engine is running. The Piston Overflow
Valve (KUEV) valve can be serviced separately from
the high-pressure fuel pump.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Fuel Rail Pressure (FRP) sensor or circuit fault
• Low fuel level
• Low-pressure fuel system leaks
• Restricted engine mounted secondary fuel filter
• Aerated fuel delivery
• Restricted low pressure fuel system
• Internal leak in high-pressure fuel system
• Leaking fuel pressure relief valve
• Leaking Piston Overflow Valve (KUEV) valve
• Stuck or sticking FPCV
• Failed low-pressure fuel pump
• Failed high-pressure fuel pump

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 700 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 FMI 0
No: Repair SPN 94 FMI 0; SPN
(FDP); SPN 157 FMI 3, 4, 20, and 21 (FRP); and SPN 633 FMI 3,
157 FMI 3, 4, 20, and 21; and
4, and 5 (FPCV).
SPN 633 FMI 3, 4, and 5. After
Is EST DTC list free of SPN 94 FMI 0; SPN 157 FMI 3, 4, 20, and repairs are complete, retest for
21; and SPN 633 FMI 3, 4, and 5? SPN 3055 FMI 1.

Step Action Decision

2 Check fuel level. Read fuel level using the vehicle instrument Yes: Go to step 3.
panel gauge and perform a visual inspection of fluid level in the
No: Add fuel and prime engine.
fuel tank.
After repairs are complete, retest
Is fuel tank fluid level above 1/2 tank? for SPN 3055 FMI 1.

Step Action Decision

3 Check fuel tank, fuel lines, and fuel filter assembles for: cracks Yes: Go to step 4.
and pitting; and loose, leaking, or damaged connections.
No: Add fuel or repair leaks, and
Are the fuel tank, fuel lines, and fuel filter assembles in good prime engine. After repairs are

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condition and Not leaking? complete, retest for SPN 3055
FMI 1.

Step Action Decision

4 Check that the engine cranks at a minimum of 130 rpm. Crank Yes: Go to step 5.
engine for maximum of 20 seconds.
No: Repair low cranking speed.
Does engine crank at a minimum of 130 rpm? After repairs are complete, retest
for SPN 3055 FMI 1.

Step Action Decision

5 Verify the engine starts. Crank engine for maximum of 20 Yes: Go to SPN 3055 FMI 15
seconds. If engine does not start, wait 2 minutes and try again. (page 703).
Does engine start and maintain idle? No: Go to step 6.

Step Action Decision

6 Check for a failed FRP sensor or circuit. Disconnect the FRP Yes: Diagnose FRP Sensor
sensor electrical connector and attempt to start engine. Crank (page 683). After repairs are
engine for maximum of 20 seconds. complete, retest for SPN 3055
FMI 1.
Does the engine start?
No: Reconnect sensor and go to
step 7.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 701

Step Action Decision

7 Check for low FDP. Perform Fuel Delivery Pressure (FDP) Test Yes: Go to step 11.
(page 129).
No: Go to step 8.
Does FDP measure > 30 psi (15 psi in ServiceMaxx™)?

Step Action Decision

8 Check for leaks or restrictions in the fuel supply to the low-pressure Yes: Go to step 11.
fuel pump. Perform Fuel Dead head Test (page 130).
No: Go to step 9.
Is fuel dead head pressure greater than 65 psi?

Step Action Decision

9 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 10.
Aeration Test (page 131).
No: Repair aeration in
Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 3055 FMI 1.

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Step Action Decision
10 Check for restriction in low-pressure fuel system. Perform Fuel Yes: Replace low-pressure
Restriction Test (page 133). fuel pump. After repairs are
complete, retest for SPN 3055
Is low-pressure fuel system free of restrictions?
FMI 1.
No: Repair restriction in
low-pressure fuel system. After
repairs are complete, retest for
SPN 3055 FMI 1.

Step Action Decision

11 Check for a restricted engine mounted secondary fuel filter. Yes: Go to step 12.
Perform High-pressure Pump Inlet Pressure Test (page 136).
No: Replace engine mounted
Does the fuel pressure gauge read > 30 psi? secondary fuel filter. After
repairs are complete, retest for
SPN 3055 FMI 1.

Step Action Decision

12 Check for excessive fuel return. Perform Fuel Rail Pressure (FRP) Yes: Go to step 15.
Return Flow Test Part 1 (page 137).
No: Go to step 13.
Is the fuel volume returned between 20-22 ml?

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 702 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

13 Check for a failed fuel pressure relief valve. Perform Fuel Rail Yes: Go to step 14.
Pressure (FRP) Return Flow Test Part 2 (page 137).
No: Replace fuel pressure
Is the line free of return fuel from fuel rail? relief valve. After repairs are
complete, retest for SPN 3055
FMI 1.

Step Action Decision

14 Check for an internal leak in the high-pressure fuel system. Yes: Retest for SPN 3055 FMI
Perform Fuel Rail Pressure (FRP) Leak Isolation (page 138). 1. If fault is still present notify
supervisor for further action.
Is fuel leaking out of High Pressure Return Line Tester ZTSE4887?
No: Replace the last capped
injector, injector tube, and all HP
lines removed during this test.
After repairs are complete, retest
for SPN 3055 FMI 1.

Step Action Decision

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15 Check for a failed Piston Overflow Valve (KUEV) valve. Perform Yes: Replace the high-pressure
the HP Pump Return Flow Test (page 139). fuel pump. After repairs are
complete, go to step 16.
Is High Pressure Return Line Tester ZTSE4887 free of fuel from
the high-pressure pump return port? No: Replace Piston Overflow
Valve (KUEV) valve. After
repairs are complete, retest for
SPN 3055 FMI 1.

Step Action Decision

16 Verify the fuel return line is free from restriction. Run HP Pump Yes: Retest for SPN 3055 FMI
Fuel Return Pressure Test (page 139). 1. If fault is still present notify
supervisor for further action.
Is pressure < 13 psi?
No: Repair restriction in
fuel return line between
high-pressure fuel pump and
fuel tank. After repairs are
complete, retest for SPN 3055
FMI 1.

NOTE: After performing all diagnostic steps, if

SPN 3055 FMI 1 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 703

SPN 3055 FMI 15 - FRP Below Minimum with Maximum Command

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure Rail pressure governor Key ON 10 seconds
(FRP) governor error > 725 psi at 600-750
Metering unit flow > function
deviation above rpm
engine speed (41,500-55,000
maximum limit 3
mm /s)
Engine mode normal
Engine speed > 0 rpm OR FRP
> 13,050 psi (90,000 kpa) for
more than 20 engine revolutions
Metering unit flow < 327,670
3
mm /sec

Fault Overview • Fuel pressure fuel system leaks

Fault code sets when the Engine Control Module • Restricted engine mounted secondary fuel filter
(ECM) detects Fuel Rail Pressure (FRP) is below
• Aerated fuel delivery
minimum when the maximum is commanded.

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• Restricted fuel supply
Malfunction Indicator Lamp (MIL) Reaction
• Internal leak in high-pressure fuel system
MIL will illuminate when this fault is detected during
• Leaking fuel pressure relief valve
two consecutive drive cycles.
• Leaking Piston Overflow Valve (KUEV) valve
Associated Faults
• Stuck or sticking FPCV
SPN 157 FMI 3, 4, 20, 21 (FRP); and SPN 633 FMI 3,
• Failed low-pressure fuel pump
4, and 5 (FPCV)
• Failed high-pressure fuel pump
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Low fuel level

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 704 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 157 FMI 3, 4,
No: Repair SPN 157 FMI 3, 4,
20, and 21 (FRP) or SPN 633 FMI 3, 4, and 5 (FPCV).
20, and 21, and SPN 633 FMI
Is the EST DTC list free of SPN 157 FMI 3, 4, 20, and 21, and 3, 4, and 5. After repairs are
SPN 633 FMI 3, 4, and 5? complete, retest for SPN 3055
FMI 15.

Step Action Decision

2 Check fuel level. Read fuel level using the vehicle instrument Yes: Go to step 3.
panel gauge and perform a visual inspection of fluid level in the
No: Add fuel and prime engine.
fuel tank.
After repairs are complete, retest
Is fuel tank fluid level above 1/2 tank? for SPN 3055 FMI 15.

Step Action Decision

3 Check fuel tank, fuel lines, and fuel filter assembles for: cracks Yes: Go to step 4.
and pitting; and loose, leaking, or damaged connections.
No: Add fuel or repair leaks, and
Are the fuel tank, fuel lines, and fuel filter assembles in good prime engine. After repairs are

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condition and Not leaking? complete, retest for SPN 3055
FMI 15.

Step Action Decision

4 Check that the engine cranks at a minimum of 130 rpm. Crank Yes: Go to step 5.
engine for maximum of 20 seconds.
No: Repair low cranking speed.
Does engine crank at a minimum of 130 rpm? After repairs are complete, retest
for SPN 3055 FMI 15.

Step Action Decision

5 Verify the engine starts. Crank engine for maximum of 20 Yes: Go to step 6.
seconds. If engine does not start, wait 2 minutes and try again.
No: Go to SPN 3055 FMI 1
Does engine start and maintain idle? (page 699).

Step Action Decision

6 Check for low FDP. Perform Fuel Delivery Pressure (FDP) Test Yes: Go to step 10.
(page 167).
No: Go to step 7.
Does FDP measure between 85 - 120 psi?

Step Action Decision

7 Check for leaks or restrictions in the fuel supply to the low-pressure Yes: Go to step 10.
fuel pump. Perform Fuel Dead head Test (page 168).
No: Go to step 8.
Is fuel dead head pressure greater than 65 psi?

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 705

Step Action Decision

8 Check for aeration in low-pressure fuel system. Perform Fuel Yes: Go to step 9.
Aeration Test (page 170).
No: Repair aeration in
Is low-pressure fuel system free from aeration? low-pressure fuel system.
After repairs are complete, retest
for SPN 3055 FMI 15.

Step Action Decision

9 Check for restriction in low-pressure fuel system. Perform Fuel Yes: Retest for SPN 3055 FMI
Restriction Test (page 170). 15. If fault is still present notify
supervisor for further action.
Is low-pressure fuel system free of restrictions?
No: Repair restriction in
low-pressure fuel system. After
repairs are complete, retest for
SPN 3055 FMI 15.

Step Action Decision

10 Check for a restricted engine mounted secondary fuel filter. Yes: Go to step 11.

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Perform High-pressure Pump Inlet Pressure Test (page 175).
No: Replace engine mounted
Does the fuel pressure gauge read > 30 psi? secondary fuel filter. After
repairs are complete, retest for
SPN 3055 FMI 15.

Step Action Decision

11 Check for excessive fuel return. Perform Fuel Rail Pressure (FRP) Yes: Go to step 14.
Return Flow Test Part 1 .
No: Go to step 12.
Is the fuel volume returned between 20-22 ml?

Step Action Decision

12 Check for a failed fuel pressure relief valve. Perform Fuel Rail Yes: Go to step 13.
Pressure (FRP) Return Flow Test Part 2 .
No: Replace fuel pressure
Is the line free of return fuel from fuel rail? relief valve. After repairs are
complete, retest for SPN 3055
FMI 15.

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 706 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

13 Check for an internal leak in the high-pressure fuel system. Yes: Retest for SPN 3055 FMI
Perform Fuel Rail Pressure (FRP) Leak Isolation (page 177). 15. If fault is still present notify
supervisor for further action.
Is fuel leaking out of High Pressure Return Line Tester ZTSE4887?
No: Replace the last capped
injector, injector tube and all HP
lines removed during this test.
After repairs are complete, retest
for SPN 3055 FMI 15.

Step Action Decision

14 Check for a failed Piston Overflow Valve (KUEV) valve. Perform Yes: Replace the high-pressure
the HP Pump Return Flow Test (page 139). fuel pump. After repairs are
complete, go to step 15.
Is High Pressure Return Line Tester ZTSE4887 free of fuel from
the high-pressure pump return port while cranking? No: Replace Piston Overflow
Valve (KUEV) valve. After
repairs are complete, retest for
SPN 3055 FMI 15.

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Step Action Decision
15 Verify the fuel return line is free from restriction. Run HP Pump Yes: Retest for SPN 3055 FMI
Fuel Return Pressure Test (page 178). 15. If fault is still present notify
supervisor for further action.
Is pressure < 13 psi?
No: Repair restriction in
fuel return line between
high-pressure fuel pump and
fuel tank. After repairs are
complete, retest for SPN 3055
FMI 15.

NOTE: After performing all diagnostic steps, if

SPN 3055 FMI 15 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 707

SPN 3055 FMI 17 - FRP Above Maximum with Minimum Command

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Fuel Rail Pressure FRP governor error less Key ON 10 seconds
(FRP) governor than 725 psi at 600-750
ECM Not in limp-home mode
deviation below rpm
minimum limit Metering unit flow < 327,670
3
mm /sec
Engine speed > 0 rpm OR FRP
> 13,053 psi (90,000 kpa) for
more than 20 engine revolutions
Fuel injector quantity command
> 5 mg/stroke
ECT1 > -40°F (-40°C)
Engine Not overrunning

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when the Engine Control Module Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference

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(ECM) detects Fuel Rail Pressure (FRP) exceeds Manual.
13,053 psi (90,000 kPa) when the Fuel Pressure
Possible Causes
Control Valve (FPCV) is commanded to minimum
pressure. • Restricted high-pressure pump fuel return line
• FRP sensor or circuit fault
Malfunction Indicator Lamp (MIL) Reaction
• Fuel Pressure Control Valve (FPCV) or circuit fault
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 94 FMI 0 (FDP); SPN 157 FMI 3, 4, 20, 21 (FRP);
and SPN 633 FMI 3, 4, and 5 (FPCV)

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 708 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 94 FMI 0
No: Repair SPN 94 FMI 0; SPN
(FDP); SPN 157 FMI 3, 4, 20; and 21 (FRP) or SPN 633 FMI 3,
157 FMI 3, 4, 20, and 21; and
4, and 5 (FPCV).
SPN 633 FMI 3, 4, and 5. After
Is the EST DTC list free of SPN 94 FMI 0; SPN 157 FMI 3, 4, 20, repairs are complete, retest for
and 21; and SPN 633 FMI 3, 4, and 5? SPN 3055 FMI 17.

Step Action Decision

2 Check for restricted fuel return line. Perform HP Pump Fuel Yes: Go to step 3.
Return Pressure Test (page 178).
No: Repair restriction in
Is pressure < 13 psi? fuel return line between
high-pressure fuel pump and
fuel tank. After repairs are
complete, retest for SPN 3055
FMI 17.

Step Action Decision

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3 Check for a failed FRP sensor or circuit. Disconnect the FRP Yes: Diagnose FRP Sensor
sensor electrical connector and attempt to start engine. Crank (page 683). After repairs are
engine for maximum of 20 seconds. complete, retest for SPN 3055
FMI 17.
Does the engine start and maintain idle?
No: Reconnect sensor and go to
step 4.

Step Action Decision

4 Check for a failed Fuel Pressure Control Valve (FPCV). Key Yes: Go to step 5.
OFF, connect Breakout Harness ZTSE4828 to FPCV and leave
No: Replace FPCV. After repairs
vehicle harness disconnected. Using a DMM, measure resistance
are complete, retest for SPN
between ZTSE4828 pin-1 and pin-2.
3055 FMI 17.
Is resistance between 2.6 and 3.2 ohms?

Step Action Decision

5 Check for a sticking FPCV. Run engine at idle. Using EST, monitor Yes: Retest for SPN 3055 FMI
the difference between the desired and actual fuel rail pressure 17.
for 5 minutes.
No: Replace FPCV. After repairs
Does the pressure difference maintain < 1160 psi (80 bar) are complete, retest for SPN
throughout the test? 3055 FMI 17.

NOTE: After performing all diagnostic steps, if

SPN 3055 FMI 17 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 709

Hard Brake Monitor

SPN FMI Condition Possible Causes Actions

1810 0 Hard Brake monitor, event log, • Incorrect Pinpoint Diagnostics
extreme programmable (page 709)
parameter value
• Hard brake event
1810 15 Hard Brake monitor, even log • Incorrect Pinpoint Diagnostics
non-extreme programmable (page 709)
parameter value
• Hard brake event

Overview
The hard brake monitor feature determines hard
vehicle speed deceleration incidents. An incident
occurs when programmable parameter 89052 Hard
Brake Decel Rate Threshold is set at too low of a
speed change. The incident is then reported to the
ECM and stored as a vehicle event.

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Tools Required
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

Pinpoint Diagnostics With ServiceMaxx™

Software

SPN 1810 FMI 0 - Hard Brake monitor, event log, extreme

1. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the Parameters session and
adjust parameter ID 89052 Hard Brake Decel Rate Threshold to 5-9 mph/s.
2. Program engine and retest for 1810 FMI 0.

SPN 1810 FMI 15- Hard Brake monitor, event log, non-extreme
1. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the Parameters session and
adjust parameter ID 89052 Hard Brake Decel Rate Threshold to 5-9 mph/s.
2. Program engine and retest for 1810 FMI 15.

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 710 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

HS (Humidity Sensor) / IAT (Inlet Air Temperature

Sensor)

SPN FMI Condition Possible Causes Actions

172 2 IAT signal does not agree with other • Biased IAT sensor Pin-Point Diagnostics
sensors or circuit (page 712)
172 3 IAT Out of Range HIGH • IAT signal circuit Pin-Point Diagnostics
OPEN or short to (page 711)
PWR
• SIG GND circuit
OPEN
• Failed IAT sensor
172 4 IAT Out of Range LOW • IAT signal circuit Pin-Point Diagnostics
short to GND (page 711)
• Failed IAT sensor
354 3 Relative Humidity signal Out of Range • HS signal circuit Pin-Point Diagnostics
HIGH OPEN or short to (page 711)
PWR

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• SIG GND circuit
OPEN
• Failed HS sensor
354 4 Relative Humidity signal Out of Range • HS signal circuit Pin-Point Diagnostics
LOW short to GND (page 711)
• Failed HS sensor

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 711

HS/IAT circuit

HS/IAT
HS/IAT
ECM 96-Pin HS/IAT connector
sensor
E1 connector connector (end view)

Pin E1 - 85
Pin E1 - 59
Pin E1 - 23
Pin E1 - 38
VREF2
HS
SIG GND
IAT
1
2
3
4
:I ~
0000058101

Figure 271 HS/IAT sensor circuit diagram

Tools Required Pinpoint Diagnostics With ServiceMaxx™

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Software
• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness Kit WARNING: To prevent personal injury or
00-01462-00 death, stay clear of rotating parts (belts and fan)
• ZTSE4498 – 3-Banana Plug Harness and hot engine surfaces.

• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4830 (HS/IAT)
• Digital Multimeter (DMM)
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.

• Electronic Service Tool (EST) with ServiceMaxx™ • If DTC is previously active, monitor signal
software while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
• J1939 and J1708 RP1210B Compliant Device and DTC will go active or pending.
• If DTC is active, continue to Cold Soak
Sensor Compare Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

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 712 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 172 FMI 2 – IAT signal does not agree with other sensors
Cold Soak Sensor Compare Check With ServiceMaxx™ Software
NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare IAT and Ambient Air Temperature (AAT). Sensor temperatures should be within 5 °C
(10 °F) of each other.
• If IAT is 5 °C (10 °F) above or below AAT, check for poor circuitry going to the IMT sensor.
• If circuits are within specification, replace HS/IAT sensor.

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716
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 713

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4830 to HS/IAT engine harness, and leave HS/IAT sensor disconnected.
Turn ignition ON.
Test Point Specification Comment– < Less than, > Greater than
EST - Monitor HSv 5.0 V ± 0.5 V If < 4.5 V check HS signal circuit for short to GND.
EST - Monitor IATv 5.0 V ± 0.5 V If < 4.5 V check IAT signal circuit for short to GND.
EST - Monitor HSv 0V If > 0.25 V, check HS signal circuit for OPEN. Do Harness
Resistance Check.
Short pin 2 to GND
EST - Monitor HSv 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check.
Short pin 2 to 3
EST - Monitor IATv 0V If > 0.25 V, check IAT signal circuit for OPEN. Do Harness
Resistance Check.
Short pin 4 to GND
EST – Monitor HSv < 1.0 V If > 1.0 V, check HS signal circuit for short to PWR.
Short 500 Ω resistor across pins
2 and 3
EST – Monitor HSv < 1.0 V If > 1.0 V, check IAT signal circuit for short to PWR.

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Short 500 Ω resistor across pins
3 and 4

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4830 to HS/IAT engine harness, and leave HS/IAT sensor disconnected.
Turn ignition ON.. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 5.0 V ± 0.5 V If < 4.5 V, check for OPEN in VREF2 circuit.
2 to GND 5.0 V ± 0.5 V If < 4.5 V, check for OPEN in HS circuit.
3 to B+ B+ If < B+, check for OPEN is SIG GND circuit.
4 to GND 5.0 V ± 0.5 V If < 4.5 V, check for OPEN in IAT circuit.

717
 714 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4830 to HS/IAT
engine harness, and leave HS/IAT sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check VREF2 circuit for short to GND.
1 to E1-85 <5Ω If > 5 Ω, check VREF2 circuit for OPEN.
2 to GND > 1k Ω If < 1k Ω, check HS circuit for short to GND.
2 to E1-59 <5Ω If > 5 Ω, check HS circuit for OPEN.
3 to GND > 1k Ω If < 1k Ω, check SIG GND circuit for short to GND.
3 to E1-23 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
4 to GND > 1k Ω If < 1k Ω, check IAT circuit for short to GND.
4 to E1-38 <5Ω If > 5 Ω, check IAT circuit for OPEN.

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718
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 715

IMP (Intake Manifold Pressure)

SPN FMI Condition Possible Causes Actions

102 2 IMP signal does not agree • Biased IMP sensor or circuit Circuit Checks (page
with BARO 717)
102 3 IMP signal Out of Range • IMP signal circuit OPEN or Circuit Checks (page
HIGH short to PWR 718)
• SIG GND circuit OPEN
• Failed IMP sensor
102 4 IMP signal Out of Range LOW • IMP signal circuit short to Circuit Checks (page
GND 718)
• VREF2 circuit OPEN
• Failed IMP sensor
102 10 IMP Boost slow response • Turbocharger 2 (TC2) Step Based Diagnostics
wastegate stuck open (page 720)
• Restricted intake air system
• Charge Air Cooler (CAC)

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hose leaking
• CAC leak
• Failed turbocharger
• Exhaust leak
• Restricted exhaust
• Exhaust Gas Recirculation
(EGR) fault

IMP circuit

IMP IMP
ECM 96-Pin connector sensor
IMP (end view)
E1 connector

-3
connector
Pin E1 _ 43 ~ G-
,--+--'S::.:.IG ND- -

Pin E1 _ 36
V REF -2
---
1MP 2
PinE1-1S

V00040

Figure 272 IMP Sensor Circuit Diagram

719
 716 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Overview 1
The IMP sensor is a variable-capacitance sensor that
measures charge-air pressure entering the air intake
throttle duct. As pressure increases, ceramic material
moves closer to a thin metal disc (internal sensor),
causing a change in capacitance that changes the
voltage sent to, and interpreted by, the Engine Control
Module (ECM). IMP is monitored by the ECM for
Exhaust Gas Recirculation (EGR) and turbocharger
wastegate control.
Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE4850 (IMP)

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0000038233
• Digital Multimeter (DMM)
Figure 273 IMP Sensor Location
• Electronic Service Tool (EST) with ServiceMaxx™
software 1. Intake Manifold Pressure (IMP) sensor

• J1939 and J1708 RP1210B Compliant Device

720
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 717

IMP circuit

IMP IMP
ECM 96-Pin connector sensor
IMP (end view)
E1 connector

-3
connector
Pin E1 - 43 SIG GND

Pin E1 - 86 VREF-2 2

Pin E1 - 18 IMP _ __
~.:..:..:..:..:, 2

V00040

Figure 274 IMP Sensor Circuit Diagram

Pinpoint Diagnostics With ServiceMaxx™

Software
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous

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Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Biased
Sensor or Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

Biased Sensor or Circuit Check

1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Continuous Monitor session.
3. Verify S_IMP volts are within specification. See “APPENDIX A: PERFORMANCE
SPECIFICATIONS."
• If voltage is not within specification, go to Circuit Checks (page 718). If circuits are within
specification, replace IMP sensor.

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 718 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4850 to IMP engine harness, and leave IMP sensor disconnected. Turn
ignition ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor IMPv 5.0 V ± 0.5 V If < 4.5 V, check IMP signal circuit for short to GND. Do
Harness Resistance Check (page 719).
DMM – Measure volts 5.0 V ± 0.5 V If > 5.5 V, check VREF2 circuit for short to PWR.
2 to GND If < 4.5 V, check VREF2 circuit for OPEN or short to GND.
Do Harness Resistance Check (page 719).
DMM – Measure 5.0 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
voltage Resistance Check (page 719).
1 to 2
EST – Monitor IMPv 0V If > 0.5 V, check IMP signal circuit for OPEN or short to
PWR. Do Harness Resistance Check (page 719).
Short across Breakout
Harness ZTSE4850
pins 1 and 3
If checks are within specifications, connect sensor and clear DTCs. If active DTC remains, replace IMP

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sensor.

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4850 to IMP engine harness, and leave IMP sensor disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to B+ B+ If < B+, check SIG GND circuit for OPEN or short to PWR.
2 to GND 5.0 V ± 0.5 V If > 5.5 V, check VREF2 for short to PWR.
If < 4.5 V, check VREF2 for OPEN or short to GND. Do
Harness Resistance Check (page 719).
3 to GND 5.0 V ± 0.5 V If < 4.5 V, check IMP signal circuit for short to GND. Do
Harness Resistance Check (page 719).

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 719

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4850 to IMP
engine harness, and leave IMP sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-43 <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check for short circuit.
2 to E1-86 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-18 <5Ω If > 5 Ω, check for OPEN circuit.

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723
 720 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 102 - FMI 10 IMP - Boost Slow Response

-
Condition / Setting Criteria Enable Conditions / Values Time Required l
Description
- -
Intake Manifold Intake Manifold Pressure Rate of Change in Engine Speed 1 event
Pressure (IMP) (IMP) does not maintain > 100 rpms
accumulated deviation less than 80 psi (550 kPa)
Time after Key ON > 0 seconds
from boost. difference between actual
and desired. Battery voltage > 10.7 V
Battery voltage < 15 V
Engine Speed > 800 rpm
Rate of Change in Injection
Quantity > 50 mg
Injection Quantity > 0 mg/stroke
I I I and < 500 mg/stroke I _J

Malfunction Indicator Lamp (MIL) Reaction

When fault is active, MIL will not illuminate.

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Associated Faults
SPN’s 27, 51, 1189, 2791, and 3464.

Drive Cycle
See 2013 HD-OBD Diagnostic Reference Manual.

IMP circuit

IMP IMP
ECM 96-Pin connector sensor
IMP (end view)
E1 connector

-3
connector
Pin E1 - 43 SIG GND
Pin E1 - 86 \..Tl~v~R=-E~F~-2~----- I

Pin E1 - 18 IMP 2

V00040

Figure 275 IMP Sensor Circuit Diagram

rStep I
'
Action l Decision 7
-
1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes. ' -
No: Repair other fault code(s).
Is SPN 102 FMI 10 the only fault code active? After repairs are complete, retest
L I I for SPN 102 FMI 10. _J

724
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 721

Step Action Decision

2 Inspect air intake system, exhaust system, and air filter for Yes: Go to step 3.
restrictions, air leaks, or physical damage. Also, inspect the fuel
No: Repair restrictions, air leaks,
system from fuel tank to AFI valve for leaks or physical damage.
fuel leaks or physical damage.
Is air intake system, exhaust system, fuel system and air filter free After repairs are complete, retest
of restrictions, leaks, and physical damage? for SPN 102 FMI 10.

Step Action Decision

3 Determine if Intake Manifold Pressure (IMP) sensor or circuit is Yes: Go to step 4.
out of specifications. Using EST with ServiceMaxx™ software, do
No: Repair IMP sensor or circuit.
IMP Biased Sensor or Circuit Check (page 717).
After repairs are complete, retest
Is IMP sensor within specifications? for SPN 102 FMI 10.

Step Action Decision

4 Verify IMP changes when Turbocharger 2 Wastegate Control IMP signal change only when
(TC2WC) and Exhaust Gas Recirculation (EGR) valve are TC2WC is commanded On: Do
commanded On. Key-On Engine-Running (KOER). Run Air EGR Pinpoint Diagnostics (page
Management Test while monitoring IMP sensor signal. 622) and check for EGR issue.

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After repairs are complete, retest
Does IMP sensor signal change:
for SPN 102 FMI 10.
• When TC2WC is commanded On?
IMP signal change only with
• When EGR valve is commanded On? EGR valve commanded On:
Do TC2WC voltage and circuit
checks (page 839). After repairs
are complete, retest for SPN 102
FMI 10.
Neither change IMP signal when
commanded On: Go to step 5.
Both change IMP signal when
commanded On: Go to step 7.

Step Action Decision

5 Verify IMP sensor and bore are not restricted due to carbon buildup. Yes: Go to step 6.
Remove and inspect IMP sensor and bore for carbon buildup.
No: Clean IMP sensor bore of
Is IMP sensor and bore free of carbon buildup? carbon deposits. After repairs
are complete, retest for SPN
102 FMI 10. Go to step 6 if
cleaning does not resolve fault
code.

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 722 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Determine if Charge Air Cooler is leaking. Do Charge Air Cooler Yes: Go to step 7.
(CAC) pressure test (page 184).
No: Correct air leak(s). After
Was CAC free of leaks? repairs are complete, retest for
SPN 102 FMI 10.

Step Action Decision

7 Do a road test (100% throttle when safe to do so) while recording Both TC1TOP and DPFDP
a snap shot of the following signals: signals are above specification:
Go to step 8.
• Diesel Particulate Filter Differential Pressure (DPFDP) = 0.5 -
0.8 psi Only TC1TOP signal above
specification: Remove Pre
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP) = 2 – 3 psi
Diesel Oxidation Catalyst
Are DPFDP and TC1TOP within specification? (Pre-DOC) and Diesel Oxidation
Catalyst (DOC) for inspection
NOTE: DPFDP and TC1TOP specifications only apply with soot
and clean or replace as
load < 40%.
necessary. After repairs are
complete, retest for SPN 102
FMI 10.

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Neither signal above
specification: Go to step
9.

Step Action Decision

8 Using EST with ServiceMaxx software, start an Onboard Filter Yes: Go to step 9.
Cleanliness Test (OBFCT).
No: Correct Parked Regen
Is OBFCT running without an Abort Message in ServiceMaxx™? Inhibitors (page 319) and restart
OBFCT.

726
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 723

Step Action Decision

9 While running OBFCT, inspect for exhaust leaks and monitor following If Parked Regen Checks
signals during test: are within specification: Go
to step 7.
Are Parked Regen Checks within specification during OBFCT?
Parked Regen Checks Specifications Pass / Fail
Engine condition Smooth, not stumbling If AFTFP1 is below 110
psi: Do Fuel Delivery
Engine Coolant Temp Above 122°F (50°C) per
Pressure (FDP) Test (page
(ECT) ServiceMaxx
167). Repair any FDP
measurements out of
specification. After repairs
are complete, retest for
SPN 102 FMI 10.
DOCIT After 5 - 10 minutes above If AFTFP2 fuel pressure
500°F (260°C) is below 40-70 psi at AFI
opening: Clean AFI valve,
DOCOT After 5 – 10 minutes above
housing, and bore. After
986°F (530°C)
cleaning procedure is
complete, retest for SPN

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102 FMI 10.
DPFOT Below 1292°F (700°C) If Parked Regen Checks
other than AFTFP1
Aftertreatment Fuel > 110 psi during test
and AFTFP2 are out
Pressure 1 (AFTFP1)
of specifications: Repair
Aftertreatment Fuel Aftertreatment Fuel Parked Regen Check
Pressure 2 (AFTFP2) Injector (pop-off valve) fuel (page 321). After repairs
pressure range between are complete, retest for
40-70 psi at opening SPN 102 FMI 10.
pressure.

Step Action Decision

10 After OBFCT is complete, does Diesel Particulate Filter Differential Yes: Go to step 11.
Pressure (DPFDP) signal measure below 0.5 psi at high idle?
No: Remove DPF and inspect
for restrictions. If restricted,
have the DPF cleaned using
the appropriate DPF cleaning
equipment. After repairs are
complete, retest for SPN 102
FMI 10.

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 724 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

11 Inspect turbochargers for signs of wear and correct operation. Yes: Repair or replace
Inspect turbocharger compressor wheel and air inlet for chipping, turbocharger as necessary.
scuffs, and rough finishes. After repairs are complete, retest
for SPN 102 FMI 10.
Is the turbocharger working correctly and undamaged?
No: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.

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728
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 725

IMT Sensor (Intake Manifold Temperature)

SPN FMI Condition Possible Causes Actions

105 2 IMT signal does not agree with other • Biased IMT sensor Pin-Point Diagnostics
sensors or circuit (page 725)
105 3 IMT signal Out of Range HIGH • IMT signal OPEN or Pin-Point Diagnostics
short to PWR (page 725)
• SIG GND circuit
OPEN
• Failed IMT sensor
105 4 IMT signal Out of Range LOW • IMT signal circuit Pin-Point Diagnostics
short to GND (page 725)
• Failed IMT sensor
105 18 IMT signal not responding as expected • IMT signal does not Pin-Point Diagnostics
rise during engine (page 725)
warm up

IMT circuit

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IMT IMT
ECM 96-Pin sensor
E1 connector IMT connector
connector (end view)

~
Pin E 1 - 37 IMT _ _ _ _ _---i
,\....---4-....!!!.'...!..._

pin E 1 - 83 SIG GND

r.....----1--~~~---, 3

V00009

Figure 276 IMT sensor circuit diagram

Tools Required • Electronic Service Tool (EST) with ServiceMaxx™

software
• 00-00956-08 – 180-Pin Breakout Box
• J1939 and J1708 RP1210B Compliant Device
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00
Pinpoint Diagnostics With ServiceMaxx™
• ZTSE4498 – 3-Banana Plug Harness Software
• ZTSE4497 – 500 Ohm Resistor Harness
WARNING: To prevent personal injury or
• ZTSE4899 – Big Bore Terminal Test Probe Kit death, stay clear of rotating parts (belts and fan)
• Breakout Harness ZTSE4883 (IMT) and hot engine surfaces.

• Digital Multimeter (DMM) 1. Using Electronic Service Tool (EST) with

ServiceMaxx™ software, run the Continuous
Monitor test.

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 726 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2. Monitor sensor voltage and verify an active

DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Cold Soak
Sensor Compare Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

Cold Soak Sensor Compare Check With ServiceMaxx™ Software

SPN 105 FMI 2 – IMT signal does not agree with other sensors
DTC sets after cold soak and IMT signal does not compare with other air temperature sensors.

SPN 105 FMI 18 – IMT signal not responding as expected

DTC sets if IMT signal does not rise 10 °C (50 °F) after a cold soak, when engine is started and run above
1400 rpm for 45 seconds.

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NOTE: Temperature values need to be measured after 8 hours of cold soak.
1. Turn ignition switch ON, engine OFF.
2. Using ServiceMaxx™ software, open the Default session.
3. Compare IMT, Ambient Air Temperature (AAT), and Air Intake Temperature (IAT). Sensor
temperatures should be within 5 °C (10 °F) of each other.
• If IMT is 5 °C (10 °F) above or below AAT, IAT, or IMT, check for poor circuitry going to the
IMT sensor.
• If circuits are within specification, replace IMT sensor.
4. Start engine while monitoring IMT signal.
• If IMT signal does not raise 10 °C (50 °F), check for poor circuitry going to the sensor.
• If circuits are within specification, replace sensor.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 727

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE4883 to IMT engine harness, and leave IMT sensor disconnected. Turn
ignition ON.
Test Point Specification Comment– < Less than, > Greater than
EST – Monitor IMTv 5.0 V ± 0.5 V If <4.5 V, check IMT signal circuit for short to GND.
EST – Monitor IMTv 0V If > 0.25 V, check IMT signal circuit for OPEN. Do
Harness Resistance Check.
Short pin 1 to GND
EST – Monitor IMTv 0V If > 0.25 V, check SIG GND circuit for OPEN. Do Harness
Resistance Check.
Short pin 1 to 3
EST – Monitor IMTv < 1.0 V If > 1.0 V, check IMT signal circuit for short to PWR.
Short 500 Ω resistor across pins
1 and 3
If checks are within specification, connect sensor and clear DTCs. If active code remains, replace IMT
sensor.

Connector Voltage Check Without ServiceMaxx™ Software

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Connect Breakout Harness ZTSE4883 to IMT engine harness, and leave IMT sensor disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 4.5 V to 5 V If < 4.5 V, check for short to GND.
3 to B+ B+ If < B+, check for short to PWR.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and sensor Breakout Harness ZTSE4883. Leave
ECM and sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND > 1k Ω If < 1k Ω, check for short circuit.
1 to E1-37 <5Ω If > 5 Ω, check for OPEN circuit.
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-83 <5Ω If > 5 Ω, check for OPEN circuit.

731
 728 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

INJ (Injector) Circuits

SPN FMI Condition Possible Causes Actions

651 4 Injector 1 short circuit • INJ1 H circuit Step-Based Diagnostics
shorted to INJ1 (page 734)
L circuit
• INJ1 H circuit short
to GND
• INJ1 L circuit short
to GND
• Fuel injector 1
shorted to engine
brake housing
• Failed fuel injector 1
651 5 Injector 1 open load/circuit • INJ1 H circuit Open Step-Based Diagnostics
or high resistance (page 738)
• INJ1 L circuit Open
or high resistance

BetterManuals.net
• Failed fuel injector 1
(Open coil)
652 4 Injector 2 short circuit • INJ2 H circuit Step-Based Diagnostics
shorted to INJ2 (page 742)
L circuit
• INJ2 H circuit short
to GND
• INJ2 L circuit short
to GND
• Fuel injector shorted
to engine brake
housing
• Failed fuel injector 2
652 5 Injector 2 open load/circuit • INJ2 H circuit Open Step-Based Diagnostics
or high resistance (page 746)
• INJ2 L circuit Open
or high resistance
• Failed fuel injector 2
(Open coil)

732
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 729

653 4 Injector 3 short circuit • INJ3 H circuit Step-Based Diagnostics

shorted to INJ3 (page 750)
L circuit
• INJ3 H circuit short
to GND
• INJ3 L circuit short
to GND
• Fuel injector shorted
to engine brake
housing
• Failed fuel injector 3
653 5 Injector 3 open load/circuit • INJ3 H circuit Open Step-Based Diagnostics
or high resistance (page 754)
• INJ3 L circuit Open
or high resistance
• Failed fuel injector 3
(Open coil)
654 4 Injector 4 short circuit • INJ4 H circuit Step-Based Diagnostics

BetterManuals.net
shorted to INJ4 (page 758)
L circuit
• INJ4 H circuit short
to GND
• INJ4 L circuit short
to GND
• Fuel injector shorted
to engine brake
housing
• Failed fuel injector 4
654 5 Injector 4 open load/circuit • INJ4 H circuit Open Step-Based Diagnostics
or high resistance (page 762)
• INJ4 L circuit Open
or high resistance
• Failed fuel injector 4
(Open coil)

733
 730 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

655 4 Injector 5 short circuit • INJ5 H circuit Step-Based Diagnostics

shorted to INJ5 (page 766)
L circuit
• INJ5 H circuit short
to GND
• INJ5 L circuit short
to GND
• Fuel injector shorted
to engine brake
housing
• Failed fuel injector 5
655 5 Injector 5 open load/circuit • INJ5 H circuit Open Step-Based Diagnostics
or high resistance (page 770)
• INJ5 L circuit Open
or high resistance
• Failed fuel injector 5
(Open coil)
656 4 Injector 6 short circuit • INJ6 H circuit Step-Based Diagnostics

BetterManuals.net
shorted to INJ6 (page 774)
L circuit
• INJ6 H circuit short
to GND
• INJ6 L circuit short
to GND
• Fuel injector shorted
to engine brake
housing
• Failed fuel injector 6
656 5 Injector 6 open load/circuit • INJ6 H circuit Open Step-Based Diagnostics
or high resistance (page 778)
• INJ6 L circuit Open
or high resistance
• Failed fuel injector 6
(Open coil)

734
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 731

2797 11 INJ Control Group 1 short circuit (INJ • INJ1 H circuit short Step-Based Diagnostics
1, 3, 5) to PWR (page 782)
• INJ1 H circuit short
to GND
• INJ1 H short to INJ1
L
• INJ1 L circuit short
to PWR
• INJ1 L circuit short
to GND
• Fuel injector 1
shorted to engine
brake housing
• Failed fuel injector 1
• INJ3 H circuit short
to PWR
• INJ3 H circuit short

BetterManuals.net
to GND
• INJ3 H short to INJ3
L
• INJ3 L circuit short
to PWR
• INJ3 L circuit short
to GND
• Fuel injector 3
shorted to engine
brake housing
• Failed fuel injector 3
• INJ5 H circuit short
to PWR
• INJ5 H circuit short
to GND
• INJ5 H short to INJ6
L
• INJ5 L circuit short
to PWR
• INJ5 L circuit short
to GND
• Fuel injector 5
shorted to engine
brake housing
• Failed fuel injector 5

735
 732 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2798 11 INJ Control Group 2 short circuit (INJ • INJ2 H circuit short Step-Based Diagnostics
2, 4, 6) to PWR (page 792)
• INJ2 H circuit short
to GND
• INJ2 H short to
INJ2 L
• INJ2 L circuit short
to PWR
• INJ2 L circuit short
to GND
• Fuel injector 2
shorted to engine
brake housing
• Failed fuel injector 2
• INJ4 H circuit short
to PWR
• INJ4 H circuit short

BetterManuals.net
to GND
• INJ4 H short to
INJ4 L
• INJ4 L circuit short
to PWR
• INJ4 L circuit short
to GND
• Fuel injector 4
shorted to engine
brake housing
• Failed fuel injector 4
• INJ6 H circuit short
to PWR
• INJ6 H circuit short
to GND
• INJ6 H short to
INJ6 L
• INJ6 L circuit short
to PWR
• INJ6 L circuit short
to GND
• Fuel injector 6
shorted to engine
brake housing
• Failed fuel injector 6

736
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 733

Fuel Injector circuits

ECM 16-Pin
E2 connector Connector
INJ1 H Injector 1
Pin E2 - 05 ~~~---
Pin E2 - 12
INJ1 L ~

INJ2 H Injector 2
Pin E2 -11
Pin E2 - 06
INJ2 L ~

INJ3 H Injector 3
Pin E2 - 04
INJ3 L ~
Pin E2 - 13

INJ4 H Injector 4
Pin E2 - 03
Pin E2 - 14
INJ4 L ~

BetterManuals.net
INJ5 H Injector 5
Pin E2- 02
Pin E2 - 15
INJ5 L ~

INJ6 H Injector 6
Pin E2 - 01
Pin E2-16
INJ6 L ~
0000159872

Figure 277 Fuel Injector circuit diagram

NOTE: See latest version of Maxxforce 11 / 13 • Breakout Harness 00-01468-00

Engine and Aftertreatment Wiring Schematic
• 500 Ohm Resistor Harness ZTSE4497
Form 0000002941 for additional circuit
information. • Big Bore Terminal Test Probe Kit ZTSE4899
• Digital Multimeter (DMM)
Overview
• Electronic Service Tool (EST) with ServiceMaxx™
When the Engine Control Module (ECM) determines
software
fueling is required to a cylinder, voltage is supplied to
the fuel injector. The fuel injector has a magnetic coil, • Interface cable (RP1210B compliant supporting
which lifts a needle inside the injector. The needle J1939 and J1708)
moving upward uncovers the spray holes directing fuel
into the cylinder. When the ECM determines injection
should end, voltage to the magnetic coil is removed.
Tools Required
• 180-Pin Breakout Box 00-00956-08

737
 734 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 651 FMI 4- Injector 1 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ1 circuit resistance to Engine Control Module (ECM) 3 events
in fuel injector 1 circuit ground < 0.5 ohms commands injector firing

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 1 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 1 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 05
. Pin E2 - 12
~-~IN~J~1~H____
INJ1 L
c@O
c:@ ~
0000159875

Figure 278 Injector 1 circuit diagram

Possible Causes
• INJ1 H circuit shorted to INJ1 L circuit
• INJ1 H circuit short to GND
• INJ1 L circuit short to GND
• Fuel injector shorted to engine brake housing
• Failed fuel injector 1
WARNING: To prevent personal injury or
death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

738
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 735

'0
1

BetterManuals.net
Figure 279 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 1 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 1 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 651
FMI 4.

739
 736 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 280
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 1 coil. Key OFF, disconnect the Yes: Go to step 3.
connectors from fuel injector 1. Using a DMM, check resistance
No: Replace fuel injector 1. After
across fuel injector 1 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 651 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 651 FMI 4.
terminals clean and undamaged?

740
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 737

Step Action Decision

4 Check for fuel injector 1 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 1. After
disconnected from fuel injector 1, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 651 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 1 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 1. After
disconnected from fuel injector 1, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 651 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

6 Check for INJ1 H short to INJ1 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ1
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ1 L circuit. After

BetterManuals.net
injector 1 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-05 and E2-12 (wiggle test may be required).
SPN 651 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ 1 H circuit for short to GND. Key OFF, connect Yes: Repair short to GND
180-pin breakout box with Breakout Harness 00-01468-00 to between E2-12 and fuel injector
ECM E2 connector, leave ECM disconnected. Using a DMM 1. After repairs are complete,
with fuel injector 1 disconnected, measure resistance between retest for SPN 651 FMI 4.
Breakout Box pin E2-05 and known good GND (wiggle test may
No: Repair short to GND
be required).
between E2-05 and fuel injector
Is resistance greater than 1000 Ohms? 1. After repairs are complete,
retest for SPN 651 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 651 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

741
 738 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 651 FMI 5- Injector 1 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ1 circuit > 30 ohms Engine Control Module (ECM) 3 events
injector 1 circuit. commands injector firing

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 1 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 1 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 05
. Pin E2 - 12
~-~IN~J~1~H____
INJ1 L
c@O
c:@ ~
0000159875

Figure 281 Injector 1 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ1 H circuit Open or high resistance
• INJ1 L circuit Open or high resistance
• Failed fuel injector 1 (Open coil)
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

742
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 739

2
0

BetterManuals.net
Figure 282
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 1. Remove upper valve cover Yes: Go to step 2.
and engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 1 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 651 FMI 5.
Are the fuel injector 1 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a failed fuel injector 1 (Open coil). Key OFF, disconnect Yes: Go to step 3.
the connectors from fuel injector 1. Using a DMM, measure
No: Replace fuel injector 1. After
resistance between fuel injector 1 H and L terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 651 FMI 5.

743
 740 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 651 FMI 5.
undamaged?

BetterManuals.net
4

0000175009

Figure 283 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

744
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 741

Step Action Decision

4 Check INJ1 H circuit for Open or high resistance (voltage drop). Yes: Repair Open or high
resistance between fuel injector
1. Key OFF, disconnect fuel injector 1 and ECM E2
1 INJ1 L ring terminal and ECM
connector.
pin E2-12. After repairs are
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper complete, retest for SPN 651
terminal into ECM pin E2-05. FMI 5.
3. Connect one end of the 500 Ohm Resistor Jumper No: Repair Open or high
Harness ZTSE4497 to terminal in E2-05, and connect the resistance between fuel injector
other end of 500 Ohm Resistor Jumper Harness to PWR 1 INJ1 H ring terminal and ECM
(use a jumper wire if needed). pin E2-05. After repairs are
complete, retest for SPN 651
4. Connect INJ1 H ring terminal to a known good GND (use
FMI 5.
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 1
INJ 1 H ring terminal and terminal in ECM pin E2-05.
Is voltage less than 0.3V?

NOTE: After performing all diagnostic steps, if

SPN 651 FMI 5 remains, verify each step was

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completed correctly and the proper decision was
made. Notify supervisor for further action.

745
 742 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 652 FMI 4- Injector 2 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ2 circuit resistance to ECM commands injector firing 3 events
in fuel injector 2 circuit ground < 0.5 ohms

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 2 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 2 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 11
. Pin E2 - 06
~-~IN~J2=--~H____
INJ2 L
c@O
c:@ ~
0000159877

Figure 284 Injector 2 circuit diagram

Possible Causes
• INJ2 H circuit shorted to INJ2 L circuit
• INJ2 H circuit short to GND
• INJ2 L circuit short to GND
• Fuel injector shorted to engine brake housing
• Failed fuel injector 2
WARNING: To prevent personal injury or
death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

746
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 743

'0
1

BetterManuals.net
Figure 285 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 2 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 2 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 652
FMI 4.

747
 744 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 286
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 2 coil. Key OFF, disconnect Yes: Go to step 3.
the wiring terminals from fuel injector 2. Using a DMM, check
No: Replace fuel injector 2. After
resistance across fuel injector 2 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 652 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 652 FMI 4.
terminals clean and undamaged?

748
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 745

Step Action Decision

4 Check for fuel injector 2 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 2. After
disconnected from fuel injector 2, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 652 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 2 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 2. After
disconnected from fuel injector 2, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 652 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

6 Check for INJ2 H short to INJ2 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ2
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ2 L circuit. After

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injector 2 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-06 and E2-11 (wiggle test may be required).
SPN 652 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ2 H circuit for short to GND. Key OFF, connect 180-pin Yes: Repair short to GND
breakout box with Breakout Harness 00-01468-00 to ECM E2 between E2-11 and fuel injector
connector, leave ECM disconnected. Using a DMM with fuel 2. After repairs are complete,
injector 2 disconnected, measure resistance between Breakout retest for SPN 652 FMI 4.
Box pin E2-06 and known good GND (wiggle test may be
No: Repair short to GND
required).
between E2-06 and fuel injector
Is resistance greater than 1000 Ohms? 2. After repairs are complete,
retest for SPN 652 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 652 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

749
 746 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 652 FMI 5- Injector 2 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ2 circuit > 30 ohms ECM commands injector firing 3 events
injector 2 circuit.

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 2 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 2 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 11
. Pin E2 - 06
~-~IN~J2=--~H____
INJ2 L
c@O
c:@ ~
0000159877

Figure 287 Injector 2 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ2 H circuit Open or high resistance
• INJ2 L circuit Open or high resistance
• Failed fuel injector
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

750
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 747

2
0

BetterManuals.net
Figure 288
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 2. Remove upper valve cover Yes: Go to step 2.
and engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 2 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 652 FMI 5.
Are the fuel injector 2 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a failed fuel injector 2 (Open coil). Key OFF, disconnect Yes: Go to step 3.
the connectors from fuel injector 2. Measure resistance between
No: Replace fuel injector 2. After
fuel injector 2 H and L terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 652 FMI 5.

751
 748 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 652 FMI 5.
undamaged?

BetterManuals.net
4

0000175009

Figure 289 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

752
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 749

Step Action Decision

4 Check INJ1 H circuit for Open or high resistance (voltage drop). Yes: Repair Open or high
resistance between fuel injector
1. Key OFF, disconnect fuel injector 2 and ECM E2
1 INJ2 L ring terminal and ECM
connector.
pin E2-11. After repairs are
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper complete, retest for SPN 652
terminal into ECM pin E2-06. FMI 5.
3. Connect one end of the 500 Ohm Resistor Jumper No: Repair Open or high
Harness ZTSE4497 to terminal in E2-06, and the other resistance between fuel injector
end of 500 Ohm Resistor Jumper Harness to PWR (use a 1 INJ2 H ring terminal and ECM
jumper wire if needed). pin E2-06. After repairs are
complete, retest for SPN 652
4. Connect INJ2 H ring terminal to a known good GND (use
FMI 5.
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 2
INJ 2 H ring terminal and terminal in ECM pin E2-06.
Is voltage less than 0.3V?

NOTE: After performing all diagnostic steps, if

SPN 652 FMI 5 remains, verify each step was

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completed correctly and the proper decision was
made. Notify supervisor for further action.

753
 750 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 653 FMI 4- Injector 3 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ3 circuit resistance to ECM commands injector firing 3 events
in fuel injector 3 circuit ground < 0.5 ohms

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 3 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 3 circuit

BetterManuals.net
ECM 16-Pin
E2 connector
Pin E2 - 04 0 ~-r--~IN_::J:_::3~H_'.___ _ _ _ _ connector Injector
(
__ 7/ __
P1_n_E_2_-_13---=0::......· ....:..:.IN~J~3--'=L~---- ~ ~
0000159879

Figure 290 Injector 3 circuit diagram

Possible Causes
WARNING: To prevent personal injury or
• INJ3 H circuit shorted to INJ3 L circuit death, shut engine down before doing voltage
checks for injector solenoids. When the engine
• INJ3 H circuit short to GND
is running, injector circuits have high voltage and
• INJ3 L circuit short to GND amperage.
• Fuel injector shorted to engine brake housing CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
• Failed fuel injector
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

754
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 751

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1

BetterManuals.net
Figure 291 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 3 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 3 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 653
FMI 4.

755
 752 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 292
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 3 coil. Key OFF, disconnect the Yes: Go to step 3.
connectors from fuel injector 3. Using a DMM, check resistance
No: Replace fuel injector 3. After
across fuel injector 3 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.6 Ohms? SPN 653 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 653 FMI 4.
terminals clean and undamaged?

756
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 753

Step Action Decision

4 Check for fuel injector 3 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 3. After
disconnected from fuel injector 3, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 653 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 3 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 3. After
disconnected from fuel injector 3, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 653 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

6 Check for INJ3 H short to INJ3 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ3
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ3 L circuit. After

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injector 3 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-04 and E2-13 (wiggle test may be required).
SPN 653 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ3 H circuit for short to GND. Key OFF, connect 180-pin Yes: Repair short to GND
breakout box with Breakout Harness 00-01468-00 to ECM E2 between E2-13 and fuel injector
connector, leave ECM disconnected. Using a DMM with fuel 3. After repairs are complete,
injector 3 disconnected, measure resistance between Breakout retest for SPN 653 FMI 4.
Box pin E2-04 and known good GND (wiggle test may be
No: Repair short to GND
required).
between E2-04 and fuel injector
Is resistance greater than 1000 Ohms? 3. After repairs are complete,
retest for SPN 653 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 653 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

757
 754 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 653 FMI 5- Injector 3 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ3 circuit > 30 ohms ECM commands injector firing 3 events
injector 3 circuit.

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 3 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 3 circuit

BetterManuals.net
ECM 16-Pin
E2 connector
Pin E2 - 04 0 ~-r--~IN_::J:_::3~H_'.___ _ _ _ _ connector Injector
(
__ 7/ __
P1_n_E_2_-_13---=0::......· ....:..:.IN~J~3--'=L~---- ~ ~
0000159879

Figure 293 Injector 3 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ3 H circuit Open or high resistance
• INJ3 L circuit Open or high resistance
• Failed fuel injector
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

758
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 755

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0

BetterManuals.net
Figure 294
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 3. Remove upper valve cover Yes: Go to step 2.
and engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 3 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 653 FMI 5.
Are the fuel injector 3 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a Open fuel injector 3 coil. Disconnect the connectors Yes: Go to step 3.
from fuel injector 3. Check resistance across fuel injector 3.
No: Replace fuel injector 3. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 653 FMI 5.

759
 756 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 653 FMI 5.
undamaged?

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4

0000175009

Figure 295 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

760
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 757

Step Action Decision

4 Check INJ3 H circuit for Open or high resistance (voltage drop). Yes: Repair INJ3 L circuit
between fuel injector 3 and
1. Key OFF, disconnect fuel injector 3 and ECM E2
pin E2-13. After repairs are
connector.
complete, retest for SPN 653
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper FMI 5.
terminal into ECM pin E2-04.
No: Repair INJ3 H circuit
3. Connect one end of the 500 Ohm Resistor Jumper between fuel injector 3 and
Harness ZTSE4497 to terminal in E2-04, and the other pin E2-04. After repairs are
end of 500 Ohm Resistor Jumper Harness to PWR (use a complete, retest for SPN 653
jumper wire if needed). FMI 5.
4. Connect INJ3 H ring terminal to a known good GND (use
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 3
INJ 3 H ring terminal and terminal in ECM pin E2-04.
Is voltage less than 0.3V

NOTE: After performing all diagnostic steps, if

SPN 653 FMI 5 remains, verify each step was

BetterManuals.net
completed correctly and the proper decision was
made. Notify supervisor for further action.

761
 758 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 654 FMI 4- Injector 4 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ3 circuit resistance to ECM commands injector firing 3 events
in fuel injector 4 circuit ground < 0.5 ohms

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 4 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 4 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 03
. Pin E2 - 14
~-~IN~J4~~H____
INJ4 L
c@O
c:@ ~
0000159882

Figure 296 Injector 4 circuit diagram

Possible Causes
• INJ4 H circuit shorted to INJ4 L circuit
• INJ4 H circuit short to GND
• INJ4 L circuit short to GND
• Fuel injector shorted to engine brake housing
• Failed fuel injector
WARNING: To prevent personal injury or
death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

762
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 759

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1

BetterManuals.net
Figure 297 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 4 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 4 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 654
FMI 4.

763
 760 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 298
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 4 coil. Key OFF, disconnect the Yes: Go to step 3.
connectors from fuel injector 4. Using a DMM, check resistance
No: Replace fuel injector 4. After
across fuel injector 4 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 654 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 654 FMI 4.
terminals clean and undamaged?

764
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 761

Step Action Decision

4 Check for fuel injector 4 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 4. After
disconnected from fuel injector 4, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 654 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 4 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 4. After
disconnected from fuel injector 4, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 654 FMI 4.
Is resistances greater than 1000 ohms?

Step Action Decision

6 Check for INJ4 H short to INJ4 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ4
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ4 L circuit. After

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injector 4 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-03 and E2-14 (wiggle test may be required).
SPN 654 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ4 H circuit for short to GND. Key OFF, connect 180-pin Yes: Repair short to GND
breakout box with Breakout Harness 00-01468-00 to ECM E2 between E2-14 and fuel injector
connector, leave ECM disconnected. Using a DMM with fuel 4. After repairs are complete,
injector 4 disconnected, measure resistance between Breakout retest for SPN 654 FMI 4.
Box pin E2-03 and known good GND (wiggle test may be
No: Repair short to GND
required).
between E2-03 and fuel injector
Is resistance greater than 1000 Ohms? 4. After repairs are complete,
retest for SPN 654 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 654 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

765
 762 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 654 FMI 5- Injector 4 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ4 circuit > 30 ohms ECM commands injector firing 3 events
injector 4 circuit.

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 4 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 4 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 03
. Pin E2 - 14
~-~IN~J4~~H____
INJ4 L
c@O
c:@ ~
0000159882

Figure 299 Injector 4 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ4 H circuit Open or high resistance
• INJ4 L circuit Open or high resistance
• Failed fuel injector
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

766
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 763

2
0

BetterManuals.net
Figure 300
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 4. Remove valve cover and Yes: Go to step 2.
engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 4 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 654 FMI 5.
Are the fuel injector 4 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a Open fuel injector 4 coil. Disconnect the connectors Yes: Go to step 3.
from fuel injector 4. Check resistance across fuel injector 4.
No: Replace fuel injector 4. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 654 FMI 5.

767
 764 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 654 FMI 5.
undamaged?

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4

0000175009

Figure 301 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

768
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 765

Step Action Decision

4 Check INJ4 H circuit for Open or high resistance (voltage drop). Yes: Repair INJ4 L circuit
between fuel injector 4 and
1. Key OFF, disconnect fuel injector 4 and ECM E2
pin E2-14. After repairs are
connector.
complete, retest for SPN 654
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper FMI 5.
terminal into ECM pin E2-03.
No: Repair INJ4 H circuit
3. Connect one end of the 500 Ohm Resistor Jumper between fuel injector 4 and
Harness ZTSE4497 to terminal in E2-03, and the other pin E2-03. After repairs are
end of 500 Ohm Resistor Jumper Harness to PWR (use a complete, retest for SPN 654
jumper wire if needed). FMI 5.
4. Connect INJ4 H ring terminal to a known good GND (use
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 4
INJ 4 H ring terminal and terminal in ECM pin E2-03.
Is voltage less than 0.3V

NOTE: After performing all diagnostic steps, if

SPN 654 FMI 5 remains, verify each step was

BetterManuals.net
completed correctly and the proper decision was
made. Notify supervisor for further action.

769
 766 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 655 FMI 4- Injector 5 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ5 circuit resistance to ECM commands injector firing 3 events
in fuel injector 5 circuit ground < 0.5 ohms

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 5 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 5 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 02
. Pin E2 - 15
~-~IN~JS~~H____
INJS L
c@O
c:@ ~
0000159889

Figure 302 Injector 5 circuit diagram

Possible Causes
• INJ5 H circuit shorted to INJ5 L circuit
• INJ5 H circuit short to GND
• INJ5 L circuit short to GND
• Fuel injector shorted to engine brake housing
• Failed fuel injector
WARNING: To prevent personal injury or
death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

770
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 767

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1

BetterManuals.net
Figure 303 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 5 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 5 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 655
FMI 4.

771
 768 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 304
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 5 coil. Key OFF, disconnect the Yes: Go to step 3.
connectors from fuel injector 5. Using a DMM, check resistance
No: Replace fuel injector 5. After
across fuel injector 5 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 655 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 655 FMI 4.
terminals clean and undamaged?

772
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 769

Step Action Decision

4 Check for fuel injector 5 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 5. After
disconnected from fuel injector 5, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 655 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 5 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 5. After
disconnected from fuel injector 5, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 655 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

6 Check for INJ5 H short to INJ5 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ5
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ5 L circuit. After

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injector 5 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-02 and E2-15 (wiggle test may be required).
SPN 655 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ5 H circuit for short to GND. Key OFF, connect 180-pin Yes: Repair short to GND
breakout box with Breakout Harness 00-01468-00 to ECM E2 between E2-15 and fuel injector
connector, leave ECM disconnected. Using a DMM with fuel 5. After repairs are complete,
injector 5 disconnected, measure resistance between Breakout retest for SPN 655 FMI 4.
Box pin E2-02 and known good GND (wiggle test may be
No: Repair short to GND
required).
between E2-02 and fuel injector
Is resistance greater than 1000 Ohms? 5. After repairs are complete,
retest for SPN 655 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 655 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

773
 770 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 655 FMI 5- Injector 5 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ5 circuit > 30 ohms ECM commands injector firing 3 events
injector 5 circuit.

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 5 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 5 circuit

BetterManuals.net
ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2 - 02
. Pin E2 - 15
~-~IN~JS~~H____
INJS L
c@O
c:@ ~
0000159889

Figure 305 Injector 5 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ5 H circuit Open or high resistance
• INJ5 L circuit Open or high resistance
• Failed fuel injector
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

774
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 771

2
0

BetterManuals.net
Figure 306
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 5. Remove upper valve cover Yes: Go to step 2.
and engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 5 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 655 FMI 5.
Are the fuel injector 5 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a Open fuel injector 5 coil. Disconnect the connectors Yes: Go to step 3.
from fuel injector 5. Check resistance across fuel injector 5
No: Replace fuel injector 5. After
terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 655 FMI 5.

775
 772 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 655 FMI 5.
undamaged?

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4

0000175009

Figure 307 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

776
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 773

Step Action Decision

4 Check INJ5 H circuit for Open or high resistance (voltage drop). Yes: Repair INJ5 L circuit
between fuel injector 5 and
1. Key OFF, disconnect fuel injector 5 and ECM E2
pin E2-15. After repairs are
connector.
complete, retest for SPN 655
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper FMI 5.
terminal into ECM pin E2-02.
No: Repair INJ5 H circuit
3. Connect one end of the 500 Ohm Resistor Jumper between fuel injector 5 and
Harness ZTSE4497 to terminal in E2-02, and the other pin E2-02. After repairs are
end of 500 Ohm Resistor Jumper Harness to PWR (use a complete, retest for SPN 655
jumper wire if needed). FMI 5.
4. Connect INJ5 H ring terminal to a known good GND (use
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 5
INJ 5 H ring terminal and terminal in ECM pin E2-02.
Is voltage less than 0.3V

NOTE: After performing all diagnostic steps, if

SPN 655 FMI 5 remains, verify each step was

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completed correctly and the proper decision was
made. Notify supervisor for further action.

777
 774 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 656 FMI 4- Injector 6 short circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short to GND detected INJ6 circuit resistance to ECM commands injector firing 3 events
in fuel injector 6 circuit ground < 0.5 ohms

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 6 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 6 circuit

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ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2-01
. Pin E2 - 16
~-~IN~J6~~H____
INJ6 L
c@O
c:@ ~
0000159891

Figure 308 Injector 5 circuit diagram

Possible Causes
• INJ6 H circuit shorted to INJ6 L circuit
• INJ6 H circuit short to GND
• INJ6 L circuit short to GND
• Fuel injector shorted to engine brake housing
• Failed fuel injector
WARNING: To prevent personal injury or
death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

778
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 775

'0
1

BetterManuals.net
Figure 309 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

1 Verify proper fuel injector and terminal orientation. Remove Yes: Go to step 2.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel to
injector 6 and injector terminals
avoid a short to ground on the engine brake housings.
will not contact the engine
Are fuel injector 6 terminals oriented correctly and Not contacting brake housing. After repairs are
the engine brake housing? complete, retest for SPN 656
FMI 4.

779
 776 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

2
0

BetterManuals.net
Figure 310
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

2 Check for a shorted fuel injector 6 coil. Key OFF, disconnect the Yes: Go to step 3.
connectors from fuel injector 6. Using a DMM, check resistance
No: Replace fuel injector 6. After
across fuel injector 6 terminals.
repairs are complete, retest for
Is resistance between 0.2 to 0.8 Ohms? SPN 656 FMI 4.

Step Action Decision

3 Inspect connections at Engine Control Module (ECM) E2 Yes: Go to step 4.
connector. Key OFF, disconnect ECM E2 connector. Check ECM
No: Repair connector, harness,
E2 connector and connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing. Are the ECM E2 connector, harness, and
SPN 656 FMI 4.
terminals clean and undamaged?

780
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 777

Step Action Decision

4 Check for fuel injector 6 high side terminal short to ground. Key Yes: Go to step 5.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 6. After
disconnected from fuel injector 6, use a DMM to test resistance
repairs are complete, retest for
between high side terminal and a known good GND.
SPN 655 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

5 Check for fuel injector 6 low side terminal short to ground. Key Yes: Go to step 6.
OFF, with ECM E2 connector disconnected and wiring terminals
No: Replace fuel injector 6. After
disconnected from fuel injector 6, use a DMM to test resistance
repairs are complete, retest for
between low side terminal and a known good GND.
SPN 656 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

6 Check for INJ6 H short to INJ6 L. Key OFF, connect 180-pin Yes: Go to step 7.
Breakout Box with Breakout Harness 00-01468-00 to ECM E2
No: Repair short between INJ6
connector, leave ECM disconnected. Using a DMM with fuel
H circuit and INJ6 L circuit. After

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injector 6 disconnected. measure resistance between Breakout
repairs are complete, retest for
Box pins E2-01 and E2-16 (wiggle test may be required).
SPN 656 FMI 4.
Is resistance greater than 1000 ohms?

Step Action Decision

7 Check INJ6 H circuit for short to GND. Key OFF, connect 180-pin Yes: Repair short to GND
breakout box with Breakout Harness 00-01468-00 to ECM E2 between E2-16 and fuel injector
connector, leave ECM disconnected. Using a DMM with fuel 6. After repairs are complete,
injector 6 disconnected, measure resistance between Breakout retest for SPN 656 FMI 4.
Box pin E2-01 and known good GND (wiggle test may be
No: Repair short to GND
required).
between E2-01 and fuel injector
Is resistance greater than 1000 Ohms? 6. After repairs are complete,
retest for SPN 656 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 656 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

781
 778 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 656 FMI 5- Injector 6 Open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open detected in fuel INJ6 circuit > 30 ohms ECM commands injector firing 3 events
injector 6 circuit.

Fault Overview
Fault code sets when a short to GND is detected in
Fuel Injector 6 circuit.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

Injector 6 circuit

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ECM 16-Pin
E2 connector connector
Injector

~) (
Pin E2-01
. Pin E2 - 16
~-~IN~J6~~H____
INJ6 L
c@O
c:@ ~
0000159891

Figure 311 Injector 6 circuit diagram

Possible Causes CAUTION: To avoid engine damage, turn the ignition

• INJ6 H circuit Open or high resistance
• INJ6 L circuit Open or high resistance
• Failed fuel injector
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.

782
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 779

2
0

BetterManuals.net
Figure 312
1.
2.
Fuel Injector Wiring Terminal Orientation
Fuel injector H wiring terminal
Fuel injector H terminal
3. Fuel injector L terminal 4.
0000291396

Fuel injector L wiring terminal

(brown wire color [typical])

Step Action Decision

1 Inspect connections at fuel injector 6. Remove upper valve cover Yes: Go to step 2.
and engine brake housing (see Engine Service Manual). Check
No: Repair connector, harness,
fuel injector 6 connector terminals for: damaged or pinched
or terminal damage. After
wires; corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 656 FMI 5.
Are the fuel injector 6 connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check for a Open fuel injector 6 coil. Disconnect the connectors Yes: Go to step 3.
from fuel injector 6. Check resistance across fuel injector 6.
No: Replace fuel injector 6. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 656 FMI 5.

783
 780 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 656 FMI 5.
undamaged?

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4

0000175009

Figure 313 Voltage drop test (typical)

1. Breakout harness 3. Terminal from ZTSE4435C 5. 500 Ohm Resistor Jumper
2. Circuit under test 4. Jumper wire Harness ZTSE4497

784
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 781

Step Action Decision

4 Check INJ6 H circuit for Open or high resistance (voltage drop). Yes: Repair INJ6 L circuit
between fuel injector 5 and
1. Key OFF, disconnect fuel injector 6 and ECM E2
pin E2-16. After repairs are
connector.
complete, retest for SPN 656
2. Using Engine Terminal Test Kit ZTSE4435C, insert proper FMI 5.
terminal into ECM pin E2-01.
No: Repair INJ6 H circuit
3. Connect one end of the 500 Ohm Resistor Jumper between fuel injector 5 and
Harness ZTSE4497 to terminal in E2-01, and the other pin E2-01. After repairs are
end of 500 Ohm Resistor Jumper Harness to PWR (use a complete, retest for SPN 656
jumper wire if needed). FMI 5.
4. Connect INJ6 H ring terminal to a known good GND (use
a jumper wire if needed)
5. Using a DMM, measure voltage between fuel injector 6
INJ 6 H ring terminal and terminal in ECM pin E2-01.
Is voltage less than 0.3V

NOTE: After performing all diagnostic steps, if

SPN 656 FMI 5 remains, verify each step was

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completed correctly and the proper decision was
made. Notify supervisor for further action.

785
 782 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 2797 FMI 11 - Injector Control Group 1 short circuit (INJ 1, 3, 5)

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short detected in fuel High side circuit short to Engine Speed > 0 rpm 5 firing events
injector 1, 3, or 5 circuits PWR impedance < 0.5
Crankshaft angle between 25
Ohms
deg BTDC and 23 deg ATDC
High side circuit short
Battery Voltage > 7 Volts
to GND impedance < 1
Ohms
Low side circuit short
to PWR impedance < 2
Ohms
Low side circuit short
to GND impedance < 2
Ohms

Fault Overview Associated Faults

Fault codes sets when a short circuit is detected in fuel SPN 651 FMI 4 and 5 (INJ); SPN 653 FMI 4 and 5

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injector 1, 3, or 5. (INJ); SPN 655 FMI 4 and 5 (INJ)

Malfunction Indicator Lamp (MIL) Reaction Drive Cycle to Determine Fault Status
MIL will illuminate when this fault is detected during Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
two consecutive drive cycles. Manual.

786
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 783

Fuel Injector circuits

ECM 16-Pin
E2 connector
~,--~~
INJ1~H- - - - - C _ o=nnector Injector 1
Pin E2 - 05
Pin E2 -12
INJ1 L ~

INJ2 H Injector 2
Pin E2 - 11
Pin E2 - 06
INJ2 L ~

INJ3 H Injector 3
Pin E2- 04
Pin E2-13
INJ3 L ~

INJ4 H Injector 4
Pin E2- 03
Pin E2-14
INJ4 L ~

INJ5 H Injector 5
Pin E2 - 02
INJ5 L ~

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Pin E2 -15

INJ6 H Injector 6
Pin E2 - 01
INJ6 L ~
Pin E2 -16
0000159872

Figure 314 Fuel Injector circuit diagram

Possible Causes • INJ3 L circuit short to GND

• INJ1 H circuit short to PWR • Fuel injector 3 wiring terminals shorted to engine
brake housing
• INJ1 H circuit short to GND
• Failed fuel injector 3
• INJ1 H short to INJ1 L
• INJ5 H circuit short to PWR
• INJ1 L circuit short to PWR
• INJ5 H circuit short to GND
• INJ1 L circuit short to GND
• INJ5 H short to INJ6 L
• Fuel injector 1 wiring terminals shorted to engine
brake housing • INJ5 L circuit short to PWR
• Failed fuel injector 1 • INJ5 L circuit short to GND
• INJ3 H circuit short to PWR • Fuel injector 5 wiring terminals shorted to engine
brake housing
• INJ3 H circuit short to GND
• Failed fuel injector 5
• INJ3 H short to INJ3 L
• INJ3 L circuit short to PWR

787
 784 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

A WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 651 FMI 4 and
No: Repair SPN 651 FMI 4 and
5 (INJ); SPN 653 FMI 4 and 5 (INJ); SPN 655 FMI 4 and 5 (INJ).
5; SPN 653 FMI 4 and 5; SPN
Is EST DTC list free of SPN 651 FMI 4 and 5; SPN 653 FMI 4 655 FMI 4 and 5. After repairs
and 5; SPN 655 FMI 4 and 5? are complete, retest for SPN
2797 FMI 11.

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788
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 785

'0
1

BetterManuals.net
Figure 315 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

2 Verify proper fuel injector wire terminal orientation. Remove Yes: Go to step 3.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel so they
injectors wire terminals will
do not short to ground on the engine brake housings or other
not contact the engine brake
components.
housing. After repairs are
Are fuel injector wire terminals oriented correctly and Not complete, retest for SPN 2797
contacting the engine brake housing? FMI 11.

Step Action Decision

3 Check for a shorted fuel injector 1 coil. Disconnect wiring terminals Yes: Go to step 4.
from fuel injector 1. Check resistance across fuel injector 1.
No: Replace fuel injector 1. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 2797 FMI 11.

789
 786 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

I Step l Action
J Decision
~
4 I Check for a shorted fuel injector 3 coil. Disconnect wiring terminals Yes: Go to step 5.
-
from fuel injector 3. Check resistance across fuel injector 3. I
No: Replace fuel injector 3. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
l l SPN 2797 FMI 11. _J
L
-
Step Action I Decision
-
5 Check for a shorted fuel injector 5 coil. Disconnect wiring terminals Yes: Go to step 6.
-
from fuel injector 5. Check resistance across fuel injector 5.
No: Replace fuel injector 5. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 2797 FMI 11.

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4

Figure 316 Fuel Injector Wiring Terminal Orientation

1. Fuel injector H wiring terminal 3. Fuel injector L terminal 4. Fuel injector L wiring terminal
2. Fuel injector H terminal (brown wire color [typical])

790
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 787

Step Action Decision

6 Check fuel injector 1 H terminal for short to GND. Key OFF with Yes: Go to step 7.
fuel injector 1 disconnected, use a DMM to measure resistance
No: Replace fuel injector 1. After
between fuel injector 1 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

Step Action Decision

7 Check fuel injector 1 L terminal for short to GND. Key OFF with Yes: Go to step 8.
fuel injector 1 disconnected, use a DMM to measure resistance
No: Replace fuel injector 1. After
between fuel injector 1 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

Step Action Decision

8 Check fuel injector 3 H terminal for short to GND. Key OFF with Yes: Go to step 9.
fuel injector 3 disconnected, use a DMM to measure resistance
No: Replace fuel injector 3. After
between fuel injector 3 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

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Step Action Decision
9 Check fuel injector 3 L terminal for short to GND. Key OFF with Yes: Go to step 10.
fuel injector 3 disconnected, use a DMM to measure resistance
No: Replace fuel injector 3. After
between fuel injector 3 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

Step Action Decision

10 Check fuel injector 5 H terminal for short to GND. Key OFF with Yes: Go to step 11.
fuel injector 5 disconnected, use a DMM to measure resistance
No: Replace fuel injector 5. After
between fuel injector 5 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

Step Action Decision

11 Check fuel injector 5 L terminal for short to GND. Key OFF with Yes: Go to step 12.
fuel injector 5 disconnected, use a DMM to measure resistance
No: Replace fuel injector 5. After
between fuel injector 5 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2797 FMI 11.

791
 788 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

12 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 13.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 2797 FMI 11.
undamaged?

Step Action Decision

13 Check for INJ1 H short to INJ1 L. Key OFF, connect 180-pin Yes: Go to step 14.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair INJ1 H short to INJ1
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 1 disconnected measure resistance between Breakout
retest for SPN 2797 FMI 11.
Box pins E2-05 and E2-12 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

14 Check for INJ3 H short to INJ3 L. Key OFF, connect 180-pin Yes: Go to step 15.
Breakout Box with Breakout Harness 00-01468-00 injector

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No: Repair INJ3 H short to INJ3
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 3 disconnected measure resistance between Breakout
retest for SPN 2797 FMI 11.
Box pins E2-04 and E2-13 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

15 Check for INJ5 H short to INJ5 L. Key OFF, connect 180-pin Yes: Go to step 16.
Breakout Box with Breakout Harness 00-01468-00 injector
No: Repair INJ5 H short to INJ5
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 5 disconnected measure resistance between Breakout
retest for SPN 2797 FMI 11.
Box pins E2-02 and E2-15 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

16. Check INJ1 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 17.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-05 and
injector 1 disconnected, measure resistance between Breakout
fuel injector 1. After repairs are
Box pin E2-05 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

792
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 789

Step Action Decision

17 Check INJ1 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 18.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-12 and
injector 1 disconnected, measure resistance between Breakout
fuel injector 1. After repairs are
Box pin E2-12 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

18 Check INJ3 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 19.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-04 and
injector 3 disconnected, measure resistance between Breakout
fuel injector 3. After repairs are
Box pin E2-04 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

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19 Check INJ3 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 20.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-13 and
injector 3 disconnected, measure resistance between Breakout
fuel injector 3. After repairs are
Box pin E2-13 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

20 Check INJ5 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 21.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-02 and
injector 5 disconnected, measure resistance between Breakout
fuel injector 5. After repairs are
Box pin E2-02 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

21 Check INJ5 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 22.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-15 and
injector 5 disconnected, measure resistance between Breakout
fuel injector 5. After repairs are
Box pin E2-15 and a known good GND (wiggle test may be
complete, retest for SPN 2797
required).
FMI 11.
Is resistance greater than 1000 ohms?

793
 790 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

22 Check INJ1 H circuit for short to PWR. Key-On Engine-Off Yes: Go to step 23.
(KOEO), connect 180-pin Breakout Box with Breakout Harness
No: Repair short to PWR
00-01468-00 to vehicle harness, and leave ECM disconnected.
between ECM pin E2-05 and
Using a DMM with fuel injector 1 disconnected, measure voltage
fuel injector 1. After repairs are
between Breakout Box pin E2-05 and a known good GND (wiggle
complete, retest for SPN 2797
test may be required).
FMI 11.
Is voltage less than 0.5 volts?

Step Action Decision

23 Check INJ1 L circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 24.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-12 and
injector 1 disconnected, measure voltage between Breakout Box
fuel injector 1. After repairs are
pin E2-12 and known good GND (wiggle test may be required).
complete, retest for SPN 2797
Is voltage less than 0.5 Volts? FMI 11.

Step Action Decision

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24 Check INJ3 H circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 25.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-04 and
injector 3 disconnected, measure voltage between Breakout Box
fuel injector 3. After repairs are
pin E2-04 and known good GND (wiggle test may be required).
complete, retest for SPN 2797
Is voltage less than 0.5 volts? FMI 11.

Step Action Decision

25 Check INJ3 L circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 26.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-13 and
injector 3 disconnected, measure voltage between Breakout Box
fuel injector 3. After repairs are
pin E2-13 and known good GND (wiggle test may be required).
complete, retest for SPN 2797
Is voltage less than 0.5 volts? FMI 11.

794
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 791

Step Action Decision

26 Check INJ5 H circuit for short to PWR. KOEO, connect 180-pin Yes: Repair short to PWR
Breakout Box with Breakout Harness 00-01468-00 to vehicle between ECM pin E2-15 and
harness, and leave ECM disconnected. Using a DMM with fuel fuel injector 5. After repairs are
injector 5 disconnected, measure voltage between Breakout Box complete, retest for SPN 2797
pin E2-02 and known good GND (wiggle test may be required). FMI 11.
Is voltage less than 0.5 volts? No: Repair short to PWR
between ECM pin E2-02 and
fuel injector 5. After repairs are
complete, retest for SPN 2797
FMI 11.

NOTE: After performing all diagnostic steps, if

SPN 2797 FMI 11 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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795
 792 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 2798 FMI 11 - Injector Control Group 2 short circuit (INJ 2, 4, 6)

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Short detected in fuel High side circuit short to Engine Speed >0 rpm 5 firing events
injector 2, 4, or 6 circuits PWR impedance < 0.5
Crankshaft angle between 25
Ohms
deg BTDC and 23 deg ATDC
High side circuit short
Battery Voltage > 7 Volts
to GND impedance < 1
Ohms
Low side circuit short
to PWR impedance < 2
Ohms
Low side circuit short
to GND impedance < 2
Ohms

Fault Overview Associated Faults

Fault codes sets when a short circuit is detected in fuel SPN 652 FMI 4 and 5 (INJ); SPN 654 FMI 4 and 5

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injector 2, 4, or 6. (INJ); SPN 656 FMI 4 and 5 (INJ)

Malfunction Indicator Lamp (MIL) Reaction Drive Cycle to Determine Fault Status
MIL will illuminate when this fault is detected during Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
two consecutive drive cycles. Manual.

796
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 793

Fuel Injector circuits

ECM 16-Pin
E2 connector
~,--~~
INJ1~H- - - - - C _ o=nnector Injector 1
Pin E2 - 05
Pin E2 -12
INJ1 L ~

INJ2 H Injector 2
Pin E2 - 11
Pin E2 - 06
INJ2 L ~

INJ3 H Injector 3
Pin E2- 04
Pin E2-13
INJ3 L ~

INJ4 H Injector 4
Pin E2- 03
Pin E2-14
INJ4 L ~

INJ5 H Injector 5
Pin E2 - 02
INJ5 L ~

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Pin E2 -15

INJ6 H Injector 6
Pin E2 - 01
INJ6 L ~
Pin E2 -16
0000159872

Figure 317 Fuel Injector circuit diagram

Possible Causes • INJ4 L circuit short to PWR

• INJ2 H circuit short to PWR
• INJ2 H circuit short to GND
• INJ2 H short to INJ2 L
• INJ2 L circuit short to PWR
• INJ2 L circuit short to GND
• Fuel injector 2 shorted to engine brake housing
• Failed fuel injector 2
• INJ4 H circuit short to PWR
• INJ4 H circuit short to GND
• INJ4 H short to INJ4 L
• INJ4 L circuit short to GND
• Fuel injector 4 shorted to engine brake housing
• Failed fuel injector 4
• INJ6 H circuit short to PWR
• INJ6 H circuit short to GND
• INJ6 H short to INJ6 L
• INJ6 L circuit short to PWR
• INJ6 L circuit short to GND
• Fuel injector 6 shorted to engine brake housing
• Failed fuel injector 6

797
 794 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

A WARNING: To prevent personal injury or

death, shut engine down before doing voltage
checks for injector solenoids. When the engine
is running, injector circuits have high voltage and
amperage.
CAUTION: To avoid engine damage, turn the ignition
switch to OFF before disconnecting connectors.
Failure to turn ignition switch to OFF will cause a
voltage spike and damage to electrical components.

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 652 FMI 4 and
No: Repair SPN 652 FMI 4 and
5 (INJ); SPN 654 FMI 4 and 5 (INJ); SPN 656 FMI 4 and 5 (INJ).
5; SPN 654 FMI 4 and 5; SPN
Is EST DTC list free of SPN 652 FMI 4 and 5; SPN 654 FMI 4 656 FMI 4 and 5. After repairs
and 5; SPN 656 FMI 4 and 5? are complete, retest for SPN
2798 FMI 11.

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798
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 795

'0
1

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Figure 318 Fuel Injector Wiring Terminal Orientation
0000290787

1. Fuel injector H wiring terminal

2. Fuel injector L wiring terminal
(brown wire color [typical])

Step Action Decision

2 Verify proper fuel injector wire terminal orientation. Remove Yes: Go to step 3.
upper valve cover and engine brake housing (see Engine Service
No: Adjust connections so fuel
Manual). Verify fuel injector terminals are installed parallel so they
injectors wire terminals will
do not short to ground on the engine brake housings or other
not contact the engine brake
components.
housing. After repairs are
Are fuel injector wire terminals oriented correctly and Not complete, retest for SPN 2798
contacting the engine brake housing? FMI 11.

Step Action Decision

3 Check for a shorted fuel injector 2 coil. Disconnect wiring terminals Yes: Go to step 4.
from fuel injector 2. Check resistance across fuel injector 2.
No: Replace fuel injector 2. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 2798 FMI 11.

799
 796 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

I Step l Action
J Decision
~
4 I Check for a shorted fuel injector 4 coil. Disconnect wiring terminals Yes: Go to step 5.
-
from fuel injector 3. Check resistance across fuel injector 4. I
No: Replace fuel injector 4. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
l l SPN 2798 FMI 11. _J
L
-
Step Action I Decision
-
5 Check for a shorted fuel injector 6 coil. Disconnect wiring terminals Yes: Go to step 6.
-
from fuel injector 5. Check resistance across fuel injector 6.
No: Replace fuel injector 6. After
Is resistance between 0.2 to 0.8 Ohms? repairs are complete, retest for
SPN 2798 FMI 11.

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4

Figure 319 Fuel Injector Wiring Terminal Orientation

1. Fuel injector H wiring terminal 3. Fuel injector L terminal 4. Fuel injector L wiring terminal
2. Fuel injector H terminal (brown wire color [typical])

800
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 797

Step Action Decision

6 Check fuel injector 2 H terminal for short to GND. Key OFF with Yes: Go to step 7.
fuel injector 2 disconnected, use a DMM to measure resistance
No: Replace fuel injector 2. After
between fuel injector 2 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

Step Action Decision

7 Check fuel injector 2 L terminal for short to GND. Key OFF with Yes: Go to step 8.
fuel injector 2 disconnected, use a DMM to measure resistance
No: Replace fuel injector 2. After
between fuel injector 2 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

Step Action Decision

8 Check fuel injector 4 H terminal for short to GND. Key OFF with Yes: Go to step 9.
fuel injector 4 disconnected, use a DMM to measure resistance
No: Replace fuel injector 4. After
between fuel injector 4 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

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Step Action Decision
9 Check fuel injector 4 L terminal for short to GND. Key OFF with Yes: Go to step 10.
fuel injector 4 disconnected, use a DMM to measure resistance
No: Replace fuel injector 4. After
between fuel injector 4 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

Step Action Decision

10 Check fuel injector 6 H terminal for short to GND. Key OFF with Yes: Go to step 11.
fuel injector 6 disconnected, use a DMM to measure resistance
No: Replace fuel injector 6. After
between fuel injector 6 H terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

Step Action Decision

11 Check fuel injector 6 L terminal for short to GND. Key OFF with Yes: Go to step 12.
fuel injector 6 disconnected, use a DMM to measure resistance
No: Replace fuel injector 6. After
between fuel injector 6 L terminal and GND.
repairs are complete, retest for
Is resistance greater than 1000 ohms? SPN 2798 FMI 11.

801
 798 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

12 Inspect connections at ECM E2 connector. Key OFF, disconnect Yes: Go to step 13.
ECM E2 connector. Check ECM E2 connector and connector
No: Repair connector, harness,
terminals for: damaged or pinched wires; corroded terminals;
or terminal damage. After
loose, bent, or broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E2 connector, harness, and terminals clean and
SPN 2798 FMI 11.
undamaged?

Step Action Decision

13 Check for INJ2 H short to INJ2 L. Key OFF, connect 180-pin Yes: Go to step 14.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair INJ2 H short to INJ2
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 2 disconnected measure resistance between Breakout
retest for SPN 2798 FMI 11.
Box pins E2-11 and E2-06 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

14 Check for INJ4 H short to INJ4 L. Key OFF, connect 180-pin Yes: Go to step 15.
Breakout Box with Breakout Harness 00-01468-00 injector

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No: Repair INJ4 H short to INJ4
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 4 disconnected measure resistance between Breakout
retest for SPN 2798 FMI 11.
Box pins E2-03 and E2-14 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

15 Check for INJ6 H short to INJ6 L. Key OFF, connect 180-pin Yes: Go to step 16.
Breakout Box with Breakout Harness 00-01468-00 injector
No: Repair INJ6 H short to INJ6
harness, leave ECM E2 disconnected. Using a DMM, with fuel
L. After repairs are complete,
injector 6 disconnected measure resistance between Breakout
retest for SPN 2798 FMI 11.
Box pins E2-01 and E2-16 (wiggle test may be required).
Is resistance greater than 1000 ohms?

Step Action Decision

16. Check INJ2 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 17.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-11 and
injector 2 disconnected, measure resistance between Breakout
fuel injector 2. After repairs are
Box pin E2-11 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

802
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 799

Step Action Decision

17 Check INJ2 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 18.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-06 and
injector 2 disconnected, measure resistance between Breakout
fuel injector 2. After repairs are
Box pin E2-06 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

18 Check INJ4 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 19.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-03 and
injector 4 disconnected, measure resistance between Breakout
fuel injector 4. After repairs are
Box pin E2-03 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

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19 Check INJ4 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 20.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-14 and
injector 4 disconnected, measure resistance between Breakout
fuel injector 4. After repairs are
Box pin E2-14 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

20 Check INJ6 H circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 21.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-01 and
injector 6 disconnected, measure resistance between Breakout
fuel injector 6. After repairs are
Box pin E2-01 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

Step Action Decision

21 Check INJ6 L circuit for short to GND. Key OFF, connect 180-pin Yes: Go to step 22.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to GND
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-16 and
injector 6 disconnected, measure resistance between Breakout
fuel injector 6. After repairs are
Box pin E2-16 and a known good GND (wiggle test may be
complete, retest for SPN 2798
required).
FMI 11.
Is resistance greater than 1000 ohms?

803
 800 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

22 Check INJ2 H circuit for short to PWR. Key-On Engine-Off Yes: Go to step 23.
(KOEO), connect 180-pin Breakout Box with Breakout Harness
No: Repair short to PWR
00-01468-00 to vehicle harness, and leave ECM disconnected.
between ECM pin E2-11 and
Using a DMM with fuel injector 2 disconnected, measure voltage
fuel injector 2. After repairs are
between Breakout Box pin E2-11 and a known good GND (wiggle
complete, retest for SPN 2798
test may be required).
FMI 11.
Is voltage less than 0.5 volts?

Step Action Decision

23 Check INJ2 L circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 24.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-06 and
injector 2 disconnected, measure voltage between Breakout Box
fuel injector 2. After repairs are
pin E2-06 and known good GND (wiggle test may be required).
complete, retest for SPN 2798
Is voltage less than 0.5 Volts? FMI 11.

Step Action Decision

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24 Check INJ4 H circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 25.
Breakout Box with Breakout Harness 00-01468-00 to vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-03 and
injector 4 disconnected, measure voltage between Breakout Box
fuel injector 4. After repairs are
pin E2-03 and known good GND (wiggle test may be required).
complete, retest for SPN 2798
Is voltage less than 0.5 volts? FMI 11.

Step Action Decision

25 Check INJ4 L circuit for short to PWR. KOEO, connect 180-pin Yes: Go to step 26.
Breakout Box with Breakout Harness 00-01468-00 vehicle
No: Repair short to PWR
harness, and leave ECM disconnected. Using a DMM with fuel
between ECM pin E2-14 and
injector 4 disconnected, measure voltage between Breakout Box
fuel injector 4. After repairs are
pin E2-14 and known good GND (wiggle test may be required).
complete, retest for SPN 2798
Is voltage less than 0.5 volts? FMI 11.

Step Action Decision

26 Check INJ6 H circuit for short to PWR. KOEO, connect 180-pin Yes: Repair short to PWR
Breakout Box with Breakout Harness 00-01468-00 to vehicle between ECM pin E2-16 and
harness, and leave ECM disconnected. Using a DMM with fuel fuel injector 6. After repairs are
injector 6 disconnected, measure voltage between Breakout Box complete, retest for SPN 2798
pin E2-01 and known good GND (wiggle test may be required). FMI 11.
Is voltage less than 0.5 volts? No: Repair short to PWR
between ECM pin E2-01 and
fuel injector 6. After repairs are
complete, retest for SPN 2798
FMI 11.

804
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 801

NOTE: After performing all diagnostic steps, if

SPN 2798 FMI 11 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 802 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

IST (Idle Shutdown Timer) System (Clean Low • Vehicle movement or a Vehicle Speed Sensor
Idle) (VSS) fault is detected.
• DPF Regeneration is enabled (Any REGEN
IST (Clean Low Idle)
State).
The Idle Shutdown Timer (IST) ("Clean Low Idle")
• Accelerator pedal movement or an Accelerator
allows the ECM to shut down the engine during
Pedal Position (APP) fault is detected.
extended idle. When parking brake is set, the idle time
can be programmed up to 5 minutes. When parking • Engine coolant operating temperature is below 16
brake is released, the idle time can be programmed °C (60 °F).
up to 15 minutes. During service, the idle time can be
• Brake pedal movement or a brake switch fault is
programmed up to 60 minutes. The ECM deactivates
detected.
the IST when the PTO is active.
• Parking brake transition is detected.
Thirty seconds before engine shutdown, the IST
engine lamp illuminates. This continues until the • Clutch pedal is pressed or clutch pedal switch fault
engine shuts down or the low idle shutdown timer is is detected (manual transmissions, if equipped
reset. Idle time is measured from the last clutch or with a clutch switch).
APP. The engine must be out of gear for the IST to
• Shift selector is moved from neutral (automatic
work. Engine shutdown time resets for one or more
transmissions).
of the following conditions:
• If the IST is enabled, the CAP will not function.
• Engine speed is not at idle speed.

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806
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 803

IST (Idle Shutdown Timer) System (Federal - • Engine coolant operating temperature is below 60
Optional) °C (140 °F).
• Ambient temperature below 16° C (60 °F) or
IST (Federal - Optional) Sensor Circuit Operation
above 44 °C (110 °F).
The optional Idle Shutdown Timer (IST) allows the
• Brake pedal movement or a brake switch fault is
ECM to shut down the engine during extended idle.
detected.
Idle time can be programmed from 5 to 120 minutes.
The ECM can be programmed to deactivate the IST • Parking brake transition is detected.
when the Power Takeoff (PTO) is active.
• Clutch pedal is pressed or clutch pedal switch fault
• Engine speed is not at idle speed (600 rpm). is detected (manual transmissions, if equipped
with a clutch switch).
• Vehicle movement or a Vehicle Speed Sensor
(VSS) fault is detected. • Shift selector is moved from neutral (automatic
transmissions).
• Manual DPF Regeneration is enabled.
• If the IST is enabled, the CAP will not function.
• Accelerator pedal movement or an Accelerator
Pedal Position (APP) fault is detected.

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807
 804 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

J1939 Data Link Communications

SPN FMI Condition Possible Causes Actions

560 19 Transmission Driveline Engaged not • Transmission driveline See Electrical System
detected on J1939 engaged switch or Troubleshooting
circuit fault Guide for
troubleshooting the
switch
639 14 J1939 Data Link Error (ECM unable • J1939 Data link circuit Circuit Checks (page
to transmit) fault 805)
• Failed ECM
639 19 J1939 Data Link Error (ECM unable to • J1939 Data link circuit Circuit Checks (page
transmit or receive) fault 805)
• Failed ECM
1590 19 Adaptive Cruise Control not detected • Incorrect Pinpoint Diagnostics
on J1939 programmable (page 806)
parameter
• J1939 Data link circuit

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fault

J1939 Datalink
All other
nodes
B+
ECM 58-Pin
C1 connector
J1939-H
Pin C1-34
J1939-L
Pin C1-47

Vehicle diagnostic connector

V00128

Figure 320 J1939 data link circuit diagram

Tools Required • Electronic Service Tool (EST) with ServiceMaxx™

software
• 00-00956-08 – 180-Pin Breakout Box
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4498 – 3-Banana Plug Harness
• Digital Multimeter (DMM)

808
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 805

Vehicle Diagnostic Connector Voltage Check

Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
B to GND B+ If < B+, check B+ circuit to vehicle diagnostic connector for
OPEN or short to GND, or blown fuse.
B to A B+ If < B+, check GND circuit to vehicle diagnostic connector
for OPEN.
C to GND 1 V to 4 V The sum of C to GND and D to GND should = 4 V to 5 V.
D to GND 1 V to 4 V The sum of C to GND and D to GND should = 4 V to 5 V.

EST Communication Check

Turn ignition switch to ON. Connect EST to vehicle diagnostic connector. If the EST is unable to
communicate with the ECM, disconnect each module connected to the J1939 data link individually, until
communication can be established.
NOTE:
• If communication to ECM is established, check J1939 circuits to disconnected node for correct
wiring. See truck Electrical System Troubleshooting Guide.

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• If communication to ECM is not established, go to next test point.
Test Point Comment
Disconnect TCM See note.
Disconnect Body Controller See note.
Disconnect instrument cluster See note.
Disconnect other nodes See note.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C to D approximately 60 Ώ If not within specification, measure individual CAN
terminating resistors.
Terminating Resistor approximately 120 If not within specification, replace faulty terminating
Terminals Ώ resistor(s).
C to C1-34 <5Ω If > 5 Ω, check J1939-H for OPEN in circuit.
C to GND > 1k Ω If < 1k Ω, check J1939-H for short to GND.
D to C1-47 <5Ω If > 5 Ω, check J1939-L for OPEN in circuit.
D to GND > 1k Ω If < 1k Ω, check J1939-L for short to GND.
A to GND <5Ω If > 5 Ω, check GND for OPEN in circuit.

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 806 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Pinpoint Diagnostics With ServiceMaxx™

Software

SPN 1590 FMI 19 - Adaptive Cruise Control not detected on J1939

1. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the Parameters session
Verify the correct Adaptive Cruise Control (ACC) system is selected under parameter ID 76102
Adaptive Cruise Control Enable (disable, Vorad, Wingman, or Wabco).
Is the correct ACC system selected under parameter ID 76102?
• Yes: Go to J1939 datalink circuit checks (page 805).
• No: Correct parameter ID 76102 and program engine. Retest for SPN 1590 FMI 19.

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810
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 807

MAF Sensor (Mass Air Flow)

SPN FMI Condition Possible Causes

None

MAF circuit
MAF
connector MAF
ECM 58-Pin MAF (end view) Sensor
C1 connector connector A
MAF

~
Pin C1-44 ~t,.......:.:.::....::._ _ _ _ _ _----l 7 1------l C
Pin C 1_54 ECM PWR OUT 1 8 D
MAF GND
Pin C1-21 l"\-L,....:..:..::....::.-=..:....:..=_ _ _ _----l 9 E
E
21-Way On/Off
Engine Harness
Interface connector
V00066

Figure 321 MAF sensor circuit diagram

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Function
The MAF sensor is connected to the engine, but is
disabled in ECM software. This sensor should never
be replaced.

811
 808 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

MIL (Malfunction Indicator Lamp)

SPN FMI Condition Possible Causes Actions

1213 3 MIL circuit short to PWR • MIL circuit Circuit Checks
short to PWR (page 809)
1213 4 MIL circuit short to GND • MIL circuit Circuit Checks
shorted to (page 809)
GND
• Failed MIL
1213 5 MIL open load/circuit • MIL circuit Circuit Checks
OPEN (page 809)
• Failed MIL

Overview • 2010 MaxxForce 11 & 13 Harness Kit

00-01462-00
The Malfunction Indicator Lamp (MIL) illuminates
when the Heavy-Duty On-Board Diagnostics • Digital Multimeter (DMM)
(HD-OBD) system detects a malfunction related to
the emissions control system. The illuminated MIL

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indicates the vehicle needs to be serviced at the first
convenient opportunity. Lamp may remain active
after repair until system operation confirms repair.
Tools Required
• 00-00956-08 – 180-Pin Breakout Box

812
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 809

MIL Connector Voltage Check Without ServiceMaxx™ Software

Turn ignition OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness between ECM C1 and C2
connectors and ECM. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
MIL circuit not activated 0.1 V to 0.3 V If no voltage is present, check for OPEN or short to GND.
C1–57 to GND If > 0.3 V, check for short to PWR.
MIL circuit activated B+ If no voltage is present, check for OPEN or short to GND.
C1–57 to GND

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1–57 to 1–H <5Ω If > 5 Ω, check for OPEN circuit.
C1–24 to 2–C <5Ω If > 5 Ω, check for OPEN circuit.

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813
 810 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

O2S (Oxygen Sensor)

SPN FMI Condition Possible Causes Actions

724 2 O2S Slow response detecting fueling • Failed O2S Pin-Point Diagnostics
to non-fueling (page 814)
• Replace sensor and
run Oxygen Sensor
(O2S) calibration
724 3 O2S circuit Fault: Open or short to • O2 circuit short to Pin-Point Diagnostics
PWR PWR (page 814)
• Failed O2S
724 4 O2S circuit Fault: Short to GND • O2 circuit short to Pin-Point Diagnostics
GND (page 814)
• Failed O2S
724 5 O2S circuit fault: Open circuit • O2S Open circuit Pin-Point Diagnostics
(page 814)
• Failed O2S
724 20 O2S adaptation above maximum limit • Oxygen sensor Step-based
contamination Diagnostics (page

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816)
• Failed oxygen sensor
• Faulty TC1TOP
signal
724 21 O2S adaptation below minimum limit • Biased TC1TOP Circuit Checks (page
sensor or circuit 819)
• Intermittent TC1TOP
circuit fault
• Restricted EBPV
tube
• Failed O2S or circuit
3223 0 O2S heater temperature above • O2 heater circuit short Step-based
maximum to GND Diagnostics (page
820)
• Failed O2S
3223 1 O2S heater temperature below • Charging System Pin-Point Diagnostics
minimum fault (Low B+ when (page 825)
O2 Heater was
commanded on)
• O2S or circuit fault
3223 3 O2S heater short to PWR • O2 heater circuit short Pin-Point Diagnostics
to PWR (page 814)
• Failed O2S

814
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 811

3223 4 O2S heater short to GND • O2 heater circuit short Pin-Point Diagnostics
to GND (page 814)
• Failed O2S
3223 5 O2S heater open load/circuit • HTR CTL circuit short Step-Based
to GND Diagnostics (page
822)
• ECM PWR OUT 1
circuit Open or high
resistance
• HTR CTL circuit
Open or high
resistance
• Failed O2S
3223 17 O2S heater temperature below • Charging system Pin-Point Diagnostics
minimum at low battery PWR fault (low B+ when (page 825)
O2 heater was
commanded ON)

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815
 812 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

02S Circuit

ECM 58 - Pin
C 1 connector
Harness
02S Sensor
connector
Pin C1 - 52 ~-=-i~:~~:ffiR~M:Af.tNctDU~R~~~~~~== I: (end view)
Pin C1 - 40 02S Heater CTL 3
5 -----=-,1
Pin C1 - 46 ECM PWR Out 1 4

Pin
Pin C1
33
C1 -- 53 ;:=t_INT
Pin C1 - 3g
I"\
B_RYJ~l;2.!M~::!R~-E5?._S_-_-_-_-_-~~~J 5
NVOLT
6
6~~1~]2
0000047211

Figure 323 O2S circuit diagram

Overview the exhaust system. A heating element is used during

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initial engine warm-up to bring the sensor up to a
The Oxygen Sensor (O2S) is a wide band oxygen
normal operating temperature of 1,436°F (780°C).
sensor used to control engine fueling and provide
The O2S heater element is only activated when
input for Exhaust Gas Recirculation (EGR) valve
engine coolant temperature reaches 104°F (40°C),
position. The O2S is a six wire sensor that provides a
and exhaust gas temperature exceeds 212°F (100°C)
variable voltage signal to the Engine Control Module
for more than 30 seconds.
(ECM) to determine the amount of oxygen entering

816
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 813

Tools Required
• 180-Pin Breakout Box 00-00956-08
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00
• 3-Banana Plug Harness ZTSE4498
• 500 Ohm Resistor Harness ZTSE4497
• Big Bore Terminal Test Probe Kit ZTSE4899
• Breakout Harness ZTSE4735A (O2S)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• Interface cable (RP1210B compliant supporting
J1939 and J1708)

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0000047114

Figure 324 Oxygen Sensor Location

1. Oxygen Sensor (O2S)

817
 814 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

02S Circuit

ECM 58 - Pin
C 1 connector
Harness
02S Sensor
connector
Pin C1 - 52 ~-=-i~:~~:ffiR~M:Af.tNctDU~R~~~~~~== I: (end view)
Pin C1 - 40 02S Heater CTL 3
5 -----=-,1
Pin C1 - 46 ECM PWR Out 1 4

Pin
Pin C1
33
C1 -- 53 ;:=t_INT
Pin C1 - 3g
I"\
B_RYJ~l;2.!M~::!R~-E5?._S_-_-_-_-_-~~~J 5
NVOLT
6
6~~1~]2
0000047211

Figure 325 O2S circuit diagram

NOTE: Inspect connectors for damaged,

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WARNING: To prevent personal injury or corrosion, or loose pins. Repair if necessary.
death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.

Pinpoint Diagnostics With ServiceMaxx™

Software
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, verify DTC is active
for this sensor.
• If code is previously active, wiggle the
harness of the suspect sensor. If the
circuit is interrupted, the DTC will go
active.
• If code is active, proceed to Connector
Voltage Check.

818
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 815

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4735A to O2S vehicle harness, and leave O2S sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to GND 2.9 V ± 1 V If < 1.9 V, check for OPEN or short to GND.
2 to GND 2.6 V ± 1 V If < 1.6 V, check for OPEN or short to GND.
3 to GND 4.8 V ± 1 V If < 3.8 V, check for OPEN or short to GND.
4 to GND 12V ± 2 V If < 10 V, check for OPEN circuit or short to GND.
5 to GND 2.9 V ± 1 V If < 1.9 V, check for OPEN or short to GND.
6 to GND 3V±1V If < 2 V , check for OPEN or short to GND.
If measurements are within specification, do Harness Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4735A to
O2S vehicle harness, and leave O2S sensor disconnected. Use DMM to measure resistance.

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Test Point Specification Comment – < Less than, > Greater than
1 to C1-52 <5Ω If > 5 Ω, check for OPEN in circuit.
1 to GND > 1k Ω If < 1k Ω, check for short to GND.
2 to C1-40 <5Ω If > 5 Ω, check for OPEN in circuit.
2 to GND > 1k Ω If < 1k Ω, check for short to GND.
3 to C1-46 <5Ω If > 5 Ω, check for OPEN in circuit.
3 to GND >1k Ω If < 1k Ω, check for short to GND.
4 to C1-33 <5Ω If > 5 Ω, check for OPEN in circuit.
4 to GND >1k Ω If < 1k Ω, check for short to GND.
5 to C1-53 <5Ω If > 5 Ω, check for OPEN in circuit.
5 to GND > 1k Ω If < 1k Ω, check for short to GND.
6 to C1-39 <5Ω If > 5 Ω, check for OPEN in circuit.
6 to GND > 1k Ω If < 1k Ω, check for short to GND.
If measurements are in specification, calibrate and install new O2S.

819
 816 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 724 FMI 20 – O2S adaptation above maximum limit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
The stored adaptation Adaptation value > 0.03 Time in overrun (motoring) >0 3 seconds
value for the oxygen seconds
sensor (O2S) is above
Exhaust Backpressure Valve
the maximum threshold
(EBPV) not closed
Ambient Air Temperature (AAT)
< 212°F (100°C)
Oxygen sensor temperature
>1400°F (760°C) and < 1472°F
(800°C)
Fresh air flow during overrun >
420 g
Not in regeneration mode
[Release from dewpoint
detection: dew point: ECT1,
>10.06 C dew point: DOCIT

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>100.1 C DOCIT exceeded for
>30 seconds]
Difference between filtered and
unfiltered O2 concentration
<0.0018

Fault Overview
Fault code sets when the learned O2S adaptation
value exceeds 0.03.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

Drive Cycle 3 in 2013 HD-OBD Diagnostic Reference
Manual.
Possible Causes
• Oxygen sensor contamination
• Failed oxygen sensor

Step Action Decision

1 Verify ECM has the latest calibration. Check calibration scorecard Yes: Go to step 2.
on Service Portal.
No: Update calibration. After
Is calibration current? update is complete, go to step 2.

820
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 817

Step Action Decision

2 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 3.
check Diagnostic Trouble Code (DTC) list for SPN 724 FMI 3,
No: Repair SPN 724 FMI 3, 4,5.
4, 5 (O2S)
After repairs are complete, retest
Is EST DTC list free of SPN 724 FMI 3, 4, 5? for SPN 724 FMI 20.

Step Action Decision

3 Check O2 sensor adaptation value. Using Electronic Service Tool Yes: Go to step 4.
(EST) with ServiceMaxx™ software, load the parameter session.
No: Clear fault. After repairs are
Find parameter ID 99162 : Lambda sensor adaptation value, and
complete, retest for SPN 724
document the value.
FMI 20.
Is the adaptation value > 0.03?

Step Action Decision

4 Run the Relative Compression Test to add oxygen to the exhaust Yes: Replace O2 Sensor. After
and then run O2 Sensor Calibration. repairs are complete, go to step
5.
• Connect a battery charger.
No: Clear fault. After repairs are

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• Using Electronic Service Tool (EST) with ServiceMaxx™
complete, retest for SPN 724
software, go to Tests > KOEO Tests> Relative Compression
FMI 20.
Test. Run the Relative Compression Test (disables the
injectors) and crank the engine for 15 seconds. Disregard the
results of the Relative Compression Test.
• Exit Relative Compression test. Go to Procedures > KOEO
Procedures > O2 Sensor Calibration, and run O2 sensor
calibration without removing the O2 sensor.
Check the value of parameter 99162 : Lambda sensor adaptation
value
Is the adaptation value > 0.03?

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 818 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

5 Run the Relative Compression Test to add oxygen to the exhaust Yes: Verify steps were
and then run O2 Sensor Calibration. performed in proper sequence
and completed correctly. Notify
• Connect a battery charger.
supervisor if fault remains.
• Using Electronic Service Tool (EST) with ServiceMaxx™
No: Go to step 6.
software, go to Tests > KOEO Tests> Relative Compression
Test. Run the Relative Compression Test (disables the
injectors) and crank the engine for 15 seconds. Disregard the
results of the Relative Compression Test.
• Exit Relative Compression test. Go to Procedures > KOEO
Procedures > O2 Sensor Calibration, and run O2 sensor
calibration without removing the O2 sensor.
Check the value of parameter 99162 : Lambda sensor adaptation
value
Is the adaptation value > 0.03?

Step Action Decision

6 Reset relevant ECM parameters in ServiceMaxx. Yes: Clear fault. After repairs

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are complete, retest for SPN 724
NOTE: Not all calibrations have all parameters available.
FMI 20.
Using EST, load the parameter session.
No: Verify steps were performed
• Set parameters 99520, 99530, and 99540 to 0. in proper sequence and
completed correctly. Notify
• Set parameter 99550 to 780°C.
supervisor if fault remains.
Were parameters programmed successfully?

NOTE: After performing all diagnostic steps, if

SPN 724 FMI 20 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

822
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 819

SPN 724 FMI 21 – O2S adaptation below minimum limit

Biased Sensor or Circuit Check
Perform TC1TOP Sensor Circuit Check (page 833). Check for restricted exhaust.
1. Check exhaust back pressure valve tube assembly between the Exhaust Back Pressure Valve
(EBPV) and Air Control Valve (ACV) for leaks.
• If leaks are found, repair or replace as necessary. Clear DTC's. If active DTC remains, continue
to next step.
• If no leaks are found, go to next step.
2. Turn ignition switch to ON, engine OFF.
3. Using ServiceMaxx™ software, run the Continuous Monitor Test.
4. Verify S_TC1TOP volts are within specification (lightly wiggle circuits while monitoring TC1TOP
signal for spikes). See “APPENDIX A: PERFORMANCE SPECIFICATIONS."
• If TC1TOP voltage is not within specification, check circuitry for poor continuity. If circuits are
acceptable, replace TC1TOP sensor.
• If TC1TOP voltage is within specification, check for a restricted exhaust system.
• If TC1TOP voltage is within specification and exhaust is not restricted, verify O2S circuits are not

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open or shorted. Calibrate and install new O2S.

823
 820 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3223 FMI 0 - O2S Heater Temperature Above Maximum

Condition / Setting Criteria Enable Conditions / Values Time Required
-
Description
O2S temperature too O2S Temperature ≥ Exhaust back pressure valve 30 seconds
high. 1472°F (800°C) open < 80%
Engine speed > 300 rpm
Heater duty cycle > 98% for
6,500 seconds (1.8 hours)
Regeneration mode inactive or
Oxygen sensor temp > 1202°F
(650°C)
- --'

Fault Overview
The Oxygen sensor (O2S) heater element is designed
to increase sensor temperature. The O2S heater is
supplied with battery voltage from ECM PWR Out 1
through pin 4 of the O2S connector. The O2S heater
is active when the Engine Control Module (ECM)

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supplies ground to the O2S Heater CTL circuit through
ECM connector 1 pin 46. If O2S temperature is above
1472°F (800°C) this fault will set.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.
O2S Circuit

ECM 58- Pin

C 1 connector
Harness
PUMPCUR 1 O2S Sensor
Pin C1 - 52 connector
VIRGND (end view)
Pin C1 -40 2
O2S Heater CTL 3 5 1
Pin C1 - 46

6~~1~]2
ECM PWR Out 1
Pin C1 - 33 4
TRIMRES
Pin C1 - 53 5 00
NVOLT 00
Pin C1 - 3g 6

0000047211

Figure 326 O2S circuit diagram

824
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 821

Step Action Decision

1 Inspect connections at Oxygen Sensor (O2S). Key OFF, Yes: Go to step 2.
disconnect O2S connector. Check sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose, bent, or
or terminal. After repairs are
broken pins; or broken connector housing.
complete, retest for SPN 3223
Are the O2S connector, harness, and terminals clean and FMI 0.
undamaged?

Step Action Decision

2 Check Heater control circuit for short to ground. Connect Breakout Yes: Replace Oxygen Sensor.
Harness ZTSE4735A and leave sensor disconnected. Run After repairs are complete retest
engine, using Electronic Service Tool (EST) with ServiceMaxx™ for SPN 3223 FMI 0.
software, monitor O2S Temp. When O2S Temp reaches 1,382°F
No: Repair short to ground
(750°C) or higher (O2S heater inactive), use a DMM to measure
between O2S harness pin 3 and
resistance between Breakout Harness ZTSE4735A test point 3,
ECM connector 1 pin 46. After
and a known good ground.
repairs are complete, retest for
Is resistance greater than 1,000 ohms? SPN 3223 FMI 0.

NOTE: After doing all diagnostic steps, if

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SPN 3223 FMI 0 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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 822 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 3223 FMI 5 – O2S heater open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Open circuit detected in O2S heater current >-100 Key ON 5 seconds
Oxygen Sensor (O2S) µA and < 100 µA
heater. _.

Fault Overview
Fault code sets when Engine Control Module (ECM)
detects an Open circuit in the Oxygen Sensor (O2S)
heater.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

Associated Faults
SPN 724 FMI 3, 4 (O2S); SPN 3223 FMI 3, 4 (O2S);
SPN 3597 FMI 4 (ECM PWR).

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Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.
O2S Circuit

ECM 58- Pin

C 1 connector
Harness
O2S Sensor
Pin C1 - 52 ~WP'.!:/U_MMl.E_P~CU~R~--- : connector
VIRGND (end view)
Pin C1 - 40
Pin C1 - 46 >-j__go~2_§S_tH~e~a~te~r~C~T~L'---7 3 5 -=-,1
Pin C1 - 33 \___LJE~C~M~PW~R~O~u~t. . :. . 1_ _

6~~1~]2
4
1

Pin C1 - 53 ~LITBR~IM!l_!:R~E~S_ _ _ _ . 5
Pin C1 - 3g ._~N~VOQjL~T_____ 6

0000047211

Figure 327 O2S circuit diagram

Possible Causes • HTR CTL circuit Open or high resistance

• HTR CTL circuit short to GND • Failed O2S
• ECM PWR OUT 1 circuit Open or high resistance

826
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 823

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 724 FMI 3, 4
No: Repair SPN 724 FMI 3,
(O2S); SPN 3223 FMI 3, 4 (O2S); SPN 3597 FMI 4 (ECM PWR).
4; SPN 3223 FMI 3, 4; SPN
Is EST DTC list free of SPN 724 FMI 3, 4; SPN 3223 FMI 3, 4; 3597 FMI 4. After repairs are
SPN 3597 FMI 4? complete, retest for SPN 3223
FMI 5.

Step Action Decision

2 Inspect connections at Oxygen Sensor (O2S). Key OFF, Yes: Go to step 3.
disconnect O2S. Check sensor and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the O2S connector, harness, and terminals clean and SPN 3223 FMI 5.
undamaged?

Step Action Decision

4 Inspect connections at ECM C1 connector. Key OFF, disconnect Yes: Go to step 5.

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ECM C1 connector. Check connector and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM C1 connector, harness, and terminals clean and SPN 3223 FMI 5.
undamaged?

Step Action Decision

5 Check for short to GND in the HTR CTL circuit. Connect Yes: Go to step 6
Breakout Harness ZTSE4735A to O2S harness, and leave sensor
No: Repair short to GND in
disconnected. Key-On, using a DMM, measure voltage between
HTR CTL circuit between O2S
ZTSE4735A pin-3 and pin-4.
connector pin-3 and ECM
Is voltage less than 5 volts? pin C1-46. After repairs are
complete, retest for SPN 3223
FMI 5.

Step Action Decision

6 Check for Open or high resistance in the HTR CTL circuit. Yes: Go to step 7
Connect 180-pin Breakout Box and ECM C1 & C2 Breakout
No: Repair Open in HTR CTL
Harness to vehicle harness, and leave ECM disconnected.
circuit between O2S connector
Connect Breakout Harness ZTSE4735A to O2S harness, and
pin-3 and ECM pin C1-46. After
leave sensor disconnected. Key-Off, using a DMM, measure
repairs are complete, retest for
resistance between ZTSE4735A pin-3 and ECM pin C1-46.
SPN 3223 FMI 5.
Is resistance less than 5 ohms?

827
 824 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

7 Check for Open or high resistance in the ECM PWR OUT 1 circuit. Yes: Replace O2S. After repairs
Connect 180-pin Breakout Box and ECM C1 & C2 Breakout are complete, retest for SPN
Harness to vehicle harness, and leave ECM disconnected. 3223 FMI 5.
Connect Breakout Harness ZTSE4735A to O2S harness, and
No: Repair Open in ECM
leave sensor disconnected. Key-Off, using a DMM, measure
PWR OUT 1 circuit between
resistance between ZTSE4735A pin-4 and ECM pin C1-33.
O2S connector pin-4 And ECM
Is resistance less than 5 ohms? pin C1-33. After repairs are
complete, retest for SPN 3223
FMI 5.

NOTE: After performing all diagnostic steps, if

SPN 3223 FMI 5 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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828
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 825

Pinpoint O2S System Fault

SPN 3223 FMI 1– O2S heater temperature below minimum

SPN 3223 FMI 17 – O2S heater temperature below minimum at low battery PWR
NOTE: SPN 3223 FMI 17 will set if battery voltage is below 10 V when the O2S heater is commanded
ON.
1. Check for other active or previously active DTCs. Repair any electrical fault before continuing
with this procedure.
2. Verify batteries and changing system are working within specifications. See "PERFORMANCE
DIAGNOSTICS."
• If charging system and battery voltage are working within specification, check for circuit faults to
the O2S. If circuits are within specification, calibrate and install new O2S.

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829
 826 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

RAPP (Remote Accelerator Pedal Position)

SPN FMI Condition Possible Causes Actions

974 3 Remote APP signal Out of Range • RPS signal circuit Circuit Checks (page
HIGH short to PWR 827)
• SIG GND circuit
OPEN
• Failed RAPP system
component
974 4 Remote APP signal Out of Range • RPS signal circuit Circuit Checks (page
LOW OPEN or short to 827)
GND
• VREF4 circuit OPEN
• Failed RAPP system
component

Overview • 2010 MaxxForce 11 & 13 Harness Kit

00-01462-00
The Remote Accelerator Pedal Position (RAPP)

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feature allows the operator to set and maintain a • ZTSE4498 – 3-Banana Plug Harness
constant engine speed from outside the vehicle cab.
• Digital Multimeter (DMM)
This feature may also be know as Remote Engine
Speed Control (RESC). Control over engine speed • Electronic Service Tool (EST) with ServiceMaxx™
is accomplished by using remote mounted switches software
to turn on the RESC and select the desired engine
• Interface cable (RP1210B compliant supporting
speed.
J1939 and J1708)
Tools Required
• 00-00956-08 – 180-Pin Breakout Box

830
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 827

Sensor Circuit Check With ServiceMaxx™ Software

Disconnect Body Builder Connector 2. Turn ignition switch to ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Run Continuous 4.5 V to 5 V If < 4.5 V, check APP1 signal circuit for OPEN. Do Harness
Monitor Test and Resistance Check (page 827).
monitor APP1v
Short pins 2–A and 2–B
DMM — Measure 5.0 V ± 0.5 V If > 5.5 V, check VREF4 for short to PWR.
voltage
If < 4.5 V, check VREF4 for OPEN or short to GND. Do
2–B to GND Harness Resistance Check (page 827).

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1
and C2 vehicle harness connectors, and leave ECM disconnected. Disconnect Body Builder Connector
2. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
2–A to C1–13 <5Ω If > 5 Ω, check for OPEN in circuit.

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2–A to GND > 1k Ω If < 1k Ω, check for short to GND.
2–B to C1–37 <5Ω If > 5 Ω, check for OPEN in circuit.
2–B to GND > 1k Ω If < 1k Ω, check for short to GND.
2–C to C1–24 <5Ω If > 5 Ω, check for OPEN in circuit.
2–C to GND >1k Ω If < 1k Ω, check for short to GND.

831
 828 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Service Interval Messages

SPN FMI Condition Possible Causes

1378 31 Change Engine Oil Service Interval • Change oil and re-set interval counter

Service Interval Messages Operation consumption. These service interval limits may be
adjusted at the owner's discretion. The change
The service interval messages are displayed on the
engine oil message below the odometer illuminates
instrument cluster message center and include engine
after a preselected parameter is reached.
oil and fuel filter change reminders.
The fuel filter change message displays when the fuel
The change oil reminder can be programmed
filter needs replacement due to high filter restriction.
for kilometers, miles, hours or calculated fuel

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832
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 829

SART (Stand Alone Real Time) Clock

SPN FMI Condition Possible Causes

251 19 ECM not detecting SART module • SART module powering circuit fault
J1939
• J1939 to SART module fault
• Failed SART module

SART module circuit SART SART

module module
connector
,---
/
ECM 58-Pin To SWBAT .__ A
/
C1 connector To GND .__ B
J1939-H
Pin C1-34 C
J1939-L
Pin C1-47
-D
V00161

Figure 328 SART circuit diagram

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Tools Required
• 00-00956-08 – 180-Pin Breakout Box
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device
NOTE: Reference the truck Chassis Electrical
Circuit Diagram Manual and Electrical System
Troubleshooting Guide for vehicle side electrical
system.

Connector Voltage Check

Test Point Specification Comment – < Less than, > Greater than
A to GND B+ If < B+, check B+ circuit to SART module for OPEN or short
to GND, or blown fuse.
B to B+ B+ If < B+, check GND circuit to SART module for OPEN.
C to GND 1 V to 4 V The sum of D to GND and C to GND should = 1 V to 4 V
D to GND 1 V to 4 V The sum of D to GND and C to GND should = 1 V to 4 V

833
 830 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box. Leave ECM disconnected.
Test Point Specification Comment – < Less than, > Greater than
C to C1-34 <5Ω If > 5 Ω, check J1939-H for OPEN in circuit.
C to GND > 1k Ω If < 1k Ω, check J1939-H for short to GND.
D to C1-47 <5Ω If > 5 Ω, check J1939-L for OPEN in circuit.
D to GND > 1k Ω If < 1k Ω, check J1939-L for short to GND.

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834
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 831

TC1TOP Sensor (Turbocharger 1 Turbine Outlet

Pressure)

SPN FMI Condition Possible Causes Actions

5541 2 TC1TOP signal does not agree with • Biased TC1TOP Pin-Point Diagnostics
BARO sensor or circuit (page 832)
• Intermittent
TC1TOP circuit
fault
• Restricted EBPV
tube
5541 3 TC1TOP signal Out of Range HIGH • TC1TOP signal Pin-Point Diagnostics
circuit OPEN or (page 832)
short to PWR
• SIG GND circuit
OPEN
• Failed TC1TOP
sensor

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5541 4 TC1TOP signal Out of Range LOW • TC1TOP signal Pin-Point Diagnostics
circuit short to GND (page 832)
• Failed TC1TOP
sensor

TC1TOP circuit

ACV
ECM 96-Pin TC1TOP (TC1TOP)
TC1TOP
E1 connector connector

1 V!:..2R~EFc.:-~3~-----conI nectar
J- (end view)
Pin E1 _ 89 8
TC1TOP 8
Pin E1 _ 61 9
SIG GND
Pin E1 _ 20 10
0

V00062

Figure 329 TC1TOP circuit diagram

Tools Required • ZTSE4899 – Big Bore Terminal Test Probe Kit

• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• Breakout Harness ZTSE6003 (TC1TOP)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with ServiceMaxx™
software
• J1939 and J1708 RP1210B Compliant Device

835
 832 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Note: The TC1TOP, TC1WC, TC2WC, and EBPV

circuits share the same connector to the ACV
assembly.

Pinpoint Diagnostics With ServiceMaxx™

Software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Using Electronic Service Tool (EST) with
ServiceMaxx™ software, run the Continuous
Monitor test.
2. Monitor sensor voltage and verify an active
DTC for this sensor.
• If DTC is previously active, monitor signal
while wiggling harness of suspect sensor.
If circuit is interrupted, signal will spike
and DTC will go active or pending.
• If DTC is active, continue to Biased

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Sensor or Circuit Check.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.

SPN 5541 FMI 2 – TC1TOP signal does not agree with BARO
Biased Sensor or Circuit Check
1. Turn ignition switch ON, engine OFF
2. Using ServiceMaxx™ software, run the Continuous Monitor test.
3. Verify S_TC1TOP volts are within specification (lightly wiggle circuits while monitoring TC1TOP
signal for spikes). See “APPENDIX A: PERFORMANCE SPECIFICATIONS."
• If TC1TOP voltage is not within specification, check circuitry for poor continuity. If circuits are
acceptable, replace TC1TOP sensor.
4. Check Exhaust Back Pressure Valve (EBPV) tube between Air Control Valve (ACV) and EBPV for
restriction.

836
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 833

Sensor Circuit Check With ServiceMaxx™ Software

Connect Breakout Harness ZTSE6003 to ACV engine harness, and leave ACV sensor disconnected.
Turn ignition ON.
Test Point Specification Comment – < Less than, > Greater than
EST – Monitor 4.5 V to 5 V If < 4.5 V, check TC1TOP signal circuit for short to GND. Do
TC1TOPv Harness Resistance Check (page 834).
DMM — Measure 5.0 V ± 0.5 V If > 5.5 V, check VREF3 for short to PWR.
voltage
If < 4.5 V, check VREF3 for OPEN or short to GND. Do
8 to GND Harness Resistance Check (page 834).
DMM — Measure 5 V ± 0.5 V If < 4.5 V, check SIG GND for OPEN. Do Harness
voltage Resistance Check (page 834).
8 to 10
EST – Monitor 0V If > 0.25 V, check TC1TOP signal for OPEN. Do Harness
TC1TOPv Resistance Check (page 834).
Short across Breakout
Harness pins 9 and 10
If checks are within specification, connect sensor and clear DTCs. Verify sensor voltage is within KOEO

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specification. See “APPENDIX A: PERFORMANCE SPECIFICATIONS." If sensor voltage is not within
specification, replace the sensor.

Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE6003 to ACV engine harness, and leave ACV sensor disconnected.
Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
8 to GND 5.0 V ± 0.5 V If > 5.5 V, check VREF3 for short to PWR.
If < 4.5 V, check VREF3 for OPEN or short to GND. Do
Harness Resistance Check (page 834).
10 to GND 0V If > 0.25 V, check SIG GND circuit for short to PWR.
9 to GND 4.5 V to 5 V If < 4.5 V, check TC1TOP signal circuit for short to GND. Do
Harness Resistance Check (page 834).

837
 834 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and E2
engine harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE6003 to ACV
engine harness, and leave ACV disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
8 to GND > 1k Ω If < 1k Ω, check for short circuit.
8 to E1-89 <5Ω If > 5 Ω, check for OPEN circuit.
9 to GND > 1k Ω If < 1k Ω, check for short circuit.
9 to E1-61 <5Ω If > 5 Ω, check for OPEN circuit.
10 to GND > 1k Ω If < 1k Ω, check for short circuit.
10 to E1–20 <5Ω If > 5 Ω, check for OPEN circuit.

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838
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 835

TC1WC (Turbocharger 1 Wastegate Control)

SPN FMI Condition Possible Causes Actions

1189 3 TC1WC short to PWR • TC1WC control Circuit Checks
circuit short to PWR
• Failed TC1WC
solenoid
1189 4 TC1WC short to GND • TC1WC control Circuit Checks
circuit short to GND
• Failed TC1WC
solenoid

TC1WC circuit
ACV
TC1WC (TC1WC)
ECM 96-Pin TC1WC connector
connector
E1 connector ~UE:.!C~M!!'.!...!P~W~R~O::.!U::...T:....=---3\/1 3 =tl(endtw)
Pin E1 - 27
1T7 4
3
Pin E1 - 02 \...-J_IT~CJ.!1WC!._~C_ _ _
~

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4
D

V00059

Figure 330 TC1WC circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box
• 2010 MaxxForce 11 & 13
00-01462-00
• ZTSE4498 – 3-Banana Plug Harness
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE6003 (TC1WC)
• Electronic Service Tool (EST) with ServiceMaxx™
software
Harness Kit
• J1939 and J1708 RP1210B Compliant Device
Note: The TC2WC, TC1TOP, and EBPV circuits
share the same connector to the Air Control Valve
(ACV) assembly.

839
 836 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Voltage Check – TC2WC Disconnected

Connect Breakout Harness ZTSE6003 to ACV engine harness, and leave ACV disconnected. Turn ignition
ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
3 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check.
4 to GND 3.5 V ± 1.0 V If < 2.5 V, check for OPEN circuit. Do Harness Resistance
Check.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure air tanks have at least 90 psi (621 kPa) of pressure.
1. Connect Breakout Harness ZTSE6003 between TC2WC and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select TC1 Wastegate Control from the drop-down menu.
3. Command TC1 Wastegate Control to 5%.

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4. Use DMM to measure voltage.
5. Command TC1 Wastegate Control to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
4 to GND 5% = 12 V ± 2.0 V If < 10 V, check for OPEN circuit.
4 to GND 95% = 0.5 V ± 0.5 V If > 1 V, check for OPEN circuit or failed ACV.

Actuator Resistance Check

Turn ignition switch OFF. Connect Breakout Harness ZTSE6003 to ACV and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Spec Comment
3 to 4 4 Ω to 11 Ω If not within specification, replace the ACV.
If measurements are within specifications, go to Harness Resistance Check.

840
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 837

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and Breakout Harness ZTSE6003. Leave ECM
and TC2WC disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
3 to GND > 1k Ω If < 1k Ω, check for short circuit.
3 to E1-27 <5Ω If > 5 Ω, check for OPEN circuit.
4 to GND > 1k Ω If < 1k Ω, check for short circuit.
4 to E1-02 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If DTC returns, replace ACV.

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841
 838 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

TC2WC (Turbocharger 2 Wastegate Control)

SPN FMI Condition Possible Causes Actions

1189 3 TC2WC short to PWR • TC2WC control Circuit Checks (page
circuit short to PWR 839)
• Failed TC2WC
solenoid
1189 4 TC2WC short to GND • TC2WC control Circuit Checks (page
circuit short to GND 839)
• Failed TC2WC
solenoid
1189 5 TC2WC open load/circuit • TC2WC control Circuit Checks (page
OPEN circuit 839)
• Failed TC2WC
solenoid

TC2WC circuit
TC2WC ACV
(TC2WC)

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ECM 96-Pin TC2WC connector
E1 connector connector (end view) 6

Pin E1 - 26 >--+--'E::..;C:;.;.M.:.:..:...P..:..W:..:.R.:..O=U..:..T..::3~+-1--1 6 7

Pin E1 - 52 J--+--T-"C"""'2"'-W'-'C'-------1-~ 7

V00060

Figure 331 TC2WC circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box • Electronic Service Tool (EST) with ServiceMaxx™
software
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00 • J1939 and J1708 RP1210B Compliant Device
• ZTSE4498 – 3-Banana Plug Harness Note: The TC2WC, TC1TOP, and EBPV circuits
share the same connector to the Air Control Valve
• ZTSE4497 – 500 Ohm Resistor Harness
(ACV) assembly.
• ZTSE4899 – Big Bore Terminal Test Probe Kit
• Breakout Harness ZTSE6003 (TC2WC)

842
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 839

Connector Voltage Check – TC2WC Disconnected

Connect Breakout Harness ZTSE6003 to ACV engine harness, and leave ACV disconnected. Turn ignition
ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
6 to GND B+ If < B+, check for OPEN circuit. Do Harness Resistance
Check.
7 to GND 3.5 V ± 1.0 V If < 2.5 V, check for OPEN circuit. Do Harness Resistance
Check.
If measurements are within specifications, do Operational Voltage Check.

Operational Voltage Check

NOTE: Ensure air tanks have at least 90 psi (621 kPa) of pressure.
1. Connect Breakout Harness ZTSE6003 between TC2WC and engine harness.
2. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Tests > KOEO Tests >
Actuator Test. Select TC2 Wastegate Control from the drop-down menu.
3. Command TC2 Wastegate Control to 5%.

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4. Use DMM to measure voltage.
5. Command TC2 Wastegate Control to 95%.
6. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
7 to GND 5% = 12 V ± 2.0 V If < 10 V, check for OPEN circuit.
7 to GND 95% = 0.5 V ± 0.5 V If > 1 V, check for OPEN circuit or failed ACV.

Actuator Resistance Check

Turn ignition switch OFF. Connect Breakout Harness ZTSE6003 to ACV and leave engine harness
disconnected. Use DMM to measure resistance.
Test Point Spec Comment
6 to 7 4 Ω to 11 Ω If not within specification, replace the ACV.
If measurements are within specifications, go to Harness Resistance Check.

843
 840 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box and Breakout Harness ZTSE6003. Leave ECM
and TC2WC disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
6 to GND > 1k Ω If < 1k Ω, check for short circuit.
6 to E1-26 <5Ω If > 5 Ω, check for OPEN circuit.
7 to GND > 1k Ω If < 1k Ω, check for short circuit.
7 to E1-52 <5Ω If > 5 Ω, check for OPEN circuit.
If voltage and resistance checks are within specifications, check for DTCs. If DTC returns, replace ACV.

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844
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 841

TC2CIS (Turbocharger 2 Compressor Inlet

Sensor)

SPN FMI Condition Possible Causes Actions

1173 2 TC2CIT signal does not agree with • TC2CIT high Step-Based Diagnostics
other sensors resistance (page 843)
• SIG GND high
resistance
• Failed TC2CIS
sensor
1173 3 TC2CIT Out of Range HIGH • TC2CIT shorted to Step-Based Diagnostics
PWR (page 846)
• TC2CIT Open or
high resistance
• SIG GND Open or
high resistance
• Failed TC2CIS
sensor

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1173 4 TC2CIT Out of Range LOW • TC2CIT shorted to Step-Based Diagnostics
GND (page 849)
• TC2CIT shorted to
SIG GND
• Failed TC2CIS
sensor
1173 16 TC2CIT signal above desired • Failed TC2CIS Step-Based Diagnostics
(Interstage CAC under cooling) (page 851)
• Failed Coolant
Control Valve (CCV)
• Restricted or leaking
LPCAC
• Inoperative engine
cooling fan
• Restricted
low-temperature
radiator
• Engine fan or shroud
problem
1177 2 TC2CIP signal erratic, intermittent, or • TC2CIP high Step-Based Diagnostics
incorrect resistance (page 854)
• SIG GND high
resistance
• Failed TC2CIS
sensor

845
 842 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

1177 3 TC2CIP signal Out of Range HIGH • TC2CIP shorted to Step-Based Diagnostics
PWR (page 856)
• TC2CIP Open or
high resistance
• SIG GND Open or
high resistance
• Failed TC2CIS
sensor
1177 4 TC2CIP signal Out of Range LOW • TC2CIP shorted to Step-Based Diagnostics
GND (page 859)
• TC2CIP shorted to
SIG GND
• Failed TC2CIS
sensor

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS

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E1 connector TC2CIS (end view) 1 sensor
connector
Pin E1 - 55 >--+-"S..;.,;IG;;;....;;:;G..;.,;N~D-----~ 1
TC2CIT
Pin E1 - 12 >--+----------~2
VREF4
Pin E1 - 58 ~+---------~3
TC2CIP_ _ _ _ _ _
~+-....;.._....;.._ 4 ~

Pin E1 - 79
4

V00039

Figure 332 TC2CIS sensor circuit diagram

NOTE: See latest version of Maxxforce 11 and 13
Engine Wiring Schematic Form 0000002941 for
additional circuit information.
Overview
The Turbocharger 2 Compressor Inlet Sensor
(TC2CIS) is a combined temperature and pressure
sensor located in the piping between the low-pressure
compressor outlet and the high-pressure compressor
inlet. This sensor monitors boost pressure for
the low-pressure turbo and the temperature of the
charge-air entering the high-pressure turbo. The
ECM uses these measurements for calculating fuel
delivery and controlling the wastegate.
Tools Required
• 180-Pin Breakout Box 00-00956-08
• ECM Breakout Harness 00-01468-00
• Breakout Harness ZTSE4830 (TC2CIS)
• Digital Multimeter (DMM)
• Charge Air Cooler (CAC) Tester ZTSE4341
• Electronic Service Tool (EST) with ServiceMaxx™
software
• Interface cable (RP1210B compliant supporting
J1939 and J1708)

846
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 843

SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Difference between TC2CIT deviation from Key ON Immediate
Turbocharger 2 IMT and IAT greater than
Engine is cold soaked (8 hours)
Compressor Inlet expected
temperature (TC2CIT)
sensor reading and
Intake Manifold
Temperature (IMT) and
Inlet Air Temperature
(IAT) sensor readings
greater than expected.

Fault Overview Associated Faults

Fault code sets when Turbocharger 2 Compressor SPN 1173 FMI 3 and 4 (TC2CIT), SPN 105 (IMT), SPN
Inlet temperature (TC2CIT) signal difference 172 (IAT)
compared to Inlet Air Temperature (IAT) and Intake
Manifold Temperature (IMT) is greater than expected. Drive Cycle to Determine Fault Status

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Drive Cycle 10 then 2 in 2013 HD-OBD Diagnostic
Malfunction Indicator Lamp (MIL) Reaction
Reference Manual.
MIL will illuminate when this fault is detected during
two consecutive drive cycles.

847
 844 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
}--+---"'S.;,_;IG:....G..::..;,_;_N.::..D_ _ _ _ _--1 1
Pin E1 - 55
}--+-'-T..:::.C.::..2C.::..lc...:..T_ _ _ _ _~ 2
Pin E1 - 12
VREF4
Pin E1 - 58 }--+------------13
TC2CIP_ _ _ _ _ _--I 4
}--+-....;;._....;;._
Pin E1 - 79
4

V00039

Figure 333 TC2CIS sensor circuit diagram

Possible Causes
• TC2CIT high resistance
• SIG GND high resistance

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• Failed TC2CIS sensor

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 1173 FMI 3
No: Repair SPN 1173 FMI 3 and
and 4 (TC2CIT).
4. After repairs are complete,
Is EST DTC list free of SPN 1173 FMI 3 and 4? retest for SPN 1173 FMI 2.

Step Action Decision

2 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 3.
(TC2CIS). Key OFF, disconnect TC2CIS sensor. Check sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 1173 FMI 2.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Inspect connections at ECM E1 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E1 connector. Check ECM and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing. Are the ECM E1
repairs are complete, retest for
connector, harness, and terminals clean and undamaged?
SPN 1173 FMI 2.

848
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 845

Step Action Decision

4 Check SIG GND for high resistance. Connect 180-pin Breakout Yes: Go to step 5.
Box and ECM Breakout Harness 00-01468-00 to ECM E1
No: Repair high resistance
harness, and leave ECM disconnected. Key-Off, using a DMM,
between TC2CIS pin-1 and
measure resistance between breakout harness pin-1 and breakout
ECM connector E1 pin-55. After
box E1 pin-55.
repairs are complete, retest for
Is resistance less than 5 ohms? SPN 1173 FMI 2.

Step Action Decision

5 Check TC2CIT for high resistance. Using a DMM, measure Yes: Replace TC2CIS sensor.
resistance between breakout harness pin-2 and Breakout Box After repairs are complete, retest
E1 pin-12. for SPN 1173 FMI 2.
Is resistance less than 5 ohms? No: Repair high resistance
between TC2CIS pin-2 and
ECM connector E1 pin-12. After
repairs are complete, retest for
SPN 1173 FMI 2.

NOTE: After performing all diagnostic steps, if

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SPN 1173 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

849
 846 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1173 FMI 3 - TC2CIT signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 TC2CIT > 4.78 volts Key ON 2 seconds
Compressor Inlet
Temperature (TC2CIT)
signal is above the
maximum valid value.

Fault Overview
Fault code sets when signal from the Turbocharger
2 Compressor Inlet Sensor (TC2CIS), Turbocharger
2 Compressor Inlet Temperature (TC2CIT) circuit is
greater then 4.78 volts.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

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Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
SIG GND
Pin E1 - 55 >--+----------~1
TC2CIT
Pin E1 - 12 >--+------------12
VREF4_ _ _ _ _ _--I 3
>--+-...;...;.:::..;___;
Pin E1 - 58
TC2CIP_ _ _ _ _ _---1 4
>--+-....::....::c...::...;,..
Pin E1 - 79
4

V00039

Figure 334 TC2CIS sensor circuit diagram

Possible Causes • SIG GND Open or high resistance

• TC2CIT shorted to PWR • Failed TC2CIS sensor
• TC2CIT Open or high resistance

850
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 847

Step Action Decision

1 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 2.
(TC2CIS) sensor. Key OFF, disconnect TC2CIS sensor. Check
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 1173 FMI 3.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check TC2CIT for a short to PWR. Connect Breakout Harness Yes: Go to step 3.
ZTSE4830 to engine harness, and leave TC2CIS disconnected.
No: Repair short to PWR
Using a DMM, Key-On Engine-Off (KOEO) measure voltage
between TC2CIS pin-2 and ECM
between breakout harness pin-2 and a known good ground.
pin E1-12. After repairs are
Is voltage less than 5.5 volts? complete, retest for SPN 1173
FMI 3.

Step Action Decision

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3 Inspect connections at ECM E1 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E1 connector. Check ECM and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E1 connector, harness, and terminals clean and SPN 1173 FMI 3.
undamaged?

Step Action Decision

4 Check SIG GND for Open or high resistance. Connect 180-pin Yes: Go to step 5.
Breakout Box and ECM Breakout Harness 00-01468-00 to ECM
No: Repair Open or high
E1 engine harness, and leave ECM disconnected. Key-Off, using
resistance between TC2CIS
a DMM, measure resistance between breakout harness pin-1 and
pin-1 and ECM connector
breakout box E1 pin-55.
E1 pin-55. After repairs are
Is resistance less than 5 ohms? complete, retest for SPN 1173
FMI 3.

Step Action Decision

5 Check TC2CIT for Open or high resistance. Key-Off, using a Yes: Replace TC2CIS sensor.
DMM, measure resistance between ECM E1 pin-12 and breakout After repairs are complete, retest
harness pin-2. for SPN 1173 FMI 3.
Is resistance less than 5 ohms? No: Repair Open or high
resistance between TC2CIS
pin-2 and ECM connector
E1 pin-12. After repairs are
complete, retest for SPN 1173
FMI 3.

851
 848 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

NOTE: After performing all diagnostic steps, if

SPN 1173 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

852
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 849

SPN 1173 FMI 4 - TC2CIT signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 TC2CIT less than 0.1 volt Key ON 0.5 seconds
Compressor Inlet
Temperature (TC2CIT)
signal is below
minimum.

Fault Overview
Fault code sets when signal from the Turbocharger
2 Compressor Inlet Sensor (TC2CIS), Turbocharger 2
Compressor Inlet Temperature (TC2CIT) circuit is less
then 0.1 volts.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
SIG GND
Pin E1 - 55 >--+----------~ 1
TC2CIT
Pin E1 - 12 >--+------------12
VREF4_ _ _ _ _ _--I 3
>--+-...;__;_:::..;____;
Pin E1 - 58
TC2CIP_ _ _ _ _ _--I 4
>--+-....::..::....::...;.;.
Pin E1 - 79
4

V00039

Figure 335 TC2CIS sensor circuit diagram

Possible Causes • TC2CIT shorted to SIG GND

• TC2CIT shorted to GND • Failed TC2CIS sensor

853
 850 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 2.
(TC2CIS) sensor. Key OFF, disconnect TC2CIS sensor. Check
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 1173 FMI 3.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check TC2CIT for a short to GND. Connect Breakout Harness Yes: Go to step 3.
ZTSE4830 to engine harness, and leave TC2CIS disconnected.
No: Repair short to GND
Using a DMM, Key OFF measure resistance between breakout
between TC2CIS pin-2 and ECM
harness pin-2 and a known good ground.
pin E1-12. After repairs are
Is resistance greater than 1000 ohms? complete, retest for SPN 1173
FMI 4.

Step Action Decision

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3 Check TC2CIT for a short to SIG GND. Using a DMM, measure Yes: Replace TC2CIS sensor.
resistance between breakout harness pin-1 and pin-2. After repairs are complete, retest
for SPN 1173 FMI 4.
Is resistance greater than 1000 ohms?
No: Repair short between
TC2CIT and SIG GND circuits.
After repairs are complete, retest
for SPN 1173 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 1173 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

854
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 851

SPN 1173 FMI 16 - TC2CIT signal above desired (Interstage CAC under cooling)
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 Difference between Engine running 3 events
Compressor Inlet TC2CIT and engine
Ambient Air Temperature (AAT)
Temperature (TC2CIT) coolant temperature >
between 19°F (-7°C) and 131°F
signal is greater than a predetermined value,
(55°C)
expected. based on engine speed
and load. Barometric Pressure (BARO) >
10.9 psi (75 kPa)
Difference between coolant
temperature and expected
temperature of the Low Pressure
Change Air Cooler (LPCAC) >
68°F (20°C) for 3 seconds or
more

Fault Overview Drive Cycle to Determine Fault Status

Fault code sets when Turbocharger 2 Compressor Drive Cycle 1 then 2 in 2013 HD-OBD Diagnostic

BetterManuals.net
Inlet Temperature (TC2CIT) is above a calculated
range, based on operating conditions.
Malfunction Indicator Lamp (MIL) Reaction
MIL will illuminate when this fault is detected during
two consecutive drive cycles.
Associated Faults
SPN 1173 FMI 3 and 4 (TC2CIT); SPN 5546 (CMV);
and SPN 5547 (CFV)
Reference Manual.
Possible Causes
• Failed TC2CIS
• Failed Coolant Control Valve (CCV)
• Restricted or leaking LPCAC
• Inoperative engine cooling fan
• Restricted low-temperature radiator
• Engine fan or shroud problem
NOTE: Repair engine cooling system problems
and engine overheating before doing this
procedure (see "Engine Symptoms Diagnostics").

855
 852 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 1173 FMI 3 and
No: Repair SPN 1173 FMI 3, 4;
4 (TC2CIT); SPN 5546 (CMV); and SPN 5547 (CFV).
SPN 5546; and SPN 5547. After
Is EST DTC list free of SPN 1173 FMI 3, 4; SPN 5546; and SPN repairs are complete, retest for
5547? SPN 1173 FMI 16.

Step Action Decision

2 Inspect for damaged or missing engine cooling fan, fan shroud, Yes: Go to step 3.
and fan hub assembly. Check for air flow restrictions around low
No: Repair air restriction, or
temperature radiator.
replace engine cooling fan or fan
Is engine cooling fan, hub, and shroud, and low temperature hub assembly. After repairs are
radiator free of air restrictions and is not missing or damaged? complete, retest for SPN 1173
FMI 16.

Step Action Decision

3 Check for an inoperative engine cooling fan. Using EST with Yes: Go to step 4.
ServiceMaxx™ software, run Tests > Key-On Engine-Running
No: Replace fan hub assembly.

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(KOER) Tests > Engine Fan Tests. Determine the engine cooling
After repairs are complete, retest
fan’s capability to maintain desired speeds.
for SPN 1173 FMI 16.
Is the engine cooling fan operating properly?

Step Action Decision

4 Check for a failed TC2CIS sensor. Run engine at high idle for Yes: Go to step 5.
20 seconds. Using EST with ServiceMaxx™ software, compare
No: Replace TC2CIS sensor.
TC2CIT temperature values with ECT1 and ECT2.
After repairs are complete, retest
Is TC2CIT within 10°F (6°C) of ECT1 and ECT2? for SPN 1173 FMI 16.

Step Action Decision

5 Check for a failed Coolant Control Valve (CCV). Using EST with Yes: Go to step 6.
ServiceMaxx™ software, run the Tests > Key-On Engine-Running
No: Replace CCV. After repairs
(KOER) Tests > Coolant Control Valve Test (page 93). Follow
are complete, retest for SPN
on screen instructions.
1173 FMI 16.
Are both Coolant Flow Valve (CFV) and Coolant Mixer Valve
(CMV) operating properly?

Step Action Decision

6 Check for a restricted or leaking interstage CAC. Install Charge Yes: Retest for SPN 1173 FMI
Air Cooler (CAC) Tester ZTSE4341 and test for leakages (see 16.
Engine Service Manual).
No: Replace the LPCAC. After
Is the LPCAC free of excessive leaks or other defects? repairs are complete, retest for
SPN 1173 FMI 16.

856
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 853

NOTE: After performing all diagnostic steps, if

SPN 1173 FMI 16 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

857
 854 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1177 FMI 2 - TC2CIP signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 Difference between Key-On Engine-Running 2 seconds
Compressor Inlet TC2CIP and BARO > (KOER)
Pressure (TC2CIP) 1.45 psi (12 kpa)
signal does not agree
with Barometric
Pressure (BARO)
sensor.

Fault Overview
Fault code sets when Turbocharger 2 Compressor
Inlet Pressure (TC2CIP) signal is not within 12 kpa of
the Barometric Pressure (BARO) sensor.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Associated Faults
SPN 1177 FMI 3 and 4 (TC2CIT)

Drive Cycle to Determine Fault Status

Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
SIG GND
Pin E1 - 55 >--+-------------1 1
TC2CIT
Pin E1 - 12 }--t----------l2
VREF4_ _ _ _ _ _---1 3
>--+-...c....;.:::..;___;
Pin E1 - 58
TC2CIP_ _ _ _ _ _---1 4
>--+-....::..:::...;:..:,,c
Pin E1 - 79
4

V00039

Figure 336 TC2CIS sensor circuit diagram

Possible Causes • SIG GND high resistance

• TC2CIP high resistance • Failed TC2CIS sensor

858
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 855

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check Diagnostic Trouble Code (DTC) list for SPN 1177 FMI 3
No: Repair SPN 1177 FMI 3 and
and 4 (TC2CIP).
4. After repairs are complete,
Is EST DTC list free of SPN 1177 FMI 3 and 4? retest for SPN 1177 FMI 2.

Step Action Decision

2 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 3.
(TC2CIS). Key OFF, disconnect TC2CIS sensor. Check sensor
No: Repair connector, harness,
and connector terminals for: damaged or pinched wires; corroded
or terminal damage. After
terminals; loose, bent, or broken pins; or broken connector
repairs are complete, retest for
housing.
SPN 1177 FMI 2.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

3 Inspect connections at ECM E1 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E1 connector. Check ECM and connector terminals for:
No: Repair connector, harness,

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damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing. Are the ECM E1
repairs are complete, retest for
connector, harness, and terminals clean and undamaged?
SPN 1177 FMI 2.

Step Action Decision

4 Check SIG GND for high resistance. Connect 180-pin Breakout Yes: Go to step 5.
Box and ECM Breakout Harness 00-01468-00 to ECM E1 engine
No: Repair high resistance
harness, and leave ECM disconnected. Key-Off, using a DMM,
between TC2CIS pin-1 and
measure resistance between breakout harness pin-1 and breakout
ECM connector pin E1-55. After
box E1 pin-55.
repairs are complete, retest for
Is resistance less than 5 ohms? SPN 1177 FMI 2.

Step Action Decision

5 Check TC2CIP for high resistance. using a DMM, measure Yes: Replace TC2CIS sensor.
resistance between breakout harness pin-4 and Breakout Box After repairs are complete, retest
E1 pin-79. for SPN 1177 FMI 2.
Is resistance less than 5 ohms? No: Repair high resistance
between TC2CIS pin-4 and
ECM connector pin E1-79. After
repairs are complete, retest for
SPN 1177 FMI 2.

NOTE: After performing all diagnostic steps, if

SPN 1177 FMI 2 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

859
 856 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1177 FMI 3 - TC2CIP signal Out of Range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 TC2CIP > 4.9 volts Key ON 0.5 seconds
Compressor Inlet
Pressure (TC2CIP)
signal is greater than
expected.

Fault Overview
Fault code sets when signal from the Turbocharger 2
Compressor Inlet Sensor (TC2CIS), Turbocharger 2
Compressor Inlet Pressure (TC2CIP) circuit is greater
then 4.9 volts.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
SIG GND
Pin E1 - 55 >--+----------~1
TC2CIT
Pin E1 - 12 >--+------------12
VREF4_ _ _ _ _ _--I 3
>--+-...;...;.:::..;___;
Pin E1 - 58
TC2CIP_ _ _ _ _ _---1 4
>--+-....::....::c...::...;,..
Pin E1 - 79
4

V00039

Figure 337 TC2CIS sensor circuit diagram

Possible Causes • SIG GND Open or high resistance

• TC2CIP shorted to PWR • Failed TC2CIS sensor
• TC2CIP Open or high resistance

860
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 857

Step Action Decision

1 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 2.
(TC2CIS) sensor. Key OFF, disconnect TC2CIS sensor. Check
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 1177 FMI 3.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check TC2CIP for a short to PWR. Connect Breakout Harness Yes: Go to step 3.
ZTSE4830 to engine harness, and leave TC2CIS disconnected.
No: Repair short to PWR
Using a DMM, Key-On Engine-Off (KOEO) measure voltage
between TC2CIS pin-4 and ECM
between breakout harness pin-4 and a known good ground.
pin E1-79. After repairs are
Is voltage less than 5.5 volts? complete, retest for SPN 1177
FMI 3.

Step Action Decision

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3 Inspect connections at ECM E1 connector. Key OFF, disconnect Yes: Go to step 4.
ECM E1 connector. Check ECM and connector terminals for:
No: Repair connector, harness,
damaged or pinched wires; corroded terminals; loose, bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Are the ECM E1 connector, harness, and terminals clean and SPN 1177 FMI 3.
undamaged?

Step Action Decision

4 Check SIG GND for Open or high resistance. Connect 180-pin Yes: Go to step 5.
Breakout Box and ECM Breakout Harness 00-01468-00 to ECM
No: Repair Open or high
E1 engine harness, and leave ECM disconnected. Key-Off, using
resistance between TC2CIS
a DMM, measure resistance between breakout harness pin-1 and
pin-1 and ECM connector
breakout box E1 pin-55.
E1 pin-55. After repairs are
Is resistance less than 5 ohms? complete, retest for SPN 1177
FMI 3.

Step Action Decision

5 Check TC2CIP for Open or high resistance. Key-Off, using a Yes: Replace TC2CIS sensor.
DMM, measure resistance between ECM E1 pin-79 and breakout After repairs are complete, retest
harness pin-4. for SPN 1173 FMI 3.
Is resistance less than 5 ohms? No: Repair Open or high
resistance between TC2CIS
pin-4 and ECM connector
E1 pin-79. After repairs are
complete, retest for SPN 1177
FMI 3.

861
 858 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

NOTE: After performing all diagnostic steps, if

SPN 1177 FMI 3 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

BetterManuals.net

862
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 859

SPN 1177 FMI 4 - TC2CIP signal Out of Range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Turbocharger 2 TC2CIP < 0.1 volt Key ON 0.5 seconds
Compressor Inlet
Pressure (TC2CIP)
signal is less than
expected.

Fault Overview
Fault code sets when signal from the Turbocharger
2 Compressor Inlet Sensor (TC2CIS), Turbocharger
2 Compressor Inlet Pressure (TC2CIP) circuit is less
then 0.1 volts.

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

BetterManuals.net
Drive Cycle to Determine Fault Status
Drive Cycle 2 in 2013 HD-OBD Diagnostic Reference
Manual.

TC2CIS circuit
TC2CIS
ECM 96-Pin connector TC2CIS
E1 connector TC2CIS (end view) 1 sensor
connector
SIG GND
Pin E1 - 55 >--+----------~ 1
TC2CIT
Pin E1 - 12 >--+------------12
VREF4_ _ _ _ _ _--I 3
>--+-...;__;_:::..;____;
Pin E1 - 58
TC2CIP_ _ _ _ _ _--I 4
>--+-....::..::....::...;.;.
Pin E1 - 79
4

V00039

Figure 338 TC2CIS sensor circuit diagram

Possible Causes • TC2CIP shorted to SIG GND

• TC2CIP shorted to GND • Failed TC2CIS sensor

863
 860 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

1 Inspect connections at Turbocharger 2 Compressor Inlet Sensor Yes: Go to step 2.
(TC2CIS) sensor. Key OFF, disconnect TC2CIS sensor. Check
No: Repair connector, harness,
sensor and connector terminals for: damaged or pinched wires;
or terminal damage. After
corroded terminals; loose, bent, or broken pins; or broken
repairs are complete, retest for
connector housing.
SPN 1177 FMI 4.
Are the TC2CIS sensor connector, harness, and terminals clean
and undamaged?

Step Action Decision

2 Check TC2CIP for a short to GND. Connect Breakout Harness Yes: Go to step 3.
ZTSE4830 to engine harness, and leave TC2CIS disconnected.
No: Repair short to GND
Using a DMM, Key OFF measure voltage between breakout
between TC2CIS pin-4 and ECM
harness pin-4 and a known good ground.
pin E1-79. After repairs are
Is resistance less than 1000 ohms? complete, retest for SPN 1177
FMI 4.

Step Action Decision

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3 Check TC2CIT for a short to SIG GND. Using a DMM, measure Yes: Replace TC2CIS sensor.
resistance between breakout harness pin-1 and pin-4. After repairs are complete, retest
for SPN 1177 FMI 4.
Is resistance greater than 1000 ohms?
No: Repair short between
TC2CIP and SIG GND circuits.
After repairs are complete, retest
for SPN 1177 FMI 4.

NOTE: After performing all diagnostic steps, if

SPN 1177 FMI 4 remains, verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

864
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 861

TOSS / VSS (Transmission Output Shaft Speed /

Vehicle Speed Sensor) Sensor

SPN FMI Condition Possible Causes Actions

84 2 Vehicle speed anti-tampering fault • Incorrect Pinpoint Diagnostics
programmable (page 864)
parameter
191 1 TOSS / VSS not detected while vehicle • VSS sensor circuit Step-based
moving OPEN Diagnostics (page
866)
• VSS sensor circuit
short PWR
• VSS sensor circuit
short to GND
• VSS sensor failure
• Air gap too large
between VSS sensor
and 16 toothed gear
• Damaged 16 toothed

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gear
191 2 TOSS / VSS signal erratic, intermittent, • VSS sensor circuit Step-based
or incorrect short PWR Diagnostics (page
869)
• VSS sensor circuit
short to GND
• VSS sensor failure
• Air gap too large
between VSS sensor
and 16 toothed gear
• Damaged 16 toothed
gear
191 3 TOSS / VSS signal out of range HIGH • VSS sensor circuit Step-based
short PWR Diagnostics (page
872)
• VSS sensor failure

865
 862 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

191 4 TOSS / VSS signal out of range LOW • VSS sensor circuit Step-based
OPEN Diagnostics (page
875)
• VSS sensor circuit
short to GND
• VSS sensor failure
191 16 TOSS / VSS reading higher then limit • VSS sensor circuit Step-based
(Hard-wired) OPEN Diagnostics (page
878)
• VSS sensor circuit
short PWR
• VSS sensor circuit
short to GND
• VSS sensor failure
• Air gap too large
between VSS sensor
and 16 toothed gear
• Damaged 16 toothed
gear

BetterManuals.net
VSS circuit

21 -Way
ECM 96- Pin harness interface vss
E 1 connector (6003) connector vss (7600) connector
connector (end view)
VSS sensor

e
VSS-H
12 A
~
VSS - L
Pin E1 - 15 13 B ~-)

0000042186

Figure 339 TOSS / VSS Circuit Diagram

866
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 863

Overview
1
Transmission tailshaft speed is detected by a
magnetic pickup mounted on the transmission that
senses the rotation of a 16 toothed gear installed
on the rear of the transmission. The AC (alternating
current) sine wave signal is received by the Engine
Control Module (ECM) and is utilized along with
tire size and axle ratio, to calculate vehicle speed.
Calculated vehicle speed is transmitted to the
instrument cluster through the Drive Train Data Link
to operate the speedometer within the instrument
cluster. Calculated vehicle speed is also utilized in the
control strategies that control features such as Cruise
Control, PTO operation and Road Speed Limiting.
Tools Required
• 00-00956-08 – 180-pin Breakout Box
®
• 2010 MaxxForce 11 & 13 Harness Kit
00-01462-00
• Digital Multimeter (DMM)

BetterManuals.net
0000042183
• Electronic Service Tool (EST) with ServiceMaxx™
software Figure 340 TOSS / VSS Location (Typical)
• J1939 and J1708 RP1210B Compliant Device 1. Transmission Output Shaft Speed / Vehicle Speed
Sensor (TOSS / VSS)

867
 864 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
E 1 connector (6003) connector vss (7600) connector
connector (end view)
VSS sensor

t
VSS - H
Pin E1 - 39 12 A
~
VSS - L
Pin E1 - 15 13 B ~-)

0000042186

Figure 341 TOSS / VSS Circuit Diagram

Pinpoint Diagnostics With ServiceMaxx™

Software

SPN 84 FMI 2 - Vehicle speed anti-tampering fault

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1. Using Electronic Service Tool (EST) with ServiceMaxx™ software, load the Parameters session.
Verify the correct value is selected under parameter ID 89003 Vehicle Speed Signal Mode
(Hardwired sensor, Public J1939 / CAN OSS, or Public J1939 / Vehicle Speed Sensor).
Is the correct value selected under parameter ID 89003 Vehicle Speed Signal Mode?
• Yes: Retest for SPN 84 FMI 2.
• No: Correct parameter ID 89003 and program engine. Retest for SPN 84 FMI 2.

TOSS / VSS Connector Voltage Check Without ServiceMaxx™ Software

Connect Breakout Harness ZTSE4850 to TOSS/VSS vehicle harness, and leave TOSS/VSS sensor
disconnected. Turn ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
B to GND 2 V to 3 V If no voltage is present, check for OPEN or short to GND.
A to GND 2 V to 3 V If no voltage is present, check for OPEN or short to GND.

TOSS / VSS Sensor Continuity Check Without ServiceMaxx™ Software

Turn ignition switch to OFF. Connect Breakout Harness ZTSE4850 to TOSS/VSS sensor harness, and leave
vehicle harness disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
B to GND > 100 Ω If < 100 Ω, check for short to GND.
A to GND > 100 Ω If > 100 Ω check for short to GND.
B to A 600 Ω to 800 Ω If not within specification, replace VSS sensor.

868
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 865

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness to ECM E1 and
E2 vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE4850 to
TOSS/VSS vehicle harness, and leave TOSS/VSS sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1–15 to B <5Ω If > 5 Ω, check for OPEN circuit.
E1–39 to A <5Ω If > 5 Ω, check for OPEN circuit.
E1–15 to GND > 100 Ω If < 100 Ω, check for short to GND.
E1–39 to GND > 100 Ω If < 100 Ω, check for short to GND.

TOSS / VSS Operational Check Without ServiceMaxx™ Software

Turn ignition switch OFF. Connect 180-Pin Breakout Box with ECM E1 and E2 harness between ECM E1
and E2 connectors and ECM. Turn ignition switch to ON. Use DMM to measure voltage or EST to read
signal. Place rear axles on jack stands and block front wheels. Have an assistant rotate drive wheels
while performing test.

A WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

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Test Point Specification Comment – < Less than, > Greater than
E1–15 to E1–39 > 2 V AC If < 2 V AC, check sensor adjustment or replace defective
sensor.

869
 866 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 191 FMI 1 TOSS / VSS not detected while vehicle moving
Condition / Setting Criteria Enable Conditions / Values Time Required
Description
No vehicle speed Vehicle speed Engine speed > 1500 rpm 1 second
reading when engine
Time after key On > 0 seconds
load is high
Battery voltage > 10.7 volts
Battery voltage < 15 volts
Engine torque > 74 lb ft (100 Nm)
Speed and torque levels met
time > 60 seconds
Engine not in PTO mode

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Drive Cycle to Determine Fault Status

BetterManuals.net
See 2013 HD-OBD Diagnostic Reference Manual.

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
E 1 connector (6003) connector vss (7600) connector
connector (end view)
VSS sensor

e
VSS-H
Pin E 1 - 39 l >---+-------l 12 A
~
VSS-L
Pin E1 - 15 13 B ~-)

0000042186

Figure 342 TOSS / VSS Circuit Diagram

Step Action Decision

1 Inspect connections at VSS sensor. Key OFF, disconnect VSS Yes: Go to step 2.
sensor connector. Check VSS sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Is the VSS sensor connector, harness, and terminal clean and SPN 191 FMI 1.
undamaged.

870
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 867

Step Action Decision

2 Disconnect VSS connector (7600). Key-On Engine-Off (KOEO), Yes: Go to step 3.
measure voltage at VSS connector (7600) pins A & B.
No: Go to step 4.
Do both pins measure 2 to 3 volts?

Step Action Decision

3 Do TOSS / VSS Sensor Continuity Check without ServiceMaxx™ Yes: Check VSS sensor air gap
Software (page 864). or 16 toothed gear and repair
as necessary. After repairs are
Is VSS sensor within specification?
complete, retest for SPN 191
FMI 1.
No: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 1.

Step Action Decision

4 Disconnect 21–Way Engine Sensor Interface connector (6033). Below 2 volts: Repair harness
KOEO, measure voltage at engine side 21 Way Engine Sensor between ECM 96–pin E1

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Interface connector (6033) pins 12 and 13. connector and 21 Way
Engine Sensor Interface (6033)
Do both pins measure 2 to 3 volts?
connector for short to ground or
open circuit. After repairs are
complete, retest for SPN 191
FMI 1.
Yes: Go to step 5.
Above 3 volts: Repair harness
between ECM 96–pin E1
connector and 21 Way
Engine Sensor Interface (6033)
connector for short to power.
After repairs are complete, retest
for SPN 191 FMI 1.

Step Action Decision

5 KOEO, measure voltage at chassis side 21 Way Engine Sensor Yes: Go to step 6.
Interface connector (6033) pins 12 and 13.
No: Repair harness between
Do both pins measure 0 volts? VSS (7600) connector and 21
Way Engine Sensor Interface
(6033) connector for short
to power. After repairs are
complete, retest for SPN 191
FMI 1.

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 868 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Do TOSS / VSS Operational Check Without ServiceMaxx™
Software (page 865).
Was voltage above 2 volts AC?
Yes: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Check VSS sensor air gap
or 16 toothed gear and repair
as necessary. After repairs are
complete, retest for SPN 191
FMI 1.

NOTE: After doing all diagnostic steps, if SPN

191 FMI 1 remain verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 869

SPN 191 FMI 2 TOSS / VSS signal erratic, intermittent, or incorrect

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
VSS signal not detected Vehicle speed sensor Time after key On > 0 seconds 5 second
voltage
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
vss (7600) connector

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E1 connector (6003) connector
connector (end view)
VSS sensor

e
VSS-H
Pin E 1 - 39 \.._}--+--------l 12 A
~
~
VSS-L
Pin E1 - 15 13 B

0000042186

Figure 343 TOSS / VSS Circuit Diagram

Step Action Decision

1 Inspect connections at VSS sensor. Key OFF, disconnect VSS Yes: Go to step 2.
sensor connector. Check VSS sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Is the VSS sensor connector, harness, and terminal clean and SPN 191 FMI 2.
undamaged.

Step Action Decision

2 Disconnect VSS connector (7600). Key-On Engine-Off (KOEO), Yes: Go to step 3.
measure voltage at VSS connector (7600) pins A & B.
No: Go to step 4.
Do both pins measure 2 to 3 volts?

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 870 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Do TOSS / VSS Sensor Continuity Check without ServiceMaxx™ Yes: Check VSS sensor air gap
Software (page 864). or 16 toothed gear and repair
as necessary. After repairs are
Is VSS sensor within specification?
complete, retest for SPN 191
FMI 2.
No: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 2.

Step Action Decision

4 Disconnect 21–Way Engine Sensor Interface connector (6033). Below 2 volts: Repair harness
KOEO, measure voltage at engine side 21 Way Engine Sensor between ECM 96–pin E1
Interface connector (6033) pins 12 and 13. connector and 21 Way
Engine Sensor Interface (6033)
Do both pins measure 2 to 3 volts?
connector for short to ground or
open circuit. After repairs are
complete, retest for SPN 191
FMI 2.

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Yes: Go to step 5.
Above 3 volts: Repair harness
between ECM 96–pin E1
connector and 21 Way
Engine Sensor Interface (6033)
connector for short to power.
After repairs are complete, retest
for SPN 191 FMI 2.

Step Action Decision

5 KOEO, measure voltage at chassis side 21 Way Engine Sensor Yes: Go to step 6.
Interface connector (6033) pins 12 and 13.
No: Repair harness between
Do both pins measure 0 volts? VSS (7600) connector and 21
Way Engine Sensor Interface
(6033) connector for short
to power. After repairs are
complete, retest for SPN 191
FMI 2.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 871

Step Action Decision

6 Do TOSS / VSS Operational Check Without ServiceMaxx™
Software (page 865).
Was voltage above 2 volts AC?
Yes: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Check VSS sensor air gap
or 16 toothed gear and repair
as necessary. After repairs are
complete, retest for SPN 191
FMI 2.

NOTE: After doing all diagnostic steps, if SPN

191 FMI 2 remain verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 872 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 191 FMI 3 TOSS / VSS signal out of range HIGH

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
VSS signal out of range Vehicle speed sensor Time after key On > 0 seconds 0.5 seconds
HIGH voltage
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
vss (7600) connector

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E1 connector (6003) connector
connector (end view)
VSS sensor

e
VSS-H
12 A
~
~
VSS-L
Pin E1 - 15 13 B

0000042186

Figure 344 TOSS / VSS Circuit Diagram

Step Action Decision

1 Inspect connections at VSS sensor. Key OFF, disconnect VSS Yes: Go to step 2.
sensor connector. Check VSS sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Is the VSS sensor connector, harness, and terminal clean and SPN 191 FMI 3.
undamaged.

Step Action Decision

2 Disconnect VSS connector (7600). Key-On Engine-Off (KOEO), Yes: Go to step 3.
measure voltage at VSS connector (7600) pins A & B.
No: Go to step 4.
Do both pins measure 2 to 3 volts?

876
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 873

Step Action Decision

3 Do TOSS / VSS Sensor Continuity Check without ServiceMaxx™ Yes: Check VSS sensor air gap
Software (page 864). or 16 toothed gear and repair
as necessary. After repairs are
Is VSS sensor within specification?
complete, retest for SPN 191
FMI 3.
No: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 3.

Step Action Decision

4 Disconnect 21–Way Engine Sensor Interface connector (6033). Below 2 volts: Repair harness
KOEO, measure voltage at engine side 21 Way Engine Sensor between ECM 96–pin E1
Interface connector (6033) pins 12 and 13. connector and 21 Way
Engine Sensor Interface (6033)
Do both pins measure 2 to 3 volts?
connector for short to ground or
open circuit. After repairs are
complete, retest for SPN 191
FMI 3.

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Yes: Go to step 5.
Above 3 volts: Repair harness
between ECM 96–pin E1
connector and 21 Way
Engine Sensor Interface (6033)
connector for short to power.
After repairs are complete, retest
for SPN 191 FMI 3.

Step Action Decision

5 KOEO, measure voltage at chassis side 21 Way Engine Sensor Yes: Go to step 6.
Interface connector (6033) pins 12 and 13.
No: Repair harness between
Do both pins measure 0 volts? VSS (7600) connector and 21
Way Engine Sensor Interface
(6033) connector for short
to power. After repairs are
complete, retest for SPN 191
FMI 3.

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 874 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Do TOSS / VSS Operational Check Without ServiceMaxx™
Software (page 865).
Was voltage above 2 volts AC?
Yes: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Check VSS sensor air gap
or 16 toothed gear and repair
as necessary. After repairs are
complete, retest for SPN 191
FMI 3.

NOTE: After doing all diagnostic steps, if SPN

191 FMI 3 remain verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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878
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 875

SPN 191 FMI 4 TOSS / VSS signal out of range LOW

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
VSS signal out of range Vehicle speed sensor Time after key On > 0 seconds 0.5 seconds
LOW voltage
Battery voltage > 10.7 volts
Battery voltage < 15 volts

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
vss (7600) connector

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E1 connector (6003) connector
connector (end view)
VSS sensor

e
VSS-H
Pin E 1 - 39 \.._}--+--------l 12 A
~
~
VSS-L
Pin E1 - 15 13 B

0000042186

Figure 345 TOSS / VSS Circuit Diagram

Step Action Decision

1 Inspect connections at VSS sensor. Key OFF, disconnect VSS Yes: Go to step 2.
sensor connector. Check VSS sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Is the VSS sensor connector, harness, and terminal clean and SPN 191 FMI 4.
undamaged.

Step Action Decision

2 Disconnect VSS connector (7600). Key-On Engine-Off (KOEO), Yes: Go to step 3.
measure voltage at VSS connector (7600) pins A & B.
No: Go to step 4.
Do both pins measure 2 to 3 volts?

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 876 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Do TOSS / VSS Sensor Continuity Check without ServiceMaxx™ Yes: Check VSS sensor air gap
Software (page 864). or 16 toothed gear and repair
as necessary. After repairs are
Is VSS sensor within specification?
complete, retest for SPN 191
FMI 4.
No: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 4.

Step Action Decision

4 Disconnect 21–Way Engine Sensor Interface connector (6033). Below 2 volts: Repair harness
KOEO, measure voltage at engine side 21 Way Engine Sensor between ECM 96–pin E1
Interface connector (6033) pins 12 and 13. connector and 21 Way
Engine Sensor Interface (6033)
Do both pins measure 2 to 3 volts?
connector for short to ground or
open circuit. After repairs are
complete, retest for SPN 191
FMI 4.

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Yes: Go to step 5.
Above 3 volts: Repair harness
between ECM 96–pin E1
connector and 21 Way
Engine Sensor Interface (6033)
connector for short to power.
After repairs are complete, retest
for SPN 191 FMI 4.

Step Action Decision

5 KOEO, measure voltage at chassis side 21 Way Engine Sensor Yes: Go to step 6.
Interface connector (6033) pins 12 and 13.
No: Repair harness between
Do both pins measure 0 volts? VSS (7600) connector and 21
Way Engine Sensor Interface
(6033) connector for short
to power. After repairs are
complete, retest for SPN 191
FMI 4.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 877

Step Action Decision

6 Do TOSS / VSS Operational Check Without ServiceMaxx™
Software (page 865).
Was voltage above 2 volts AC?
Yes: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Check VSS sensor air gap
or 16 toothed gear and repair
as necessary. After repairs are
complete, retest for SPN 191
FMI 4.

NOTE: After doing all diagnostic steps, if SPN

191 FMI 4 remain verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 878 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 191 FMI 16 TOSS / VSS reading higher then limit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
TOSS / VSS reading Vehicle speed sensor Time after key on > 0 seconds 0.5 seconds
higher then limit voltage
Battery voltage > 10.7 volts
(Hard-wired)
Battery voltage < 15 volts

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two drive cycles.

Drive Cycle to Determine Fault Status

See 2013 HD-OBD Diagnostic Reference Manual.

VSS circuit

21 -Way
ECM 96- Pin harness interface vss
vss (7600) connector

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E1 connector (6003) connector
connector (end view)
VSS sensor

e
VSS-H
12 A
~
~
VSS-L
Pin E1 - 15 13 B

0000042186

Figure 346 TOSS / VSS Circuit Diagram

Step Action Decision

1 Inspect connections at VSS sensor. Key OFF, disconnect VSS Yes: Go to step 2.
sensor connector. Check VSS sensor and connector terminals
No: Repair connector, harness,
for: damaged or pinched wires; corroded terminals; loose bent, or
or terminal damage. After
broken pins; or broken connector housing.
repairs are complete, retest for
Is the VSS sensor connector, harness, and terminal clean and SPN 191 FMI 16.
undamaged.

Step Action Decision

2 Disconnect VSS connector (7600). Key-On Engine-Off (KOEO), Yes: Go to step 3.
measure voltage at VSS connector (7600) pins A & B.
No: Go to step 4.
Do both pins measure 2 to 3 volts?

882
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 879

Step Action Decision

3 Do TOSS / VSS Sensor Continuity Check without ServiceMaxx™ Yes: Check VSS sensor air gap
Software (page 864). or 16 toothed gear and repair
as necessary. After repairs are
Is VSS sensor within specification?
complete, retest for SPN 191
FMI 16.
No: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 16.

Step Action Decision

4 Disconnect 21–Way Engine Sensor Interface connector (6033). Below 2 volts: Repair harness
KOEO, measure voltage at engine side 21 Way Engine Sensor between ECM 96–pin E1
Interface connector (6033) pins 12 and 13. connector and 21 Way
Engine Sensor Interface (6033)
Do both pins measure 2 to 3 volts?
connector for short to ground or
open circuit. After repairs are
complete, retest for SPN 191
FMI 16.

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Yes: Go to step 5.
Above 3 volts: Repair harness
between ECM 96–pin E1
connector and 21 Way
Engine Sensor Interface (6033)
connector for short to power.
After repairs are complete, retest
for SPN 191 FMI 16.

Step Action Decision

5 KOEO, measure voltage at chassis side 21 Way Engine Sensor Yes: Go to step 6.
Interface connector (6033) pins 12 and 13.
No: Repair harness between
Do both pins measure 0 volts? VSS (7600) connector and 21
Way Engine Sensor Interface
(6033) connector for short
to power. After repairs are
complete, retest for SPN 191
FMI 16.

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 880 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

6 Do TOSS / VSS Operational Check Without ServiceMaxx™
Software (page 865).
Was voltage above 2 volts AC?
Yes: After doing all diagnostic
steps, verify each step was
completed correctly and the
proper decision was made.
Notify supervisor for further
action.
No: Check VSS sensor air gap
or 16 toothed gear and repair
as necessary. After repairs are
complete, retest for SPN 191
FMI 16.

NOTE: After doing all diagnostic steps, if SPN 191

FMI 16 remain verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 881

VREF (Voltage Reference)

SPN FMI Condition Possible Causes Action

3509 14 VREF1 voltage deviation ECM pins: • VREF1 circuit short Pin-Point Tests (page
C1-36 to GND 883)
• VREF1 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF1
circuit
3510 14 VREF2 voltage deviation ECM pins: • VREF2 circuit short Pin-Point Tests (page
E1-85 and E1-86 to GND 884)
• VREF2 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF2
circuit

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3511 14 VREF3 voltage deviation ECM pins: • VREF3 circuit short Pin-Point Tests (page
E1-89 to GND 884)
• VREF3 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF3
circuit
3512 14 VREF4 voltage deviation ECM pins: • VREF4 circuit short Pin-Point Tests (page
C1-37, C1-49, and C2-08, E1-58 to GND 885)
• VREF4 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF4
circuit
• Failed fan clutch

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 882 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

3513 14 VREF5 voltage deviation ECM pins: • VREF5 circuit short Pin-Point Tests (page
C1-50, E1-81, and E1-82 to GND 886)
• VREF5 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF5
circuit
3514 14 VREF6 voltage deviation ECM pin: • VREF6 circuit short Pin-Point Tests (page
E1-88 to GND 887)
• VREF6 circuit short
to PWR
• Failed sensor
causing short to
GND on VREF6
circuit

----H ----
VREF 1 VREF2 VREF 3

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( E1-65 C1-36 )
@O @O
----..
E1-58
VREF4
----C1-37 ----
E1-80
VREF5
----
C1-50 (
VREF6
E1-88 )
E1-91 C1-43
E1-81
C1-49
E1-82
E1-84
C2-08
E1-93
V00163

Figure 347 VREF circuit diagram

Tools Required • Digital Multimeter (DMM)

• 00-00956-08 – 180-Pin Breakout Box • Electronic Service Tool (EST) with ServiceMaxx™
software
• ZTSE4498 – 3-Banana Plug Harness
• J1939 and J1708 RP1210B Compliant Device
• ZTSE4497 – 500 Ohm Resistor Harness
• ZTSE4899 – Big Bore Terminal Test Probe Kit

886
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 883

Voltage Checks for SPN 3509 FMI 14 – VREF1

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF1 for short to PWR.
• If voltage is below 4.3 V, check VREF1 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF1 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage
down.
• If voltage remains below specification after disconnecting all sensors on VREF1 circuit. Go to
Harness Resistance Check (page 883) and look for VREF1 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
C1-36 to GND 5 V ± 0.7 V See Result Comments.

Harness Resistance Check for SPN 3509 FMI 14 – VREF1

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.

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Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF1 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-36 to GND > 1k Ω If < 1k Ω, check for short circuit.

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 884 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Voltage Checks for SPN 3510 FMI 14 – VREF2

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF2 for short to PWR
• If voltage is below 4.3 V, check VREF2 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF2 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage
down.
• If voltage remains below specification after disconnecting all sensors on VREF2 circuit. Go to
Harness Resistance Check (page 884) and look for VREF2 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
E1-85 to GND 5 V ± 0.7 V See Result Comments.
E1-86 to GND 5 V ± 0.7 V See Result Comments.

Harness Resistance Check for SPN 3510 FMI 14 – VREF2

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NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF2 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-85 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-86 to GND > 1k Ω If < 1k Ω, check for short circuit.

Voltage Checks for SPN 3511 FMI 14 – VREF3

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF3 for short to PWR
• If voltage is below 4.3 V, check VREF3 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF3 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage
down.
• If voltage remains below specification after disconnecting all sensors on VREF3 circuit. Go to
Harness Resistance Check (page 885) and look for VREF3 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
E1-89 to GND 5 V ± 0.7 V See Result Comments.

888
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 885

Harness Resistance Check for SPN 3511 FMI 14 – VREF3

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF3 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-89 to GND > 1k Ω If < 1k Ω, check for short circuit.

Voltage Checks for SPN 3512 FMI 14 – VREF4

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF4 for short to PWR.
• If voltage is below 4.3 V, check VREF4 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF4 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage

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down.
• If voltage remains below specification after disconnecting all sensors on VREF4 circuit. Go to
Harness Resistance Check (page 885) and look for VREF4 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
C1-37 to GND 5 V ± 0.7 V See Result Comments.
C1-49 to GND 5 V ± 0.7 V See Result Comments.
C2-08 to GND 5 V ± 0.7 V See Result Comments.
E1-58 to GND 5 V ± 0.7 V See Result Comments.

Harness Resistance Check for SPN 3512 FMI 14 – VREF4

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF4 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-37 to GND > 1k Ω If < 1k Ω, check for short circuit.
C1-49 to GND > 1k Ω If < 1k Ω, check for short circuit.
C2-08 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-58 to GND > 1k Ω If < 1k Ω, check for short circuit.

889
 886 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Voltage Checks for SPN 3513 FMI 14 – VREF5

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF5 for short to PWR
• If voltage is below 4.3 V, check VREF5 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF5 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage
down.
• If voltage remains below specification after disconnecting all sensors on VREF5 circuit. Go to
Harness Resistance Check (page 886) and look for VREF5 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
C1-50 to GND 5 V ± 0.7 V See Result Comments.
E1-81 to GND 5 V ± 0.7 V See Result Comments.
E1-82 to GND 5 V ± 0.7 V See Result Comments.

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Harness Resistance Check for SPN 3513 FMI 14 – VREF5
NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.
Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF5 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
C1-50 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-81 to GND > 1k Ω If < 1k Ω, check for short circuit.
E1-82 to GND > 1k Ω If < 1k Ω, check for short circuit.

890
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 887

Voltage Checks for SPN 3514 FMI 14 – VREF6

NOTE: If circuit fault is intermittent, wiggle harness while measuring voltage.
1. Connect 180-Pin Breakout Box between ECM and engine harness. Use DMM to measure voltage.
Result Comments
• If voltage is above 5.7 V, check VREF6 for short to PWR
• If voltage is below 4.3 V, check VREF6 for short to GND. Go to next step.
2. Disconnect one component at a time on VREF6 circuit.
• If voltage returns within specification, replace the internally shorted sensor that pulled voltage
down.
• If voltage remains below specification after disconnecting all sensors on VREF6 circuit. Go to
Harness Resistance Check (page 887) and look for VREF6 circuit short to GND.
Test Point Specification Comment – < Less than, > Greater than
E1-88 to GND 5 V ± 0.7 V See Result Comments.

Harness Resistance Check for SPN 3514 FMI 14 – VREF6

NOTE: If circuit fault is intermittent, wiggle harness while measuring resistance.

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Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Leave VREF6 sensors disconnected. Use
DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
E1-88 to GND > 1k Ω If < 1k Ω, check for short circuit.

891
 888 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

WIF Sensor (Water In Fuel)

SPN FMI Condition Possible Causes Action

4192 3 WIF signal Out of Range HIGH • WIF circuit short to Pin-Point Diagnostics
PWR (page 889)
4192 4 WIF signal Out of Range LOW • WIF circuit short to Pin-Point Diagnostics
GND (page 889)

WIF circuit
WIF
WIF sensor
connector
ECM 58-Pin WIF (end view)
C2 connector connector

Pin C2-37
v-i-___:_:___
WIF
_ _ _ __ J 2
2

Pin C2-34 ~____:::S'...'..:IG~G~N~D_ _ _ _ _ __j 1

V00036

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Figure 348 WIF circuit diagram

Tools Required • ZTSE4899 – Big Bore Terminal Test Probe Kit

• 00-00956-08 – 180-Pin Breakout Box • Breakout Harness ZTSE6002 (WIF)
• 2010 MaxxForce 11 & 13 Harness Kit • Digital Multimeter (DMM)
00-01462-00
• Electronic Service Tool (EST) with ServiceMaxx™
• ZTSE4498 – 3-Banana Plug Harness software
• ZTSE4497 – 500 Ohm Resistor Harness • J1939 and J1708 RP1210B Compliant Device

892
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 889

Pinpoint Diagnostics With ServiceMaxx™

Software

A WARNING: To prevent personal injury or

death, stay clear of rotating parts (belts and fan)
and hot engine surfaces.
1. Drain a fuel sample from the water drain valve
on the primary fuel filter housing. See Drain
Water from Primary Fuel Filter in the “ENGINE
SYMPTOMS DIAGNOSTICS."
• If water is present, drain all the water out
of the system.
• If no water is present in the fuel sample,
continue to next step.
2. Using Electronic Service Tool (EST)
with ServiceMaxx™ software, open the
Continuous Monitor session.
NOTE: The WIF signal will read YES if there
is water in the fuel filter housing, or if the WIF

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signal circuit is shorted high.
• If DTC is inactive, monitor the signal
while wiggling the connector and all wires
at suspected location. If the circuit is
interrupted, the signal will change from
No to Yes and the DTC will go active.
• If DTC is active, go to the next step.
3. Disconnect engine harness from sensor.
NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.
4. Connect Breakout Harness ZTSE6002 to
engine harness. Leave sensor disconnected.

Voltage Check
Connect Breakout Harness ZTSE6002 to WIF vehicle harness, and leave WIF sensor disconnected. Turn
ignition ON. Use DMM to measure voltage.
Test Point Specification Comment – < Less than, > Greater than
1 to B+ B+ If < B+, check SIG GND circuit for OPEN.
2 to GND 4.6 V If > 5.5 V, check WIF circuit for short to PWR.
If < 4.0 V, check WIF circuit for short to GND.

893
 890 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Connector Resistance Check to GND

Turn ignition switch OFF. Connect Breakout Harness ZTSE6002 to WIF vehicle harness, and leave WIF
sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to GND <5Ω If > 5 Ω, check SIG GND for OPEN circuit.
2 to GND > 1k Ω If < 1k Ω, check WIF circuit for short to GND.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-Pin Breakout Box with ECM C1 and C2 harness to ECM C1 and
C2 vehicle harness connectors, and leave ECM disconnected. Connect Breakout Harness ZTSE6002 to
WIF vehicle harness, and leave WIF sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment – < Less than, > Greater than
1 to C2-34 <5Ω If > 5 Ω, check for OPEN circuit.
2 to C2-37 <5Ω If > 5 Ω, check for OPEN circuit.

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894
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 891

WIFL (Water In Fuel Lamp)

SPN FMI Condition Possible Causes Actions

97 3 WIFL short to PWR • WIFL circuit short to Step-Based
PWR Diagnostics (page
892)
• Failed WIFL
97 4 WIFL short to GND • WIFL circuit short to Step-Based
GND Diagnostics (page
893)
• Failed WIFL
97 5 WIFL Open load / circuit • WIFL circuit open Step-Based
Diagnostics (page
• Failed WIFL
895)

WIFL circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector Water in fuel
(190) lamp connector
(1456)

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Pin C2 - 14 c l---+-_,_W,._,_l,_,FL=------ S 1-----------,

Engine / Dash
connector (190) Fuse F10 - D IGN adapter
(Located on dash panel) (464M) (494M)

0000045757

Figure 349 WIFL Circuit Diagram (PayStar)

Overview • Electronic Service Tool (EST) with ServiceMaxx™

software
The Water-in-Fuel Lamp (WIFL) informs the operator
when the fuel / water separator is getting full of water. • J1939 and J1708 RP1210B Compliant Device
Water must be drained from the separator to protect
the fuel system from contamination.
Tools Required
• Digital Multimeter (DMM)

895
 892 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 97 - FMI 3 - WIFL short to PWR

WIFL circuit (PayStar)

ECM connector 2 Engine/ Dash

(6019) connector Water in fuel
(190) lamp connector
(1456)
Pin C2 - 14 t >----+~W~l~F=L--------1 S 1------------11

Engine / Dash
connector (190) Fuse F10 - D IGN adapter
(Located on dash panel) (464M) (494M)

0000045757

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Figure 350 WIFL Circuit Diagram (PayStar)

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 97 FMI 3 the only fault code active? After repairs are complete, retest
for SPN 97 FMI 3.

Step Action Decision

2 Measure for short to power on engine side of WIFL circuit. Yes: Replace Water in Fuel
Disconnect WIFL connector (1456) located in the vehicle Lamp. After repairs are
instrument panel (see WIFL Circuit Diagram and vehicle Electrical complete, retest for SPN 97 FMI
Circuit Diagrams manual for additional details). Key ON, measure 3.
voltage at pin B of connector (1456).
No: Repair short to power
Is voltage less than 4.2 volts? between WIFL connector (1456)
pin B and ECM 58-pin connect
C2 pin 14. After repairs are
complete, retest for SPN 97 FMI
3.

NOTE: After doing all diagnostic steps, if SPN 97

FMI 3 remains verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

896
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 893

SPN 97 - FMI 4 - WIFL short to GND

WIFL circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector Water in fuel
(190) lamp connector
(1456)
Pin C2 - 14 t }---+---'-W'-'-IF,....,L=----------, s 1-----------1

Engine / Dash
connector (190) Fuse F10 - D IGN adapter
(Located on dash panel) (464M) (494M)

0000045757

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Figure 351 WIFL Circuit Diagram (PayStar)

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 97 FMI 4 the only fault code active? After repairs are complete, retest
for SPN 97 FMI 4.

Step Action Decision

2 Measure engine side of WIFL circuit for short to ground. Yes: Go to step 3.
Disconnect WIFL connector (1456) located in the vehicle
No: Repair short to ground
instrument panel (see WIFL Circuit Diagram and vehicle Electrical
between WIFL connector (1456)
Circuit Diagrams for additional details). Key OFF, measure
pin B and ECM 58-pin connector
resistance between pin B of connector (1456) and a known good
C2 pin 14. After repairs are
ground.
complete, retest for SPN 97 FMI
Is resistance greater than 1000 ohms? 4.

897
 894 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

3 Measure vehicle side of WIFL circuit for short to ground. Key Yes: Replace Water in Fuel
OFF, measure resistance between pin A of connector (1456) and Lamp.
a known good ground.
No: Repair short to ground
Is resistance greater than 1000 ohms? between WIFL connector
(1456) pin A and vehicle wiring
(see WIFL Circuit Diagram
and vehicle Electrical Circuit
Diagrams for additional details)
. After repairs are complete,
retest for SPN 97 FMI 4.

NOTE: After doing all diagnostic steps, if SPN 97

FMI 4 remains verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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898
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 895

SPN 97 - FMI 5 - WIFL open / load circuit

WIFL circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector Water in fuel
(190) lamp connector
(1456)
Pin C2 - 14 t }---+---'-W'-'-IF,....,L=----------, s 1-----------1

Engine / Dash
connector (190) Fuse F10 - D IGN adapter
(Located on dash panel) (464M) (494M)

0000045757

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Figure 352 WIFL Circuit Diagram (PayStar)

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 97 FMI 5 the only fault code active? After repairs are complete, retest
for SPN 97 FMI 5.

Step Action Decision

2 Check 15 amp fuse F10-D (464M) (see vehicle Electrical Circuit Yes: Go to step 3.
Diagrams for additional details).
No: Replace 15 amp fuse
Is fuse in good condition and not blown (Open)? F10–D (464M). After repairs are
complete, retest for SPN 97 FMI
5.

Step Action Decision

3 Test vehicle side of circuit for Open. Key OFF, disconnect WIFL Yes Go to step 4.
connector (1456) located in the vehicle instrument panel (see
No: Repair Open or high
vehicle Electrical Circuit diagrams for additional details). Key ON,
resistance between WIFL
measure voltage at pin A of connector (1456).
connector pin A and vehicle
Is voltage 12 volts or greater while the WIFL circuit is activated? wiring (see WIFL Circuit Diagram
and vehicle Electrical Circuit
Diagrams for additional details).
After repairs are complete, retest
for SPN 97 FMI 5.

899
 896 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Step Action Decision

4 Measure engine side of WIFL circuit for Open. Key OFF, Yes: Repair open or high
disconnect Engine Control Module (ECM) C2 connector. Measure resistance in circuit between
resistance between ECM connector C2 pin 14 and WIFL ECM connector C2 pin 14 and
connector pin B. WIFL connector pin B.
Is resistance more than 5 ohms? No: Replace Water in Fuel
Lamp. After repairs are
complete, retest for SPN 97 FMI
5.

NOTE: After doing all diagnostic steps, if SPN 97

FMI 5 remains verify each step was completed
correctly and the proper decision was made.
Notify supervisor for further action.

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900
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 897

WTSL (Wait to Start Lamp)

SPN FMI Condition Possible Causes Actions

1081 3 WTSL circuit short to PWR • Failed WTSL Step-Based
Diagnostics (page
• WTSL circuit shorted to
898)
PWR
1081 4 WTSL circuit short to GND • Failed WTSL Step-Based
Diagnostics (page
• WTSL circuit shorted to
900)
GND
1081 5 WTSL open load/circuit • Failed WTSL Step-Based
Diagnostics (page
• Fuse blown / open
902)
• WTSL circuit OPEN

WTS circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector
(190) Wait to start lamp

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(1455)

Pin C2 - 15 l r--+--'--'W,....,T_,,,S'--------, s ,________.

Engine / Dash
connector (190) Fuse F10- D IGN adapter
(Located on dash panel) (464M) (494M)
7

Water in fuel
(1456)

0000042224

Figure 353 WTSL Circuit Diagram

Overview lamp stops flashing, the IAHFI and the IAHS valve
are deactivated. If the operator accelerates while
The wait-to-start lamp illuminates when the ignition
the wait-to-start lamp is flashing, the inlet air heater
switch is turned ON. For Engine Coolant Temperature
system will shutdown.
(ECT) lower than 50°F (10°C), the Engine Control
Module (ECM) activates the Inlet Air Heater Relay Tools Required
(IAHR). The IAHR then energizes the Inlet Air Heater
• Electronic Service Tool (EST) with ServiceMaxx™
Fuel Igniter (IAHFI) for approximately 35 seconds.
software
Once the IAHFI is heated, the wait-to-start lamp
starts to flash and the engine is ready to be started. • J1939 and J1708 RP1210B Compliant Device
Once the engine starts, the IAHFI remains energized
• Digital Multimeter (DMM)
and the wait-to-start lamp continues to flash for a
maximum of four minutes. When the wait-to-start

901
 898 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1081 - FMI 3 - WTSL circuit short to PWR

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Wait to Start Lamp ECM indicates short to Battery voltage > 10.7 volts 0.5 seconds
(WTSL) circuit short to battery
Battery voltage < 15 volts
power.
Key On

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

WTS circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector
(190) Wait to start lamp
(1455)

Pin C2 - 15 l J--+-..,__W,_,T....,,S'---------, s 1-----------<

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Engine / Dash
connector (190) Fuse F10- D IGN adapter
(Located on dash panel) (464M) (494M)
7

Water in fuel
(1456)

0000042224

Figure 354 WTSL Circuit Diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 1081 FMI 3 the only fault code active? After repairs are complete, retest
for SPN 1081 FMI 3.

902
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 899

Step Action Decision

2 Measure for short to power on engine side of WTSL circuit. Yes: Replace Wait to Start Lamp.
Disconnect WTSL connector (1455) located in the vehicle After repairs are complete, retest
instrument panel (see WTSL Circuit Diagram and vehicle Electrical for SPN 1081 FMI 3.
Circuit Diagrams manual for additional details). Key ON, measure
No: Repair short to power
voltage at pin B of connector (1455).
between WTSL connector
Is voltage less than 4.2 volts? (1455) pin B and ECM 58–pin
connector C2 pin 15. After
repairs are complete, retest for
SPN 1081 FMI 3.

NOTE: After doing all diagnostic steps, if

SPN 1081 FMI 3 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

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903
 900 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1081 - FMI 4 - WTSL circuit short to GND

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Wait to Start Lamp ECM indicates short to Battery voltage > 10.7 volts 0.5 seconds
(WTSL) circuit short to ground
Battery voltage < 15 volts
ground.
Key On

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

WTS circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector
(190) Wait to start lamp
(1455)

Pin C2 - 15 l J--+-..,__W,_,T....,,S'---------, s 1-----------<

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Engine / Dash
connector (190) Fuse F10- D IGN adapter
(Located on dash panel) (464M) (494M)
7

Water in fuel
(1456)

0000042224

Figure 355 WTSL Circuit Diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 1081 FMI 4 the only fault code active? After repairs are complete, retest
for SPN 1081 FMI 4.

904
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 901

Step Action Decision

2 Measure engine side of WTSL circuit for short to ground. Yes: Go to step 3.
Disconnect WTSL connector (1455) located in the vehicle
No: Repair short to ground
instrument panel (see vehicle Electrical Circuit Diagrams for
between WTSL connector
additional details). Key OFF, measure resistance between pin B
(1455) pin B and ECM 58–pin
of connector (1455) and a known good ground.
connector C2 pin 15. After
Is resistance greater than 1000 ohms? repairs are complete, retest for
SPN 1081 FMI 4.

Step Action Decision

3 Measure vehicle side of WTSL circuit for short to ground. Key Yes: Replace Wait to Start Lamp.
OFF, measure resistance between pin A of connector (1455) and After repairs are complete, retest
a known good ground. for SPN 1081 FMI 4.
Is resistance greater than 1000 ohms? No: Repair short to ground
between WTSL connector
(1455) pin A and vehicle wiring
(see WTSL Circuit Diagram
and vehicle Electrical Circuit
Diagrams for additional details).

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After repairs are complete, retest
for SPN 1081 FMI 4.

NOTE: After doing all diagnostic steps, if

SPN 1081 FMI 4 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

905
 902 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

SPN 1081 - FMI 5- WTSL open load / circuit

Condition / Setting Criteria Enable Conditions / Values Time Required
Description
Wait to Start Lamp ECM indicates no load Battery voltage > 10.7 volts 0.5 seconds
(WTSL) circuit open.
Battery voltage < 15 volts
Key On

Malfunction Indicator Lamp (MIL) Reaction

MIL will illuminate when this fault is detected during
two consecutive drive cycles.

WTS circuit (PayStar)

ECM connector 2 Engine / Dash

(6019) connector
(190) Wait to start lamp
(1455)

Pin C2 - 15 l J--+-..,__W,_,T....,,S'---------, s 1-----------<

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Engine / Dash
connector (190) Fuse F10- D IGN adapter
(Located on dash panel) (464M) (494M)
7

Water in fuel
(1456)

0000042224

Figure 356 WTSL Circuit Diagram

Step Action Decision

1 Using Electronic Service Tool (EST) with ServiceMaxx™ software, Yes: Go to step 2.
check for other fault codes.
No: Repair other fault code(s).
Is SPN 1081 FMI 5 the only fault code active? After repairs are complete, retest
for SPN 1081 FMI 5.

Step Action Decision

2 Check 15 amp fuse F10-D (464M) (see vehicle Electrical Circuit Yes: Go to step 3.
Diagrams for additional details).
No: Replace 15 amp fuse
Is fuse in good condition and not blown (Open)? F10-D (464M). After repairs are
complete, retest for SPN 1081
FMI 5.

906
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 903

Step Action Decision

3 Test vehicle side of circuit for Open. Key OFF, disconnect WTSL Yes: Go to step 4.
connector (1455) located in the vehicle instrument panel (see
No: Repair Open or high
vehicle Electrical Circuit Diagrams for additional details). Key ON,
resistance between WTSL
measure voltage at pin A of connector (1455).
connector pin A and vehicle
Is voltage 12 volts or greater while the WTSL circuit is activated? wiring (see WTSL Circuit
Diagram and vehicle Electrical
Circuit Diagrams for additional
details). After repairs are
complete, retest for SPN 1081
FMI 5.

Step Action Decision

4 Measure engine side of WTSL circuit for Open. Key OFF, Yes: Repair open or high
disconnect Engine Control Module (ECM) C2 connector. Measure resistance in circuit between
resistance between ECM connector C2 pin 15 and WTSL ECM connector C2 pin 15 and
connector pin B. WTSL connector pin B. After
repairs are complete, retest for
Is resistance more than 5 ohms?
SPN 1081 FMI 5.

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No: Replace Wait to Start Lamp.
After repairs are complete, retest
for SPN 1081 FMI 5.

NOTE: After doing all diagnostic steps, if

SPN 1081 FMI 5 remains verify each step was
completed correctly and the proper decision was
made. Notify supervisor for further action.

907
 904 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

Sensor and Actuator Locations

Engine Mounted Components

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Figure 357 Component location – right side/front
1. Humidity Sensor (HS) / Inlet Air 7. Inlet Air Heater Fuel Igniter 11. Turbocharger 2 Compressor
Temperature (IAT) (IAHFI) Inlet Sensor (TC2CIS)
2. Mass Air Flow (MAF) sensor 8. Engine Oil Temperature (EOT) 12. Exhaust Back Pressure Valve
3. Air Control Valve (ACV) sensor (behind the CCV in oil (EBPV)
assembly module flange) 13. Oxygen Sensor (O2S)
4. Engine Coolant Temperature 2 9. Coolant Control Valve (CCV)
(ECT2) sensor assembly (CCV contains CMV
5. Crankcase Oil Separator Speed and CFV)
(CCOSS) sensor 10. Engine Oil Pressure (EOP)
6. Exhaust Gas Recirculation sensor
Temperature (EGRT) sensor

908
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 905

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Figure 358 Component location – left side/rear
1. Charger Air Cooler Outlet 7. Exhaust Gas Recirculation 14. Fuel Delivery Pressure (FDP)
Temperature (CACOT) sensor (EGR) valve sensor
2. Intake Manifold Pressure (IMP) 8. Camshaft Position (CMP) sensor 15. Fuel Pressure Control Valve
sensor 9. Engine Coolant Temperature (FPCV) (at back of high-pressure
3. Inlet Air Heater Solenoid (ECT1) sensor fuel pump)
(IAHFS) 10. Oxygen Sensor (O2S) connector 16. Fuel Rail Pressure (FRP) sensor
4. Engine Control Module (ECM) 11. Crankshaft Position (CKP) (behind ECM, at front of fuel rail)
with Barometric Pressure sensor 17. Engine Throttle Valve (ETV)
(BARO) internal sensor 12. Engine Oil level (EOL) sensor
5. Inlet Air Heater Relay (IAHR) 13. Downstream Injection (DSI) (DSI
6. Intake Manifold Temperature unit contains AFTFD, AFTFIS,
(IMT) sensor AFTFP2, and AFTFSV sensors)

909
 906 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

AFT System

V00144

Figure 359 AFT System Operation

1. Diesel Oxidation Catalyst Inlet 3. Diesel Oxidation Catalyst Outlet 5. Diesel Particulate Filter
Temperature (DOCIT) Temperature (DOCOT) Differential Pressure (DPFDP)

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2. Diesel Oxidation Catalyst (DOC) 4. Diesel Particulate Filter (DPF) 6. Diesel Particulate Filter Outlet
Temperature (DPFOT)

910
 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 907

Engine Compression Brake Locations

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Figure 360
1.
Engine Compression Brake (Solenoid Assembly)
Engine Compression Brake 1
(ECB1)
2. Engine Compression Brake 2
(ECB2)

Vehicle Mounted Components The APP sensor is mounted on the accelerator pedal.
Accelerator Pedal Position Sensor
Ambient Air Temperature Sensor
. . . ~

The AAT is mounted in various cab locations,

··t-~ depending on vehicle configuration.

.,, '\'· I'; .,<

...
,,,p,,,,:,~
,:_::,-.,:,,,_:;;.,,f.><·,·;.._ ,,.
~f)"~·
i.\ )\ (, -
..-,, . -, • ..•.![, ·\•h,,,,..,e• .,. . ·. ' ' < -,, ._
.;,~''2J~•'··i,i..-•,·•~· '-~ . ' .•

,~Iii~~-
Figure 361
sensor
Accelerator Pedal Position (APP)

911
 908 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS

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912
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 909

Table of Contents

Electrical Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911

180-Pin Breakout Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
3-Banana Plug Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
500 Ohm Resistor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .912
Electronic Engine Terminal Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .912
Big Bore Terminal Test Probe Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .912
Digital Multimeter (DMM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913
EXP-1000 HD by Midtronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913
®
EZ-Tech Electronic Service Tool (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
ServiceMaxx™ Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
Interface cable (RP1210B compliant supporting J1939 and J1708). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
®
MaxxForce 11 and 13 Engine Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
Breakout Harness 4485A (APP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915
Breakout Harness 4602 (AFTFSV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915
Breakout Harness 4735A (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915
Breakout Harness 4760A (DOCIT, DOCOT, DPFOT, and EGRT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915

BetterManuals.net
Breakout Harness 4761A (DPFDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
Breakout Harness 4827 (IAHFS, ECT1, ECT2, EOL, and EOT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
Breakout Harness 4828 (AFTFD and FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
Breakout Harness 4829 (FRP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
Breakout Harness 4830 (AFTFIS, HS/IAT, and TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
Breakout Harness 4844 (EFAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
Breakout Harness 4850 (IMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
Breakout Harness 4870 (CMV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .917
Breakout Harness 4871 (AAT and CFV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
Breakout Harness 4881 (FDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
Breakout Harness 4882 (EOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
Breakout Harness 4883 (IMT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
Breakout Harness 4885 (IAHR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
Breakout Harness 4951 (CCOSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
Breakout Harness 4993 (CACOT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
Breakout Harness 6002 (WIF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
Breakout Harness 6003 (EBPV, TC1TOP, TC1WC, and TC2WC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .920
Breakout Harness 6004 (ECB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .920
Breakout Harness 6016 (ETV and EGR Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .920
Breakout Harness 6021 (CKP and CMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .920
Breakout Harness 6027 (AFTFP2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .921

Mechanical Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922

Air Cap, Fuel Cap and Plug Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922
Air Compressor Coolant Line Release Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922
Air Intake Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922
Blow-by Test Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923
Clean Fuel Source Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923
Inlet Air Heater Solenoid Test Adapter Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924
Digital Manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924

913
 910 8 DIAGNOSTIC TOOLS AND ACCESSORIES

EGR Cooler Leak Detection Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925

Lash Gauge (0.50mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925
Lash Gauge (0.80mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925
Fuel Block Off Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925
Fuel Injector Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926
Fuel Inlet Restriction and Aeration Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926
Fuel Line Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926
Fuel Line Disconnect Tool 11.8 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926
Fuel Line Disconnect Tool 16 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .927
Fuel Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .927
High Pressure Rail Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .928
High Pressure Return Line Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .928
Pressure Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .928
Radiator Pressure Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929
®
Slack Tube Manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929
UV Leak Detection Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .930

BetterManuals.net

914
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 911

Electrical Tools This box is universal and can adapt to any control
system by means of a unique jumper harness. Each
180-Pin Breakout Box
jumper harness is a separate part, complete with a
180-Pin Breakout Box overlay (pin identifier) sheet.
The standard box layout is as follows:
• Two 90-pin connectors which feed 90 banana plug
probing points.
• Each 90-pin section of the box is basically a
INTERNATIONAL TRUCK AND ENGINE CORPORATION
stand-alone box.

180 PIN DIAGNOSTIC • The top row is all fuse protected circuits, the
BREAKOUT BOX second row is all twisted pair circuits.

_,_....,.. __ 3-Banana Plug Harness

BetterManuals.net M31166
ZTSE4498
Figure 362 00-00956-08
Figure 363 ZTSE4498

The 180-Pin Breakout Box allows testing of electronic

control system components without disturbing The 3-Banana Plug Harness is used for sensor end
connections or piercing wire insulation to access diagnostics of sensor circuits.
various signal voltages in the electronic control
system.
CAUTION: To prevent damage to the 180-Pin
Breakout Box, the 180-Pin Breakout Box is used for
measurement only, not to activate or control circuits.
High current passing through the 180-Pin Breakout
Box will burn out the internal circuitry.

915
 912 8 DIAGNOSTIC TOOLS AND ACCESSORIES

500 Ohm Resistor Harness The Electronic Engine Terminal Test Kit is used to
access circuits in the connector harness and allows
for the use of a DMM without damaging the harness
connectors.

Big Bore Terminal Test Probe Kit

ZTSE4497

Figure 364 ZTSE4497

BetterManuals.net
The 500 Ohm Resistor Harness is used for sensor
end diagnostics of sensor circuits, and for performing
loaded circuit tests. ZTSE4899

Figure 366 ZTSE4899

Electronic Engine Terminal Test Kit

The terminal test probe kit is used to access circuit

in the connector harness and allows for the use of a
DMM without damaging the harness connectors.

ZTSE4899

Figure 365 ZTSE4435C

916
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 913

Digital Multimeter (DMM) EXP-1000 HD by Midtronics

BetterManuals.net
Figure 367 ZTSE4357
ZTSE4357

Figure 368 EXP-1000 HD INTL

The DMM is used to troubleshoot electrical

The EXP-1000 HD by Midtronics is used to measure
components, sensors, injector solenoids, relays,
current draw for the inlet air heater system.
and wiring harnesses. The DMM has a high input
impedance that allows testing of sensors while the
engine is running, without loading the circuit being
tested. This ensures the signal voltage measurement
will not be affected by the voltmeter.

917
 914 8 DIAGNOSTIC TOOLS AND ACCESSORIES

® ®
EZ-Tech Electronic Service Tool (EST) MaxxForce 11 and 13 Engine Tool Kit

ZTSE4904

Figure 370 ZTSE4904

The Breakout Harness Kit contains the following:

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• Breakout Harness 4485A
• Breakout Harness 4735A
• Breakout Harness 4760A
• Breakout Harness 4761A
Figure 369 Electronic Service Tool (EST) • Breakout Harness 4827
(typical)
• Breakout Harness 4828
• Breakout Harness 4830
The EST is used to run ServiceMaxx™ software for
diagnosing and troubleshooting engine and vehicle • Breakout Harness 4833
problems. • Breakout Harness 4834
• Breakout Harness 4844
ServiceMaxx™ Software • Breakout Harness 4850
ServiceMaxx™ software, loaded to an EST or laptop • Breakout Harness 4870
computer, is used to check performance of engine
systems, diagnose engine problems, and store • Breakout Harness 4871
troubleshooting history for an engine. • Breakout Harness 4881
• Breakout Harness 4882
Interface cable (RP1210B compliant supporting • Breakout Harness 4883
J1939 and J1708)
• Breakout Harness 4885
The Interface cable (RP1210B compliant supporting
J1939 and J1708) is used to connect the EST to the
vehicle. It is available from various suppliers.

918
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 915

Breakout Harness 4485A (APP) Breakout Harness 4735A (O2S)

ZTSE4485A
Figure 373 ZTSE4735A
Figure 371 ZTSE4485A

Breakout Harness 4735A is used to measure voltage

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Breakout Harness 4485A is used to measure voltage and resistance on circuits connected to the Oxygen
and resistance on circuits that go to the Accelerator Sensor (O2S).
Pedal Position (APP) sensor.

Breakout Harness 4760A (DOCIT, DOCOT, DPFOT,

Breakout Harness 4602 (AFTFSV) and EGRT)

Figure 374 ZTSE4760A

ZTSE4602
Breakout Harness 4760A is used to measure voltage
Figure 372 ZTSE4602 and resistance on circuits that go to the Diesel
Oxidation Catalyst Inlet Temperature (DOCIT), Diesel
Oxidation Catalyst Outlet Temperature (DOCOT),
Breakout Harness 4602 is used to measure voltage Diesel Particulate Filter Outlet Temperature (DPFOT),
and resistance on circuits that go to the Aftertreatment and Exhaust Gas Recirculation Temperature (EGRT)
Fuel Shutoff Valve (AFTFSV). sensors.

919
 916 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness 4761A (DPFDP) Breakout Harness 4828 (AFTFD and FPCV)

ZTSE4761A

Figure 375 ZTSE4761A

Breakout Harness 4761A is used to measure voltage ZTSE4828

and resistance on circuits that go to the Diesel
Particulate Filter Differential Pressure (DPFDP) Figure 377 ZTSE4828
sensor.
Breakout Harness 4828 is used to measure
voltage and resistance on circuits connected to

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Breakout Harness 4827 (IAHFS, ECT1, ECT2,
EOL, and EOT) the Aftertreatment Fuel Doser (AFTFD) and Fuel
Pressure Control Valve (FPCV) .

Breakout Harness 4829 (FRP)

ZTSE4827

Figure 376 ZTSE4827

ZTSE4829
Breakout Harness 4827 is used to measure voltage Figure 378 ZTSE4829
and resistance on circuits connected to the Inlet
Air Heater Fuel Solenoid (IAHFS), Engine Coolant
Temperature 1 (ECT1), Engine Coolant Temperature Breakout Harness 4829 is used to measure voltage
2 (ECT2), Engine Oil Level (EOL), and Engine Oil and resistance on circuits connected to the Fuel Rail
Temperature (EOT) sensors. Pressure (FRP) sensor.

920
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 917

Breakout Harness 4830 (AFTFIS, HS/IAT, and Breakout Harness 4850 (IMP)
TC2CIS)

Figure 381 ZTSE4850

ZTSE4830
Breakout Harness 4850 is used to measure voltage
Figure 379 ZTSE4830 and resistance on circuits connected to the Intake
Manifold Pressure (IMP) sensor.

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Breakout Harness 4830 is used to measure
voltage and resistance on circuits connected to Breakout Harness 4870 (CMV)
the Aftertreatment Fuel Inlet Sensor (AFTFIS),
Humidity/Inlet Air Temperature (HS/IAT) sensor, and
Turbocharger 2 Compressor Inlet Sensor (TC2CIS).

Breakout Harness 4844 (EFAN)

ZTSE4870

Figure 382 ZTSE4870

Breakout Harness 4870 is used to measure voltage

ZTSE4844 and resistance on circuits connected to the Coolant
Mixer Valve (CMV).
Figure 380 ZTSE4844

Breakout Harness 4844 is used to measure voltage

and resistance on circuits connected to the variable
Electronic Fan (EFAN) control .

921
 918 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness 4871 (AAT and CFV) Breakout Harness 4882 (EOP)

ZTSE4871 ZTSE4882

Figure 383 ZTSE4871 Figure 385 ZTSE4882

Breakout Harness 4871 is used to measure voltage Breakout Harness 4882 is used to measure voltage
and resistance on circuits connected to the Ambient

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and resistance on circuits connected to the Engine Oil
Air Temperature (AAT) sensor and Coolant Flow Valve Pressure (EOP) sensor.
(CFV).

Breakout Harness 4881 (FDP) Breakout Harness 4883 (IMT)

ZTSE4881 ZTSE4883

Figure 384 ZTSE4881 Figure 386 ZTSE4883

Breakout Harness 4881 is used to measure voltage Breakout Harness 4883 is used to measure voltage
and resistance on circuits connected to the Fuel and resistance on circuits connected to the Intake
Delivery Pressure (FDP) sensor. Manifold Temperature (IMT) sensor.

922
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 919

Breakout Harness 4885 (IAHR) Breakout Harness 4951 is used to measure voltage
and resistance on circuits connected to the Crankcase
Oil Separator Speed (CCOSS) sensor.

Breakout Harness 4993 (CACOT)

ZTSE4885 ZTSE4993

Figure 387 ZTSE4885 Figure 389 ZTSE4993

Breakout Harness 4885 is used to measure voltage Breakout Harness 4993 is used to measure voltage

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and resistance on circuits connected to the Inlet Air and resistance on circuits that go to the Charge Air
Heater Relay (IAHR). Cooler Outlet Temperature (CACOT) sensor.

Breakout Harness 4951 (CCOSS) Breakout Harness 6002 (WIF)

ZTSE6002

Figure 390 ZTSE6002

ZTSE4951 Breakout Harness 6002 is used to measure voltage

and resistance on circuits that go to the Water In Fuel
Figure 388 ZTSE4951 (WIF) sensor.

923
 920 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness 6003 (EBPV, TC1TOP, TC1WC, Breakout Harness 6016 (ETV and EGR Valve)
and TC2WC)

ZTSE6016

Figure 393 ZTSE6016

ZTSE6003
Breakout Harness 6016 is used to measure voltage
Figure 391 ZTSE6003 and resistance on circuits that go to the Engine
Throttle Valve (ETV) and EGR valve.
Breakout Harness 6003 is used to measure voltage
and resistance on circuits that go to the Exhaust Breakout Harness 6021 (CKP and CMP)
Back Pressure Valve (EBPV), Turbocharger 1 Turbine
Outlet Pressure (TC1TOP) sensor, Turbocharger 1

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Wastegate Control (TC1WC), and Turbocharger 2
Wastegate Control (TC2WC).

Breakout Harness 6004 (ECB)

• - Figure 394 ZTSE6021

ZTSE6021

Breakout Harness 6021 is used to measure voltage

ZTSE6004 and resistance on circuits that go to the Crankshaft
Position (CKP) and Camshaft Position (CMP)
Figure 392 ZTSE6004 sensors.

Breakout Harness 6004 is used to measure voltage

and resistance on circuits that go to the Engine
Compression Brake (ECB).

924
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 921

Breakout Harness 6027 (AFTFP2) Breakout Harness 6027 is used to measure voltage
and resistance on circuits that go to the Aftertreatment
Fuel Pressure 2 (AFTFP2) sensor.

ZTSE6027

Figure 395 ZTSE6027

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925
 922 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Mechanical Tools Air Compressor Coolant Line Release Tool releases

the locking mechanism to allow the removal of the
Air Cap, Fuel Cap and Plug Kit
coolant line on the air compressor.

Air Intake Guard

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Figure 396 ZTSE4891

ZTSE4891 'f,''"'''''
f
ZTSE4893

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The Disposable Air and Fuel Caps are used to cap Figure 398 ZTSE4893
the fuel system lines and fittings when the fuel system
is disconnected for diagnostics. The Disposable Air
and Fuel Caps prevent dirt and foreign particles from The Air Intake Guard is used to protect the
entering and contaminating the fuel system. turbochargers while performing diagnostics with the
air cleaner disconnected.

Air Compressor Coolant Line Release Tool

ZTSE4778

Figure 397 ZTSE4778

926
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 923

Blow-by Test Tool Clean Fuel Source Tool

ZTSE4039

Figure 399 ZTSE4039 (0.406 in. diameter)

1. To magnehelic gauge or manometer
2. To valve cover
Figure 400 15-637-01

The Blow-by Test Tool is used to measure combustion

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gas flow from the crankcase oil separator and may be The Clean Fuel Source Tool is used to provide a clean,
®
used with the digital or Slack Tube manometer. alternative fuel source to aid in the diagnosis of the fuel
Use the pressure readings obtained with this adapter system.
as the main source of engine condition. Use oil
consumption trend data if the pressure readings
are over the specified limits. Neither changes in
oil consumption trends nor crankcase diagnostic
pressure trends can establish a specific problem.
These changes only indicate that a problem exists.

927
 924 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Inlet Air Heater Solenoid Test Adapter Kit Digital Manometer

ZTSE6059-1

Figure 401 ZTSE6059-1

ZTSE6059-2

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Figure 402 ZTSE6059-2

The Inlet Air Heater Solenoid Test Adapter Kit is used

with the Fuel Pressure Gauge to test fuel pressure at
the Inlet Air Heater Fuel Igniter (IAHFI) and Inlet Air
Heater Fuel Solenoid (IAHFS).
k35211

Figure 403 Obtain locally

The Digital Manometer is used to measure low

vacuum due to intake restriction or low crankcase
pressure. A variety of digital manometers are
available for purchase locally. The Water Manometer
kit (ZTSE2217A) is an alternative to the Digital
Manometer.

928
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 925

EGR Cooler Leak Detection Test Kit This tool is used to measure intake valve lash.

Lash Gauge (0.80mm)

0000290801

Figure 406 ZTSE6076-7A

This tool is used to measure exhaust valve lash.

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Fuel Block Off Tool

Figure 404 12-892-02

The EGR Cooler Leak Detection Test Kit is used to

pressure test the EGR cooler to check for leaks.
ZTSE4905

Lash Gauge (0.50mm) Figure 407 ZTSE4905

The Fuel Block Off Tool is used to block the

T-connector fuel line at the high pressure pump in
order to measure the low pressure pump output
pressure.
Figure 405 ZTSE6076-5A

929
 926 8 DIAGNOSTIC TOOLS AND ACCESSORIES

Fuel Injector Cups The Fuel Inlet Restriction and Aeration Tool is used
to check for pressure and aerated fuel in the low fuel
pressure system.

Fuel Line Coupler

ZTSE4906

Figure 410 ZTSE4906

The Fuel Line Coupler is used in conjunction with the

Fuel Inlet Restriction and Aeration Tool to measure the
fuel pressure in the return line.

Fuel Line Disconnect Tool 11.8 mm

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Figure 408 ZTSE4892

Fuel Injector Cups protects and prevents dirt and

debris from damaging the injectors while out of the
engine.

Fuel Inlet Restriction and Aeration Tool

ZTSE4773

Figure 411 ZTSE4773

The Fuel Line Disconnect Tool 11.8 mm is used to

release the locking mechanism on low pressure fuel
line connectors.

ZTSE4886

Figure 409 ZTSE4886

930
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 927

Fuel Line Disconnect Tool 16 mm Fuel Pressure Gauge

ZTSE4772

Figure 412 ZTSE4772

The Fuel Line Disconnect Tool 16 mm is used to ZTSE4681

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release the locking mechanism on low pressure fuel
line connectors. Figure 413 ZTSE4681
1. Quick disconnect check valve
2. Fuel test line
3. Fuel Pressure Gauge
4. Inline shut-off valve
5. Clear test line

The Fuel Pressure Gauge is used to check for fuel

pressure and aerated fuel in the low fuel pressure
system.

931
 928 8 DIAGNOSTIC TOOLS AND ACCESSORIES

High Pressure Rail Plugs The High Pressure Return Line Tester is used to check
for fuel returning from the pressure pipe rail or from
the cylinder head fuel return port. Tool consists of
two adapters, ZTSE4887-1 (17mm) and ZTSE4887-2
(19mm), and hose ZTSE4887-3.

Pressure Test Kit

ZTSE6098

Figure 414 ZTSE6098

The High Pressure Rail Plugs are used to isolate

ZTSE4409
individual injectors by blocking the pressure pipe rail

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output. Figure 416 ZTSE4409

High Pressure Return Line Tester The Pressure Test Kit is used to measure intake
manifold (boost) pressure, fuel system inlet restriction,
fuel pressure, oil pressure, air cleaner intake
restriction, and crankcase pressure.
• 0 to 200 kPa (0 to 30 psi) measures intake
manifold pressure.
• 0-30 in Hg vacuum /0 to 200 kPa (0 to 30 psi)
compound gauge measures fuel system inlet
restriction and intake manifold pressure.
0-30 in H2O 0 to 7.5 kPa (0 to 1 psi) maximum
pressure magnehelic gauge measures crankcase
pressure and air inlet restriction.
• 60 to 1100 kPa (0 to 160 psi) gauge may be used
ZTSE4887 to check the fuel pressure and oil pressure.

Figure 415 ZTSE4887

932
 8 DIAGNOSTIC TOOLS AND ACCESSORIES 929

®
Radiator Pressure Test Kit Slack Tube Manometer

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ii CLEAN ONLY W ITH :!
j] SOAP ji
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, , 0 I
l

I
ZTSE2384
-3-
Figure 417 ZTSE2384 -2-
-1- f A
The Radiator Pressure Test Kit is used to check -0-
-1-
'
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pressure caps and cooling systems. The pressure
gauge indicates if the pressure cap holds the correct -2-
pressure and whether the cooling system has leaks -3-
or holds pressure.

u Figure 418 ZTSE2217A

.

ZTSE2217A

®
The Slack Tube Manometer is a U-shaped tube with
a scale mounted between the legs of the tube. When
the portability of the Pressure Test Kit is not required,
this manometer is used to measure low vacuum
for intake restriction, low pressure for crankcase, or
exhaust back pressure.
Filling
Fill the manometer with water before checking
pressure. Use only distilled water. Add some colored
water vegetable dye so the scale can be read more
easily. With both legs of the manometer open to
the atmosphere, fill the tube until the top of the fluid
column is near the zero mark on the scale. Shake the
tube to eliminate any air bubbles.
Installing, Reading, and Cleaning

933
 930 8 DIAGNOSTIC TOOLS AND ACCESSORIES

1. Support the manometer vertically. Make sure the UV Leak Detection Kit
fluid level is in line with the zero indicator on the
graduated scale.
2. Connect one leg of the manometer to the source
of the pressure or vacuum. Leave the other leg
open to atmospheric pressure.
3. Start the engine and allow it to reach normal
operating temperature. Then run the engine to
high idle. The manometer can be read after 10
seconds.
4. Record the average position of the fluid level
when it is above and below the zero indicator.
Add the two figures together. The sum of the
two is the total column of fluid (distance A). This
represents the crankcase pressure in inches of
water (in H2O).
At times, both columns of the manometer will not
travel the same distance. This is no concern if
the leg not connected to the pressure or vacuum
source is open to the atmosphere.

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5. Compare the manometer reading with engine
ZTSE4618
specifications.
6. When the test is done, clean the tube thoroughly Figure 419 ZTSE4618
using soap and water. Avoid liquid soaps and
solvents.
The UV Leak Detection Kit is used with fuel dye to
quickly identify leaks. The fuel dye combines with
fuel and migrates out at the leak. The ultraviolet
lamp illuminates the leaking fuel dye, which appears
fluorescent yellow-green in color.

934
 9 ABBREVIATIONS AND ACRONYMS 931

Table of Contents

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .933

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935
 932 9 ABBREVIATIONS AND ACRONYMS

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936
 9 ABBREVIATIONS AND ACRONYMS 933

Abbreviations and Acronyms BBDC – Before Bottom Dead Center

BC – Body Controller
A or amp – Ampere
BCP – Brake Control Pressure
AAT – Ambient Air Temperature
BCS – Boost Control Solenoid
ABDC – After Bottom Dead Center
BDC – Bottom Dead Center
ABS – Antilock Brake System
bhp – Brake Horsepower
AC – Alternating Current
BNO – Brake Normally Open
A/C – Air Conditioner
BOO – Brake On / Off
ACC – Air Conditioner Control
BPP – Brake Pedal Position
ACCEL – Accelerator
BPS – Brake Pressure Switch
ACD – Air Conditioner Demand
BSV – Brake Shut-off Valve
ACM – Aftertreatment Control Module
BTDC – Before Top Dead Center
ACT PWR GND – Actuator Power Ground
BTU – British Thermal Unit
ACV – Air Control Valve
A/F – Air to Fuel ratio
C – Celsius
AFD – Aftertreatment Fuel Drain
CAC – Charge Air Cooler
AFI – Aftertreatment Fuel Injector
CACOT – Charge Air Cooler Outlet Temperature
AFP – Aftertreatment Fuel Pressure
CAN – Controller Area Network
AFS – Aftertreatment Fuel Supply
CAP – Cold Ambient Protection
AFT – Aftertreatment
CARB – California Air Resources Board
AFTFD – Aftertreatment Fuel Doser
cc – Cubic centimeter
AFTFDH – Aftertreatment Fuel Doser High
CCA – Cold Cranking Ampere

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AFTFDL – Aftertreatment Fuel Doser Low
CCV – Coolant Control Valve
AFTFIT – Aftertreatment Fuel Inlet Temperature
CCOSS – Crankcase Oil Separator Speed
AFTFIS – Aftertreatment Fuel Inlet Sensor
CCPS – Crankcase Pressure Sensor
AFTFP – Aftertreatment Fuel Pressure
CCS – Cruise Control Switches
AFTFP1 – Aftertreatment Fuel Pressure 1
CDR – Crankcase Depression Regulator
AFTFP2 – Aftertreatment Fuel Pressure 2
cfm – Cubic feet per minute
AFTFSH – Aftertreatment Fuel Shutoff High
cfs – Cubic feet per second
AFTFSL – Aftertreatment Fuel Shutoff Low
CFV – Coolant Flow Valve
AFTFSV – Aftertreatment Fuel Shutoff Valve
CID – Cubic Inch Displacement
Amb – Ambient
CKP – Crankshaft Position
amp or A – Ampere
CKPH – Crankshaft Position High
AMS – Air Management System
CKPL – Crankshaft Position Low
API – American Petroleum Institute
CKPO – Crankshaft Position Out
APP – Accelerator Pedal Position
cm – Centimeter
APP1 – Accelerator Pedal Position 1
CMP – Camshaft Position
APP2 – Accelerator Pedal Position 2
CMPH – Camshaft Position High
APS – Accelerator Position Sensor
CMPL – Camshaft Position Low
APS/IVS – Accelerator Position Sensor / Idle
CMPO – Camshaft Position Out
Validation Switch
CMV – Coolant Mixer Valve
ASTM – American Society for Testing and Materials
CO – Carbon Monoxide
ATA – American Trucking Association
COO – Cruise On / Off switch
ATAH – American Trucking Association Link High
CPU – Central Processing Unit
ATAL – American Trucking Association Link Low
CTC – Coolant Temperature Compensation
ATDC – After Top Dead Center
Cyl – Cylinder
AWG – American Wire Gauge
AWL – Amber Warning Lamp
DB – Decibel
DC – Direct Current
B+ or VBAT – Battery Voltage
DCA – Diesel Coolant Additive
BAP or BARO – Barometric Absolute Pressure
DDI – Digital Direct Fuel Injection
BARO or BAP – Barometric Absolute Pressure

937
 934 9 ABBREVIATIONS AND ACRONYMS
DDS – Driveline Disengagement Switch
DLC – Data Link Connector
DME – Dimethyl Ether
DMM – Digital Multimeter
DOC – Diesel Oxidation Catalyst
DOCIT – Diesel Oxidation Catalyst Inlet Temperature
DOCOT – Diesel Oxidation Catalyst Outlet
Temperature
DPF – Diesel Particulate Filter
DPFDP – Diesel Particulate Filter Differential
Pressure
DPFIT – Diesel Particulate Filter Inlet Temperature
DPFOT – Diesel Particulate Filter Outlet Temperature
DSI – Down Stream Injection
DT – Diesel Turbocharged
DTC – Diagnostic Trouble Code
DTCs – Diagnostic Trouble Codes
DTRM – Diesel Thermo Recirculation Module
EBC – Exhaust Brake Controller
EBP – Exhaust Back Pressure
EBPD – Exhaust Back Pressure Desired
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EBPV – Exhaust Back Pressure Valve
ECB – Engine Compression Brake
ECB1 – Engine Compression Brake 1
ECB2 – Engine Compression Brake 2
ECB3 – Engine Compression Brake 3
ECBP – Engine Compression Brake Pressure
ECI – Engine Crank Inhibit
ECL – Engine Coolant Level
ECM – Engine Control Module
ECM GND – Engine Control Module Ground
ECM PWR – Engine Control Module Power
ECS – Engine Coolant System
ECSR – Engine Controlled Shutdown Request
ECT – Engine Coolant Temperature
ECT1 – Engine Coolant Temperature 1
ECT2 – Engine Coolant Temperature 2
EFAN – Engine Fan
EFANS – Engine Fan Speed
EFC – Engine Fan Control
EFP – Engine Fuel Pressure
EFRC – Engine Family Rating Code
EFS – Engine Fan Speed
EFT – Engine Fuel Temperature
EG – Ethylene Glycol
EGC – Electronic Gauge Cluster
EGBP – Exhaust Gas Back Pressure
EGDP – Exhaust Gas Differential Pressure
EGR – Exhaust Gas Recirculation
EGRC – Exhaust Gas Recirculation Control
EGRH – Exhaust Gas Recirculation High control
EGRL – Exhaust Gas Recirculation Low control
EGROT – Exhaust Gas Recirculation Outlet
Temperature
EGRP – Exhaust Gas Recirculation Position
EGRT – Exhaust Gas Recirculation Temperature
EGT – Exhaust Gas Temperature
EGT1 – Exhaust Gas Temperature 1
EGT2 – Exhaust Gas Temperature 2
EGT3 – Exhaust Gas Temperature 3
EIM – Engine Interface Module
ELS – Exhaust Lambda Sensor
EMI – Electromagnetic Interference
EMP – Exhaust Manifold Pressure
EMT – Exhaust Manifold Temperature
EOP – Engine Oil Pressure
EOT – Engine Oil Temperature
EPA – Environmental Protection Agency
EPR – Engine Pressure Regulator
ESC – Electronic System Controller
ESN – Engine Serial Number
EST – Electronic Service Tool
ETC – Engine Throttle Control
ETCH – Engine Throttle Control High
ETCL – Engine Throttle Control Low
ETP – Engine Throttle Position
ETV – Engine Throttle Valve
EVB – Exhaust Valve Brake
EWPS – Engine Warning Protection System
F – Fahrenheit
FCV – Fuel Coolant Valve
FDP – Fuel Delivery Pressure
FEL – Family Emissions Limit
fhp – Friction horsepower
FMI – Failure Mode Indicator
FPC – Fuel Pump Control
FPCV – Fuel Pressure Control Valve
fpm – Feet per minute
FPM – Fuel Pump Monitor
fps – Feet per second
FRP – Fuel Rail Pressure
ft – Feet
FVCV – Fuel Volume Control Valve
GND – Ground (electrical)
gal – Gallon
gal/h – U.S. Gallons per hour
gal/min – U.S. Gallons per minute
GCW – Gross Combined Weight
GCWR – Gross Combined Weight Rating
938
 9 ABBREVIATIONS AND ACRONYMS 935

GND – Ground ITVH – Intake Throttle Valve High control

GPC – Glow Plug Control ITVL – Intake Throttle Valve Low control
GPD – Glow Plug Diagnostic ITVP – Intake Throttle Valve Position
GPR – Glow Plug Relay IVS – Idle Validation Switch
GVW – Gross Vehicle Weight
J1939H – J1939 Data Link High
H2O – Water J1939L – J1939 Data Link Low
HC – Hydrocarbons JCT – Junction (electrical)
HCI – Hydrocarbon Injection
HEST – High Exhaust System Temperature kg – Kilogram
HFCM – Horizontal Fuel Conditioning Module km – Kilometer
Hg – Mercury km/h – Kilometers per hour
hp – Horsepower km/l – Kilometers per liter
HPCAC – High-Pressure Charge Air Cooler KOEO – Key-On Engine-Off
HPCR – High-Pressure Common Rail KOER – Key-On Engine-Running
HPFP – High-Pressure Fuel Pump kPa – Kilopascal
hr – Hour
HS – Humidity Sensor L – Liter
Hyd – Hydraulic L/h – Liters per hour
L/m – Liters per minute
IAH – Inlet Air Heater L/s – Liters per second
IAHC – Inlet Air Heater Control lb – Pound

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IAHD – Inlet Air Heater Diagnostic lbf – Pounds of force
IAHFI – Inlet Air Heater Fuel Igniter lb/s – Pounds per second
IAHFS – Inlet Air Heater Fuel Solenoid lbf ft – Pounds of force per foot
IAHR – Inlet Air Heater Relay lb in – Pounds of force per inch
IAHS – Inlet Air Heater Solenoid lbm – Pounds of mass
IAHR – Inlet Air Heater Relay LPCAC – Low-pressure Charge Air Cooler
IAT – Inlet Air Temperature LSD – Low Sulfur Diesel
IC – Integrated Circuit
ICP – Injection Control Pressure m – Meter
ICPR – Injection Control Pressure Regulator m/s – Meters per second
ICG1 – Injector Control Group 1 MAF – Mass Air Flow
ICG2 – Injector Control Group 2 MAF GND – Mass Air Flow Ground
ID – Inside Diameter MAG – Magnetic
IDM – Injector Driver Module MAP – Manifold Absolute Pressure
IGN – Ignition MAP/IAT – Manifold Absolute Pressure / Inlet Air
ILO – Injector Leak Off Temperature
IMP – Intake Manifold Pressure MAT – Manifold Air Temperature
IMT – Intake Manifold Temperature mep – Mean effective pressure
in – Inch mi – Mile
inHg – Inch of mercury MIL – Malfunction Indicator Lamp
inH2O – Inch of water mm – Millimeter
INJs – Injectors mpg – Miles per gallon
IPR – Injection Pressure Regulator mph – Miles per hour
IPR PWR – Injection Pressure Regulator Power MPR – Main Power Relay
ISC – Interstage Cooler MSDS – Material Safety Data Sheet
®
ISIS – International Service Information Solutions MSG – Micro Strain Gauge
IST – Idle Shutdown Timer MSM – Multiplex System Module
ITP – Internal Transfer Pump MY – Model Year
ITV – Intake Throttle Valve

939
 936 9 ABBREVIATIONS AND ACRONYMS
NC – Normally Closed (electrical)
NETS – Navistar Electronics Technical Support
Nm – Newton meter
NO – Normally Open (electrical)
NOX – Nitrogen Oxides
O2S – Oxygen Sensor
O2SH – Oxygen Sensor Heater
OAT – Organic Acid Technology
OCC – Output Circuit Check
OCP – Overcrank Protection
OD – Outside Diameter
OL – Over Limit
ORH – Out-of-Range High
ORL – Out-of-Range Low
OSHA – Occupational Safety and
Administration
OWL – Oil/Water Lamp
PID – Parameter Identifier
P/N – Part Number
PDOC – Pre-Diesel Oxidation Catalyst
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ppm – Parts per million
PROM – Programmable Read Only Memory
psi – Pounds per square inch
psia – Pounds per square inch absolute
psig – Pounds per square inch gauge
pt – Pint
PTO – Power Takeoff
PWM – Pulse Width Modulate
PWR – Power (voltage)
qt – Quart
RAM – Random Access Memory
RAPP – Remote Accelerator Pedal Position
RAS – Resume / Accelerate Switch (speed control)
REPTO – Rear Engine Power Takeoff
RFI – Radio Frequency Interference
rev – Revolution
rpm – Revolutions per minute
RPRE – Remote Preset
RSE – Radiator Shutter Enable
RVAR – Remote Variable
SAE – Society of Automotive Engineers
SCA – Supplemental Cooling Additive
SCCS – Speed Control Command Switches
SCS – Speed Control Switch
SHD – Shield (electrical)
SID – Subsystem Identifier
SIG GND – Signal Ground
SIG GNDB – Signal Ground Body
SIG GNDC – Signal Ground Chassis
SIG GNDE – Signal Ground Engine
S/N – Serial Number
SPEEDO – Speedometer
SPN – Suspect Parameter Number
SW – Switch (electrical)
SWBAT – Switch Battery
SYNC – Synchronization
TACH – Tachometer output signal
TBD – To Be Determined
TC2CIS – Turbocharger 2 Compressor Inlet Sensor
TC1TOP – Turbocharger 1 Turbine Outlet Pressure
Health TC2TOP – Turbocharger 2 Turbine Outlet Pressure
TC1WC – Turbocharger 1 Wastegate Control
TC2WC – Turbocharger 2 Wastegate Control
TCAPE – Truck Computer Analysis of Performance
and Economy
TCM – Transmission Control Module
TDC – Top Dead Center
TDE – Transmission Driving Engaged
TOP – Transmission Oil Pressure
TOSS – Transmission Output Shaft Speed
TOT – Transmission Oil Temperature
TTS – Transmission Tailshaft Speed
ULSD – Ultra-Low Sulfur Diesel
UVC – Under Valve Cover
V – Volt
VBAT or B+ – Battery Voltage
VC – Volume Control
VEPS – Vehicle Electronics Programming System
VGT – Variable Geometry Turbo
VIGN – Ignition Voltage
VIN – Vehicle Identification Number
VOP – Valve Opening Pressure
VRE – Vehicle Retarder Enable
VREF – Reference Voltage
VREFB – Reference Voltage Body
VREFC – Reference Voltage Chassis
VREFE – Reference Voltage Engine
VSO – Vehicle Speed Output
VSO or VSS_CAL – Vehicle Speed Output
VSS – Vehicle Speed Sensor
VSS_CAL or VSO – Vehicle Speed Output
VSSH – Vehicle Speed Sensor High
VSSL – Vehicle Speed Sensor Low
940
 9 ABBREVIATIONS AND ACRONYMS 937

WTSL – Wait to Start Lamp XCS – Transfercase

WEL – Warn Engine Lamp XMSN – Transmission
WIF – Water In Fuel
WIFL – Water In Fuel Lamp
WTEC – World Transmission Electronically Controlled
automatic transmissions (Allison)

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941
 938 9 ABBREVIATIONS AND ACRONYMS

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942
 10 TERMINOLOGY 939

Table of Contents

Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .941

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943
 940 10 TERMINOLOGY

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944
 10 TERMINOLOGY
Terms
Accelerator Pedal Position (APP) sensor – A
potentiometer sensor that indicates the position of the
throttle pedal.
Accessory work – The work per cycle required
to drive engine accessories (normally, only those
essential to engine operation).
Actuator – A device that performs work in response
to an input signal.
Actuator Control – The ECM controls the actuators
by applying a low-level signal (low-side driver) or a
high-level signal (high side driver). When switched on,
both drivers complete a ground or power circuit to an
actuator.
Aeration – The entrainment of air or combustion gas
in coolant, lubricant, or fuel.
Aftercooler (Charge Air Cooler) – A heat exchanger
mounted in the charge air path between the
turbocharger and engine intake manifold. The
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aftercooler reduces the charge air temperature by
transferring heat from the charge air to a cooling
medium (usually air).
Aftertreatment Fuel Doser (AFTFD) – A part of
the Down Stream Injection (DSI) unit that sends
pressurized fuel to the Aftertreatment Fuel Injector
(AFI) to inject fuel into the exhaust pipe.
Aftertreatment Fuel Injector (AFI) – Injects fuel into
the exhaust system to increase temperature of the
exhaust gases.
Aftertreatment (AFT) system – A part of the exhaust
system that processes engine exhaust to meet
emission requirements and traps particulate matter
(soot) to prevent it from leaving the tailpipe.
Air Control Valve (ACV) – Contains the LP
turbocharger wastegate control port, HP turbocharger
wastegate control port, the EBPV control port, and
the TC1TOP port. Although these components are
integral to the ACV, each circuit is controlled by the
ECM. The ACV controls compressed air for each
control valve.
Ambient temperature – The environmental air
temperature in which a unit is operating. In general,
the temperature is measured in the shade (no solar
radiation) and represents the air temperature for other
engine cooling performance measurement purposes.
Air entering the radiator may or may not be the same
941
ambient due to possible heating from other sources
or recirculation. (SAE J1004 SEP81)
Ampere (amp) – The standard unit for measuring the
strength of an electrical current. The flow rate of a
charge in a conductor or conducting medium of one
coulomb per second. (SAE J1213 NOV82)
Analog – A continuously variable voltage.
Analog to digital converter (A/D) – A device in the
ECM that converts an analog signal to a digital signal.
American Trucking Association (ATA) Datalink –
A serial datalink specified by the American Trucking
Association and the SAE.
Boost pressure – 1. The pressure of the charge air
leaving the turbocharger.
2. Inlet manifold pressure that is greater than
atmospheric pressure. Obtained by turbocharging.
Bottom Dead Center (BDC) – The lowest position of
the piston during the stroke.
Brake Horsepower (bhp) – The power output from
an engine, not the indicated horsepower. The power
output of an engine, sometimes-called flywheel
horsepower, is less than the indicated horsepower by
the amount of friction horsepower consumed in the
engine.
Brake Horsepower (bhp) net – Net brake
horsepower is measured with all engine components.
The power of an engine when configured as a fully
equipped engine. (SAE J1349 JUN90)
Calibration – ECM programming strategy to solve
engine performance equations and make decisions.
Calibration values are stored in ROM and put into the
processor during programming to allow the engine to
operate within certain parameters.
Camshaft Position (CMP) sensor – A magnetic
pickup sensor that provides the ECM with a camshaft
speed and position signal.
Carbon Monoxide (CO) – A colorless, odorless,
highly poisonous gas that is formed by the incomplete
combustion of carbon burning diesel engine. It is
present in the exhaust gases of diesel engines.
Catalyst – A substance that produces a chemical
reaction without undergoing a chemical change itself.
Catalytic converter – An antipollution device in the
exhaust system that contains a catalyst for chemically
945
 942 10 TERMINOLOGY
converting some pollutants in the exhaust gases
(carbon monoxide, unburned hydrocarbons, and
oxides of nitrogen) into harmless compounds.
Cavitation – A dynamic condition in a fluid system that
forms gas-filled bubbles (cavities) in the fluid.
Cetane number – 1. The auto-ignition quality of
diesel fuel.
2. A rating applied to diesel fuel similar to octane
rating for gasoline.
3. A measure of how readily diesel fuel starts to burn
(self-ignites) at high compression temperature.
Diesel fuel with a high cetane number self-ignites
shortly after injection into the combustion chamber.
Therefore, it has a short ignition delay time. Diesel
fuel with a low cetane number resists self-ignition.
Therefore, it has a longer ignition delay time.
Charge air – Dense, pressurized, heated air
discharged from the turbocharger.
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Charge Air Cooler (CAC) – See Aftercooler.
Charge Air Outlet Temperature (CACOT) sensor –
A thermistor sensor that monitors the temperature of
charge air entering the intake air duct.
Closed crankcase – A crankcase ventilation that
recycles crankcase gases through a breather, then
back to the clean air intake.
Closed loop operation – A system that uses sensors
to provide feedback to the ECM. The ECM uses the
sensor input to continuously monitor variables and
adjust actuators to match engine requirements.
Cloud point – The point when wax crystals occur in
fuel, making fuel cloudy or hazy. Usually below -12°C
(10°F).
Cold cranking ampere rating (battery rating) – The
sustained constant current (in amperes) needed to
produce a minimum terminal voltage under a load of
7.2 volts per battery after 30 seconds.
Controller Area Network (CAN) – A J1939
high-speed communication link.
Coolant – A fluid used to transport heat from one point
to another.
Coolant level switch – A switch sensor used to
monitor coolant level.
Coolant Flow Valve (CFV) – The CFV is ECM
controlled and redirects coolant through the fuel
cooler, based on EFT, when directed.
Coolant Mixer Valve (CMV) – Controls coolant flow
through the low-temperature radiator.
Continuous Monitor Test – An ECM function that
continuously monitors the inputs and outputs to
ensure that readings are within set limits.
Crankcase – The housing that encloses the
crankshaft, connecting rods, and allied parts.
Crankcase breather – A vent for the crankcase to
release excess interior air pressure.
Crankcase Oil Separator Speed (CCOSS) sensor
– The CCOSS sensor sends the ECM information
about the speed of the crankcase oil separator internal
components.
Crankcase pressure – The force of air inside the
crankcase against the crankcase housing.
Crankshaft Position (CKP) sensor – A magnetic
pickup sensor that determines crankshaft position and
speed.
Current – The flow of electrons passing through a
conductor. Measured in amperes.
Damper – A device that reduces the amplitude of
torsional vibration. (SAE J1479 JAN85)
Deaeration – The removal or purging of gases (air or
combustion gas) entrained in coolant or lubricating oil.
946
 10 TERMINOLOGY
Deaeration tank – A separate tank in the coolant
system used for one or more of the following functions:
• Deaeration
• Coolant reservoir (fluid expansion and afterboil)
• Coolant retention
• Filling
• Fluid level indication (visible)
Diagnostic Trouble Code (DTC) – 2010 model
year vehicles no longer utilize DTC identification by
number. DTCs are now identified using the Suspect
Parameter Number (SPN) and Failure Mode Indicator
(FMI) identifiers only.
Diesel Particulate Filter (DPF) – A diesel particulate
filter, sometimes called a DPF, is a device designed
to remove diesel particulate matter or soot from the
exhaust gas of a diesel engine.
Diesel Oxidation Catalyst (DOC) – A DOC is part of
the diesel exhaust Aftertreatment system. DOCs are
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devices that use a chemical process to break down
pollutants in the exhaust stream into less harmful
components. More specifically, DOCs utilize rare
metals such as palladium and platinum to reduce
hydrocarbon based Soluble Organic Fraction (SOF)
and carbon monoxide content of diesel exhaust by
simple oxidation. The DOC can be used during
an active regeneration to create higher exhaust
temperatures, thereby reducing soot in the DPF.
Digital Multimeter (DMM) – An electronic meter that
uses a digital display to indicate a measured value.
Preferred for use on microprocessor systems because
it has a very high internal impedance and will not load
down the circuit being measured.
Disable – A computer decision that deactivates a
system and prevents operation of the system.
Displacement – The stroke of the piston multiplied by
the area of the cylinder bore multiplied by the number
of cylinders in the engine.
Down Stream Injection (DSI) – The DSI system
injects fuel into the exhaust system to increase
temperature of the exhaust gases, and is necessary
for DPF regeneration.
Driver (high side) – A transistor within an electronic
module that controls the power to an actuator circuit.
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Driver (low side) – A transistor within an electronic
module that controls the ground to an actuator circuit.
Dual Stage Turbocharger – An assembly of two
turbochargers (low-pressure and high-pressure) in
series to provide a wide range of charge air pressures
efficiently.
Duty cycle – A control signal that has a controlled
on/off time measurement from 0 to 100%. Normally
used to control solenoids.
EGR Cooler – A cooler that allows heat to dissipate
from the exhaust gasses before they enter the intake
manifold.
Engine Back Pressure Valve (EBPV) – The ECM
commands the EBPV to control the Exhaust Brake.
Engine Compression Brake (ECB) valve – The
ECB valve controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery. This
activates the brake actuator pistons and opens the
exhaust valves.
Engine Compression Brake 1 (ECB1) solenoid –
The ECB1 solenoid controls pressure entering the
brake oil gallery from the high-pressure oil rail gallery.
Engine Compression Brake 2 (ECB2) solenoid –
The ECB2 solenoid controls pressure entering the
brake oil gallery from the high-pressure oil rail gallery.
Engine Compression Brake Pressure (ECBP)
sensor – A high-pressure sensor that provides a
feedback signal to the ECM indicating brake control
pressure.
Engine Control Module (ECM) – An electronic
processor that monitors and controls the engine.
Engine Coolant Level (ECL) sensor – A switch
sensor that monitors coolant level.
Engine Coolant Temperature 1 (ECT1) sensor
– A thermistor sensor that detects engine coolant
temperature.
Engine Coolant Temperature 2 (ECT2) sensor
– A thermistor sensor that detects engine coolant
temperature.
Engine Fuel Temperature (EFT) sensor – A
thermistor sensor that measures fuel temperature.
Engine lamp – An instrument panel lamp that comes
on when DTCs are set. DTCs can be read as flash
codes (red and amber instrument panel lamps).
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 944 10 TERMINOLOGY

Engine OFF tests – Tests that are done with the
ignition switch ON and the engine OFF.
Engine Oil Pressure (EOP) sensor – A variable
capacitance sensor that measures oil pressure.
Engine Oil Temperature (EOT) sensor – A
thermistor sensor that measures oil temperature.
Engine rating – Engine rating includes Rated hp and
Rated rpm.
Engine RUNNING tests – Tests done with the engine
running.
Engine Throttle Valve (ETV) and Engine Throttle
Position Sensor – The ETV valve is used to
control airflow during a regeneration process of the
aftertreatment system. The ETV valve is also used
to ensure a smooth engine shut down by restricting
airflow to the engine at shut down.
Engine Warning Protection System (EWPS) –
Safeguards the engine from undesirable operating
conditions to prevent engine damage and to prolong
Exhaust Manifold Pressure (EMP) sensor – A
variable capacitance sensor used to indicate air
pressure in the exhaust manifold.
Exhaust Manifold Temperature (EMT) sensor
– A thermistor style sensor used to indicate air
temperature in the exhaust manifold.
Fault detection/management – An alternate control
strategy that reduces adverse effects that can be
caused by a system failure. If a sensor fails, the ECM
substitutes a good sensor signal or assumed sensor
value in its place. A lit amber instrument panel lamp
signals that the vehicle needs service.
Failure Mode Indicator (FMI) – Identifies the fault or
condition effecting the individual component.
Filter restriction – A blockage, usually from
contaminants, that prevents the flow of fluid through
a filter.
Flash code – See Diagnostic Trouble Code (DTC).
Fuel Delivery Pressure (FDP) sensor – A variable

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engine life. capacitance sensor that monitors fuel pressure
coming from the fuel tank and sends a signal to the
Exhaust Back Pressure (EBP) – The pressure
ECM.
present in the exhaust system during the exhaust
period. Fuel inlet restriction – A blockage, usually from
contaminants, that prevents the flow of fluid through
Exhaust Back Pressure Valve (EBPV) – A valve that
the fuel inlet line.
regulates the amount of air pressure applied to the
EBPV pneumatic actuator. Fuel pressure – The force fuel exerts on the fuel
system as it is pumped through the fuel system.
Exhaust brake – A brake device using engine
exhaust back pressure as a retarding medium. Fuel Pressure Control Valve (FPCV) – The FPCV
controls the fuel pressure to the fuel rails and is
Exhaust Gas Recirculation (EGR) – A system used
controlled by the ECM. FPCV control depends on fuel
to recirculate a portion of the exhaust gases into the
pressure and fuel temperature.
power cylinder in order to reduce oxides of nitrogen.
Fuel Rail Pressure (FRP) – The amount of pressure
Exhaust Gas Temperature (EGT) – The temperature
in the fuel rail.
of exhaust gases.
Fuel Rail Pressure (FRP) sensor – A variable
Exhaust Gas Recirculation Temperature (EGRT)
capacitance sensor that monitors fuel pressure in the
sensor – A thermistor sensor that detects the exhaust
fuel rail and sends a signal to the ECM.
gas temperature entering the EGR cooler.
Fuel strainer – A pre-filter in the fuel system that
Exhaust Gas Recirculation (EGR) valve – The
keeps larger contaminants from entering the fuel
EGRV controls the flow of exhaust gases to the intake
system.
manifold. The EGRV is integrated with an EGR
Position (EGRP) sensor.
Exhaust manifold – Exhaust gases flow through the
exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.

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 10 TERMINOLOGY
Fuel Volume Control Valve (FVCV) – The FVCV
regulates the volume of flow sent to the HPFP.
The FVCV allows a sufficient quantity of fuel to be
delivered to the HPFP depending on engine load,
speed, injector quantity, fuel temperature, and number
of injections per cycle.
Fully equipped engine – A fully equipped engine
is an engine equipped with only those accessories
necessary to perform its intended service. A fully
equipped engine does not include components
that are used to power auxiliary systems. If these
components are integral with the engine or, for any
reason are included on the test engine, the power
absorbed may be determined and added to the net
brake power. (SAE J1995 JUN90)
Fusible link (fuse link) – A fusible link is a special
section of low tension cable designed to open the
circuit when subjected to an extreme current overload.
(SAE J1156 APR86)
Gradeability – The maximum percent grade, which
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the vehicle can transverse for a specified time at a
specified speed. The gradeability limit is the grade
upon which the vehicle can just move forward. (SAE
J227a)
Gross Combined Weight Rating (GCWR) –
Maximum combined weight of towing vehicle
(including passengers and cargo) and the trailer. The
GCWR indicates the maximum loaded weight that the
vehicle is allowed to tow.
Gross brake horsepower – The power of a complete
basic engine, with air cleaner, without fan, and
alternator, and air compressor not charging.
H-Bridge Circuit – An H-Bridge (bipolar) circuit
operates like putting a power source on one side of a
motor and connecting the other side of the motor to a
ground. This turns the motor. By shifting the leads on
the motor, it will turn in the opposite direction.
Hall effect – The development of a transverse electric
potential gradient in a current-carrying conductor or
semiconductor when a magnetic field is applied.
Hall effect sensor – Transducer that varies its output
voltage in response to changes in a magnetic field.
Commonly used to time the speed of wheels and
shafts.
High-pressure Fuel Pump (HPFP) assembly –
The HPFP is a volumetric pump that supplies fuel
945
at high-pressure. The HPFP is mounted in the rear
valley on the top of the engine and is driven by the
camshaft.
High-pressure Piezo Common Rail (HPCR) – The
HPFP pumps fuel through separate tubes to each
fuel rail. Each fuel rail has four fuel tubes, one for
each injector, that maintain constant pressure from the
high-pressure pump to each injector.
High-speed digital inputs – Inputs to the ECM from
a sensor that generates varying frequencies (engine
speed and vehicle speed sensors).
Horsepower (hp) – Horsepower is the unit of work
done in a given period of time, equal to 33,000 pounds
multiplied by one foot per minute. 1 hp = 33,000 lb x
1 ft. /1 min.
Humidity Sensor (HS) – A sensor that measures
the moisture content of filtered air entering the intake
system.
Hydrocarbons – Organic compounds consisting of
hydrogen and carbon (fuel and oil).
Injection Pressure Regulator (IPR) valve – A valve
that is used to maintain desired injection control
pressure.
Injection Control Pressure (ICP) sensor – Provides
a feedback signal to the ECM indicating injection
control pressure.
Inlet Air Heater (IAH) – The IAH is primarily used to
assist in starting the engine during cold weather. In
addition, it helps to reduce white smoke emissions by
heating the incoming air.
Inlet Air Heater Fuel Igniter (IAHFI) – The IAHFI
heats the intake air by vaporizing and igniting fuel in
the air inlet duct.
Inlet Air Heater Fuel Solenoid (IAHFS) – As the
engine is cranked, the ECM energizes the IAHFS
valve, introducing fuel into the IAHFI, which ignites
and warms the air being drawn into the engine.
Inlet Air Heater Relay (IAHR) – The IAHR provides
voltage to the IAHFI, and is controlled by the ECM.
Inlet Air Temperature (IAT) sensor – A thermistor
sensor that monitors intake air temperature.
Intake manifold – Engine component that evenly
supplies air to each intake port in the cylinder head(s).
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 946 10 TERMINOLOGY
Intake Manifold Pressure (IMP) sensor – A variable
capacitance sensor used to indicate air pressure in the
intake manifold.
Intake Manifold Temperature (IMT) sensor – A
thermistor sensor used to indicate air temperature in
the intake manifold.
Internal Transfer Pump (ITP) – The ITP is part of
the HPFP assembly and driven off the same shaft
as the HPFP assembly. The ITP supplies fuel at a
slightly higher pressure and flow to the HPFP though
the Fuel Volume Control Valve (FVCV). The ITP
also provides fuel for cooling and lubrication of the
HPFP. Fuel is rerouted as pump return flow through
the HPFP cooling and lubrication valve. Pressure is
maintained at the inlet of the HPFP piston pump by
an ITP regulator.
International NGV Tool Utilized for Next
Generation Electronics (INTUNE) – The diagnostics
software for chassis related components and
systems.
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Interstage Cooler (ISC) – Uses cooled coolant to
lower the charged air temperature that exits from the
turbocharger low-pressure compressor and enters the
turbocharger high-pressure compressor.
Low speed digital inputs – Switched sensor inputs
that generate an on/off (high/low) signal to the ECM.
The input to the ECM from the sensor could be from
a high input source switch (usually 5 or 12 volts) or
from a grounding switch that grounds the signal from
a current limiting resistor in the ECM that creates a low
signal (0 volts).
Low temperature radiator thermostat – Coolant
flow to the low temperature radiator is regulated by
the low temperature radiator thermostat.
Lubricity – Lubricity is the ability of a substance
to reduce friction between solid surfaces in relative
motion under loaded conditions.
Lug (engine) – A condition when the engine is run at
an overly low RPM for the load being applied.
Manifold Absolute Pressure (MAP) – Boost
pressure in the manifold that is a result of the
turbocharger.
Manifold Absolute Pressure (MAP) sensor – A
variable capacitance sensor that measures boost
pressure.
Manometer – A double-leg liquid-column gauge, or a
single inclined gauge, used to measure the difference
between two fluid pressures. Typically, a manometer
records in inches of water.
Mass Air Flow – The intake airflow in an engine.
Mass Air Flow (MAF) sensor – The MAF sensor is
used for closed loop control of the EGR valve and ITV.
The ECM monitors the MAF signal so that the ECM
can control the EGR and intake throttle systems.
®
MasterDiagnostics (MD) – Diagnostics software for
engine related components and systems.
Magnehelic Gauge – A gauge that measures
pressure in inches of water.
Magnetic Pickup Sensor – A magnetic pickup sensor
generates an alternating frequency that indicates
speed. Magnetic pickups have a two-wire connection
for signal and ground. This sensor has a permanent
magnetic core surrounded by a wire coil. The signal
frequency is generated by the rotation of the gear
teeth that disturb the magnetic field.
Metering unit valve assembly – The Metering unit
valve assembly provides a metered amount of fuel to
the Aftertreatment Fuel Injector (AFI).
Microprocessor – An integrated circuit in a
microcomputer that controls information flow.
Micro Strain Gauge (MSG) Sensor – A MSG sensor
measures pressure. Pressure exerts force on a
pressure vessel that stretches and compresses to
change resistance of strain gauges bonded to the
surface of the pressure vessel. Internal sensor
electronics convert the changes in resistance to a
ratiometric voltage output.
Nitrogen Oxides (NOx) – Nitrogen oxides form by
a reaction between nitrogen and oxygen at high
temperatures and pressures in the combustion
chamber.
Normally closed – Refers to a switch that remains
closed when no control force is acting on it.
Normally open – Refers to a switch that remains open
when no control force is acting on it.
Ohm (Ω) – The unit of electrical resistance. One ohm
is the value of resistance through which a potential of
one volt will maintain a current of one ampere. (SAE
J1213 NOV82)
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 10 TERMINOLOGY
On demand test – A self-test the technician initiates
using the EST that is run from a program in the
software.
Output Circuit Check (OCC) – An on-demand test
done during an Engine OFF self-test to check the
continuity of selected actuators.
Oxides of Nitrogen (NOx) – Nitrogen oxides formed
by a reaction between nitrogen and oxygen at high
temperatures.
Oxygen Sensor (O2S) – A sensor that monitors
oxygen levels in the exhaust.
pH – A measure of the acidity or alkalinity of a solution.
Particulate matter – Particulate matter includes
mostly burned particles of fuel and engine oil.
Piezometer – An instrument for measuring fluid
pressure.
Power – Power is a measure of the rate at which
work (force x distance) is done during a specific time.
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Compare with Torque.
Power TakeOff (PTO) – Accessory output, usually
from the transmission, used to power a hydraulic
pump for a special auxiliary feature (garbage packing,
lift equipment, etc).
Pulse Width Modulation (PWM) – Succession of
digital electrical pulses, rather than an analog signal.
Efficient method of providing power between fully on
and fully off.
Random Access Memory (RAM) – Computer
memory that stores information. Information can
be written to and read from RAM. Input information
(current engine speed or temperature) can be stored
in RAM to be compared to values stored in Read Only
Memory (ROM). All memory in RAM is lost when the
ignition switch is turned off.
Rated gross horsepower – Engine gross
horsepower at rated speed as declared by the
manufacturer. (SAE J1995 JUN90)
Rated horsepower – Maximum brake horsepower
output of an engine as certified by the engine
manufacturer. The power of an engine when
configured as a basic engine. (SAE J1995 JUN90)
Rated net horsepower – Engine net horsepower at
rated speed as declared by the manufacturer. (SAE
J1349 JUN90)
947
Rated speed – The speed, as determined by the
manufacturer, at which the engine is rated. (SAE
J1995 JUN90)
Rated torque – Maximum torque produced by an
engine as certified by the manufacturer.
Ratiometric Voltage – In a Micro Strain Gauge
(MSG) sensor, pressure to be measured exerts force
on a pressure vessel that stretches and compresses
to change resistance of strain gauges bonded to
the surface of the pressure vessel. Internal sensor
electronics convert the changes in resistance to a
ratiometric voltage output.
Reference voltage (VREF) – A 5 volt reference
supplied by the ECM to operate the engine sensors.
Reserve capacity – Time in minutes that a fully
charged battery can be discharged to 10.5 volts at 25
amperes.
Regeneration – Oxidation of accumulated soot
(carbon-based particulates) in the Diesel Particulate
Filter (DPF). The soot is reduced to ash and stored in
the PDF.
Return Fuel System – The return fuel system moves
unused fuel from the fuel injectors to the fuel cooler.
Excess fuel out of the FVCV and the FPCV mix with
fuel from the fuel injectors on the way to the fuel cooler.
ServiceMaxx™ software – Diagnostics software for
engine related components and systems.
Signal Conditioner – The signal conditioner in the
internal microprocessor converts analog signals to
digital signals, squares up sine wave signals, or
amplifies low-intensity signals to a level that the ECM
microprocessor can process.
Signal ground – The common ground wire to the
ECM for the sensors.
Speed Control Command Switches (SCCS) – A set
of switches used for cruise control, Power Take Off
(PTO), and remote hand throttle system.
Steady state condition – An engine operating
at a constant speed and load and at stabilized
temperatures and pressures. (SAE J215 JAN80)
Strategy – A plan or set of operating instructions
that the microprocessor follows for a desired goal.
Strategy is the computer program itself, including
all equations and decision making logic. Strategy is
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 948 10 TERMINOLOGY
always stored in ROM and cannot be changed during
calibration.
Stroke – The movement of the piston from Top Dead
Center (TDC) to Bottom Dead Center (BDC).
Substrate – Material that supports the wash coating
or catalytic materials.
Suspect Parameter Number (SPN) – A 19-bit
number used to identify the item for which diagnostics
are being reported. The SPN is used for multiple
purposes, some that are specific to diagnostics are
as follows;
• Identify the least repairable subsystem that has
failed.
• Identify subsystems or assemblies that may not
have hard failures but may be exhibiting abnormal
operating performance.
• Identify a particular event or condition that will be
reported.
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• Report a component and non-standard failure
mode.
System restriction (air) – The static pressure
differential that occurs at a given airflow from air
entrance through air exit in a system. Usually
measured in inches (millimeters) of water. (SAE
J1004 SEP81)
Tachometer output signal – Engine speed signal for
remote tachometers.
Thermistor – A semiconductor device. A sensing
element that changes resistance as the temperature
changes.
Thermistor Sensor – Changes electrical resistance
with changes in temperature. Resistance in the
thermistor decreases as temperature increases, and
increases as temperature decreases. Thermistors
work with a resistor that limits current to form a voltage
signal matched with a temperature value.
Thrust load – A thrust load pushes or reacts through
a bearing in a direction parallel to the shaft.
Top Dead Center (TDC) – The uppermost position of
the piston during the stroke.
Torque – A force having a twisting or turning effect.
For a single force, the cross product of a vector from
some reference point to the point of application of the
force within the force itself. Also known as moment of
force or rotation moment. Torque is a measure of the
ability of an engine to do work.
Truck Computer Analysis of Performance and
Economy (TCAPE) – A computer program that
simulates the performance and fuel economy of
trucks.
Turbocharger – A turbine driven compressor
mounted on the exhaust manifold. The turbocharger
increases the pressure, temperature and density of
intake air to charge air.
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
sensor – A variable capacitance sensor that monitors
exhaust back-pressure.
Turbocharger 2 Compressor Inlet (TC2CIS) sensor
– The TC2CIS sensor includes a thermistor sensor
that monitors the temperature of charge air entering
the HP turbocharger. This sensor also monitors boost
pressure for the LP turbocharger.
Turbocharger Wastegate Control (TCWC) solenoid
– Controls the TCWC actuator by regulating the
amount of charge air pressure supplied to the TCWC
actuator. The TCWC solenoid is controlled by signals
from the ECM in response to engine speed, required
fuel quantity, boost, exhaust back-pressure, and
altitude.
Turbocharger 1 Wastegate Control (TC1WC)
solenoid – Controls the TC1WC actuator by
regulating the amount of charge air pressure supplied
to the TC1WC actuator. The TC1WC solenoid is
controlled by signals from the ECM in response to
engine speed, required fuel quantity, boost, exhaust
back-pressure, and altitude. The TC1WC actuator is
part of the turbocharger assembly.
NOTE: TC1WC does not affect engine
performance and is removed from postproduction
engines.
Turbocharger 2 Wastegate Control (TC2WC)
solenoid – Controls the TC2WC actuator by
regulating the amount of charge air pressure supplied
to the wastegate actuator. The TC2WC solenoid is
controlled by signals from the ECM in response to
engine speed, required fuel quantity, boost, exhaust
back-pressure, and altitude. The TC2WC actuator is
part of the turbocharger assembly.
Variable capacitance sensor – A variable
capacitance sensor measures pressure. The
pressure forces a ceramic material closer to a thin
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 10 TERMINOLOGY
metal disc in the sensor, changing the capacitance of
the sensor.
Vehicle Electronic System Programming System –
The computer system used to program electronically
controlled vehicles.
Vehicle Retarder Enable/Engage – Output from the
ECM to a vehicle retarder.
Vehicle Speed Sensor (VSS) – Normally a magnetic
pickup sensor mounted in the tailshaft housing of the
transmission, used to indicate ground speed.
Viscosity – The internal resistance to the flow of any
fluid.
Viscous fan – A fan drive that is activated when a
thermostat, sensing high air temperature, forces fluid
through a special coupling. The fluid activates the fan.
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949
Volt (v) – A unit of electromotive force that will move
a current of one ampere through a resistance of one
Ohm.
Voltage – Electrical potential expressed in volts.
Voltage drop – Reduction in applied voltage from the
current flowing through a circuit or portion of the circuit
current multiplied by resistance.
Voltage ignition – Voltage supplied by the ignition
switch when the key is ON.
Washcoat – A layer of alumina applied to the
substrate in a monolith-type converter.
Water In Fuel (WIF) sensor – A switch sensor that
measures the amount of water in the fuel.
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 950 10 TERMINOLOGY

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954
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 951

Table of Contents

All Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .953

®
MaxxForce 11 (10.5 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959
330 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959
370 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .960
390 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .961
®
MaxxForce 13 (12.4 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .962
410 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .962
430 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .963
450 hp @ 1700 rpm (Allison Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .964
450 hp @ 1700 rpm (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .965
475 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .966

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955
 952 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

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956
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 953

All Ratings
Key-On Engine-Off

Barometric pressure (500 ft. above sea level) 99.01 kPa (14.36 psi) / 3.91 V

Fuel rail pressure 0 kPa (0 psi) / 0.5 V

Turbocharger 1 turbine outlet pressure 0 kPa (0 psi) / 0.84 V

Fuel delivery pressure 0 kPa (0 psi) / 0.5 V

Intake manifold pressure 0 kPa (0 psi) / 1.06 V

Diesel particulate filter differential pressure 0 kPa (0 psi) / 0.5 V

Exhaust gas recirculation valve position 0.47 V / 0 %

Engine throttle valve position 4.5 %

Accelerator pedal position sensor (at idle) 0.7 V / 0 %

Accelerator pedal position sensor (depressed to floor) 3.75 V / 99.6 %

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Engine oil pressure 0 kPa (0 psi) / 0.5 V

Engine Cranking

Battery voltage (min. based on ECM drop out) 10.5 V

Cranking rpm (min.) 130 rpm

20 seconds maximum crank time per attempt. Wait 2 to 3 minutes before repeating.

With Gauge: 207 kPa (30 psi) / 1.15 V

Fuel delivery pressure (min.)
With EST: 103 kPa (15 psi) / 1.15 V

Fuel rail pressure 20 MPa (3000 psi) / 1 V

Turbocharger 1 turbine outlet pressure < 34 kPa (< 5 psi) / 0.84 V

Fuel dead head test pressure > 448 kPa (> 65 psi)

Fuel inlet restriction 203 - 305 mmHg (8 - 12 inHg)

High-pressure pump inlet pressure > 207 kPa (> 30 psi)

Inlet air heater fuel solenoid fuel supply pressure 55 - 82 kPa (8 - 12 psi)

Inlet air heater fuel igniter fuel supply pressure 55 - 82 kPa (8 - 12 psi)

Diesel particulate filter differential pressure 0 kPa (0 psi) / 0.66 V

Exhaust gas recirculation valve 0%

957
 954 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

Low Idle, no load, stabilized engine operating temperature

Fuel delivery pressure (min.) 413 kPa (60 psi) / 1.8 V

Fuel delivery pressure (max.) 827 kPa (120 psi) / 3.2 V

Fuel rail pressure 86700 kPa (12574 psi) / 1.945 V

Engine speed 600 - 650 rpm

Intake manifold pressure < 21 kPa (< 3 psi) / 1.026 V

Turbocharger 1 turbine outlet pressure < 34 kPa (< 5 psi) / 0.84 V

Fuel inlet restriction 330 - 432 mmHg (13 - 17 inHg)

High-pressure pump inlet pressure 482 - 896 kPa (70 - 130 psi)

High-pressure fuel return flow 20 - 22 ml

Crankcase oil separator speed 5720 rpm

Engine coolant temperature 1 (at thermostat opening) 86° C (186° F) / 0.571 V

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Engine coolant temperature 1 (max. before DTC is set) 120 °C (248 °F) / 0.64 V

Engine coolant temperature 2 (at thermostat opening) 55 °C (131 °F) / 1.26 V

Engine coolant temperature 2 (max. before DTC is set) 120 °C (248 °F) / 0.64 V

Engine oil pressure (min. with gauge) 68 kPa (10 psi) / 1.5 V

Engine oil temperature 98 °C (208 °F) / 0.405 V

Intake air temperature 2 (boost) 48 °C (118 °F) / 1.06 V

Intake air temperature 2 (boost) (max. before DTC is set) 95 °C (203 °F) / 1.11 V

Intake manifold air temperature 53 °C (127 °F) / 1.329 V

Intake manifold air temperature (max. before DTC is set) 135 °C (275 °F) / 0.47 V

Actuator supply pressure (min.) 620 kPa (90 psi)

Turbocharger wastegate control supply pressure (min.) 358 kPa (52 psi)

958
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 955

High Idle, no load, stabilized engine operating temperature

Air cleaner restriction (max.) 3.7 kPa (15 in H2O)

Fuel delivery pressure (min.) 413 kPa (60 psi) / 1.8 V

Fuel delivery pressure (max.) 827 kPa (120 psi) / 3.2 V

Fuel rail pressure 211 MPa (30542 psi) / 4.01 V

Engine speed 1550 - 2200 rpm

Intake manifold pressure 90 - 110 kPa (13 - 16 psi)

Turbocharger 1 turbine outlet pressure < 34 kPa (< 5 psi) / 0.84 V

High-pressure pump fuel return pressure 90 kPa (13 psi)

Diesel particulate filter differential pressure (max. before DTC is set) 35 kPa (5 psi) / 1.9 V

Engine oil pressure (min. with gauge) 275 - 482 kPa (40 - 70 psi) / 4.7 V

Full load, rated speed on dynamometer, stabilized engine operating temperature

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Air cleaner restriction (max.) 3.3 kPa (13.4 in H2O)

Fuel rail pressure 220 MPa (31900 psi) / 4.1 V

Fuel delivery pressure (min.) 413 kPa (60 psi) / 1.3 V

Fuel delivery pressure (max.) 827 kPa (120 psi) / 3.2 V

Engine speed 1550 - 2200 rpm

Intake manifold pressure > 206 kPa (30 psi) / 2.18 V

Turbocharger 1 turbine outlet pressure < 34 kPa (< 5 psi) / 0.84 V

Engine oil pressure (min. with gauge) 500 kPa (72 psi) / 3.9 V

Engine oil temperature (max.) 98 °C (208 °F) / 0.41 V

Diesel particulate filter differential pressure (max. before DTC is set) 35 kPa (5 psi) / 1.9 V

Exhaust back pressure (max.) 35 kPa (5 psi)

Water temperature differential across radiator (top and bottom) 9 °C (16 °F)

959
 956 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

Component Specifications

Temperature Sensors (Engine Coolant Temperature 1 [ECT1], Engine Coolant Temperature 2 [ECT2], Engine Oil
Temperature [EOT], Intake Manifold Air Temperature [IMAT])

Temperature at -18 °C (0 °F) 4.2 V / 14030 Ω

Temperature at 0 °C (32 °F) 3.6 V / 5876 Ω

Temperature at 21 °C (70 °F) 2.6 V / 2404 Ω

Temperature at 65 °C (150 °F) 0.94 V / 507 Ω

Temperature at 93 °C (200 °F) 0.47 V / 224 Ω

Temperature Sensors (Intake Air Temperature [IAT])

Temperature at -18 °C (0 °F) 4.21 V / 13866 Ω

Temperature at 0 °C (32 °F) 3.59 V / 5988 Ω

Temperature at 21 °C (70 °F) 2.67 V / 2561 Ω

Temperature at 65 °C (150 °F) 1.05 V / 576 Ω

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Temperature Sensors (Diesel Oxidation Catalyst Inlet Temperature [DOCIT], Diesel Oxidation Catalyst Outlet Temperature
[DOCOT], Diesel Particulate Filter Outlet Temperature [DPFOT])

Temperature at 21 °C (70 °F) 4.5 V / 19.4 Ω

Temperature at 65 °C (150 °F) 3.9 V / 7.1 Ω

Temperature at 93 °C (200 °F) 3.4 V / 4.3 Ω

Temperature at 204 °C (400 °F) 1.6 V / 0.96 Ω

Temperature at 482 °C (900 °F) 0.34 V / 0.146 Ω

Other Components

Camshaft Position (CMP) sensor 860 Ω ± 10% @ 20 °C

Crankshaft Position (CKP) sensor 860 Ω ± 10% @ 20 °C

Coolant Mixer Valve (CMV) 5.45 - 6.00 Ω @ 24 °C

Coolant Flow Valve (CFV) 5.45 - 6.00 Ω @ 24 °C

Inlet Air Heater Fuel Solenoid (IAHFS) 8 Ω ± 1 Ω @ room temperature

Turbocharger Wastegate Control (TC1WC and TC2WC) solenoid 9.5 Ω ± 10%, -5% @ 20 °C

960
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 957

Actuator Output State

Exhaust Gas Recirculation (EGR) valve control Output state low – 5 %

Output state high – 95 %

Exhaust Gas Recirculation Position (EGRP) Output state low – 5 %

Output state high – 95 %

Exhaust Back Pressure (EBP) valve Output state low – 0 %

Output state high – 95%

Engine Throttle Valve (ETV) control Output state low – 5 %

Output state high – 95 %

Engine Throttle Valve (ETV) position Output state low – 5 %

Output state high – 95 %

Turbocharger Wastegate Control (TC1WC and TC2WC) solenoid Output state low – 5 %

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Output state high – 95 %

Fuel Pressure Control Valve (FPCV) Output state low – 5 %

Output state high – 95 %

Coolant Flow Valve (CFV) Output state low – 5 %

Output state high – 95 %

Coolant Mixer Valve (CMV) Output state low – 5 %

Output state high – 95 %

Aftertreatment Fuel Doser Control (AFTFD) Output state low – 5 %

Output state high – 95 %

Inlet Air Heater Fuel Igniter (IAHFI) Output state low – 5 %

Output state high – 95 %

Engine Fan Control (EFC) Output state low – 5 %

Output state high – 95 %

961
 958 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

Inlet Air Heater System

Inlet air heater fuel igniter current draw 15 A

Crankcase Pressure

High idle no load - crankcase blow by flow < 8 in H2O

EBPV Rod Extension

Full travel 42 mm

TC2WC Rod Extension

Full travel 13 mm

BetterManuals.net

962
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 959

®
MaxxForce 11 (10.5 L)

330 hp @ 1700 rpm

® ®
International MaxxForce 11 330 hp @ 1700 rpm / 1250 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT330

Engine Family Rating Code (EFRC) 2232 and 1132

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

BetterManuals.net
Intake manifold pressure (gauge) Peak torque – 203 kPa (30 psi) / 2.25 V

Rated speed – 288 kPa (42 psi) / 3.22 V

963
 960 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

370 hp @ 1700 rpm

® ®
International MaxxForce 11 370 hp @ 1700 rpm / 1350 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT370

Engine Family Rating Code (EFRC) 2222 and 1122

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 227 kPa (33 psi) / 2.52 V

Rated speed – 288 kPa (42 psi) / 3.22 V

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964
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 961

390 hp @ 1700 rpm

® ®
International MaxxForce 11 390 hp @ 1700 rpm / 1400 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT390

Engine Family Rating Code (EFRC) 2212 and 1112

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 257 kPa (37 psi) / 2.87 V

Rated speed – 295 kPa (43 psi) / 3.30 V

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965
 962 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

®
MaxxForce 13 (12.4 L)

410 hp @ 1700 rpm

® ®
International MaxxForce 13 410 hp @ 1700 rpm / 1450 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT410

Engine Family Rating Code (EFRC) 2231 and 1131

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

BetterManuals.net
Intake manifold pressure (gauge) Peak torque – 196 kPa (29 psi) / 2.17 V

Rated speed – 295 kPa (43 psi) / 3.30 V

966
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 963

430 hp @ 1700 rpm

® ®
International MaxxForce 13 430 hp @ 1700 rpm / 1550 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT430

Engine Family Rating Code (EFRC) 2221 and 1121

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 213 kPa (31 psi) / 2.36 V

Rated speed – 298 kPa (43 psi) / 3.33 V

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967
 964 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

450 hp @ 1700 rpm (Allison Automatic

Transmission)

® ®
International MaxxForce 13 450 hp @ 1900 rpm / 1250 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT450

Engine Family Rating Code (EFRC) 2221 and 1121

Injection timing Nonadjustable

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 124kPa (18 psi) / 1.36 V

Rated speed – 269 kPa (39 psi) / 3.15 V

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968
 11 APPENDIX A: PERFORMANCE SPECIFICATIONS 965

450 hp @ 1700 rpm (Manual Transmission)

® ®
International MaxxForce 13 450 hp @ 1700 rpm / 1700 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT450

Engine Family Rating Code (EFRC) 2211 and 1111

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 214 kPa (31 psi) / 2.73 V

Rated speed – 285 kPa (41 psi) / 3.33 V

BetterManuals.net

969
 966 11 APPENDIX A: PERFORMANCE SPECIFICATIONS

475 hp @ 1700 rpm

® ®
International MaxxForce 13 475 hp @ 1700 rpm / 1700 ft•lb @ 1000 rpm

50 state 2010 Model Year (MY)

Engine model GDT475

Engine Family Rating Code (EFRC) 2211 and 1111

Injection timing Nonadjustable

High idle speed - manual transmission 2200 rpm

High idle speed - automatic transmission 2200 rpm

Low idle speed 600 rpm

Full load on chassis dynamometer or highway, stabilized engine operating temperature

Intake manifold pressure (gauge) Peak torque – 214 kPa (31 psi) / 2.73 V

Rated speed – 285 kPa (41 psi) / 3.33 V

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970
 12 APPENDIX B: SIGNAL VALUES 967

Table of Contents

Signal Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .969

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971
 968 12 APPENDIX B: SIGNAL VALUES

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972
 12 APPENDIX B: SIGNAL VALUES 969

Signal Values

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and with
Breakout Harness 00-01467-00 connected between the Engine Control Module (ECM) and vehicle
harness. See “APPENDIX A: PERFORMANCE SPECIFICATIONS” (page 953) for actuator output
voltages, sensor values, and component specifications in a range of conditions.

ECM 58-pin C2 Connector

ECM Pin Abbreviation Circuit Name KOEO
C2-01 B+ Battery Power B+
C2-02 GND Ground 0V
C2-07 AFTFS-H AFT Fuel Shutoff Valve High 1.18 V
C2-08 VREF4 Voltage Reference 4 5.00 V
C2-09 TACH Tachometer 11.35 V
C2-10 XCS Transfercase 0.10 V
C2-13 AES Auxiliary Engine Switch N/A
C2-14 WIFL Water in Fuel Lamp 3.62 V

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C2-15 WTSL Wait to Start Lamp 3.60 V
C2-16 EGRP Exhaust Gas Recirculation Position 2.83 V
C2-17 WEL Warn Engine Lamp 3.60 V
C2-20 AFTFS-L AFT Fuel Shutoff Valve Low 1.18 V
C2-22 COO Cruise On/Off Switch 0.10 V
C2-23 RAS Resume Accel Switch 1.10 V
C2-26 TSA Two-Speed Axle Switch N/A
C2-27 ACD_Sw A/C Demand Switch N/A
C2-28 RSL Red Stop Lamp 3.58 V
C2-30 VSS CAL Vehicle Speed Sensor Calibration B+
C2-34 SIG GND Signal Ground 0V
C2-35 RVAR Remote Variable PTO 0.10 V
C2-36 CP_Sw Clutch Position Switch N/A
C2-37 WIF Water in Fuel Sensor 3.85 V +/- 0.20 V
C2-39 PB_Sw Parking Brake Switch N/A
C2-40 EB_Sw1 Engine Brake Switch 1 N/A
C2-41 SIG GND Signal Ground 0V
C2-42 SIG GND Signal Ground 0V
C2-43 SIG GND Signal Ground 0V
C2-46 RPAS Remote Pedal Activation Switch 0.10 V

973
 970 12 APPENDIX B: SIGNAL VALUES

ECM 58-pin C2 Connector

ECM Pin Abbreviation Circuit Name KOEO
C2-48 RPRE Remote Preset PTO 0.10 V
C2-49 ECL Engine Coolant Level 0.10 V +/- 0.10 V
C2-50 AFTFP2 AFT Fuel Pressure 2 0.40 V
C2-52 SCS Speed Control Switch 0.10 V
C2-53 EB_Sw2 Engine Brake Switch 2 N/A
C2-54 APP1 Accelerator Pedal Position 1 1.16 V +/- 0.10 V
C2-55 APP2 Accelerator Pedal Position 2 0.66 V

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974
 12 APPENDIX B: SIGNAL VALUES 971

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and with
Breakout Harness 00-01467-00 connected between the Engine Control Module (ECM) and vehicle
harness. See “APPENDIX A: PERFORMANCE SPECIFICATIONS” (page 953) for actuator output
voltages, sensor values, and component specifications in a range of conditions.

ECM 58-pin C1 Connector

ECM Pin Abbreviation Circuit Name KOEO
C1-01, 03, 05 B+ Battery Power B+
C1-02, 04, 06 GND Ground 0V
C1-08 EF GND Engine Fan Ground 0V
C1-10 SIG GND Signal Ground 0V
C1-11 SIG GND Signal Ground 0V
C1-12 DPFDP DPF Differential Pressure 0.78 V
C1-13 RPS Remote Pedal Sensor 0.08 V
C1-16 DOCOT DOC Outlet Temperature 4.47 V
C1-17 SWBAT Switched Battery B+

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C1-18 EFC Engine Fan Control 0.21 V - 6.25 V
C1-19 TIMER Stand-Alone Real Timer B+
C1-22 SIG GND Signal Ground 0V
C1-23 SIG GND Signal Ground 0V
C1-24 SIG GND Signal Ground 0V
C1-25 AFTFP1 AFT Fuel Pressure 1 1.20 V +/- 0.30 V
C1-26 AFTFT AFT Fuel Temperature 3.24 V
C1-27 DPFOT DPF Outlet Temperature 4.56 V
C1-28 DOCIT DOC Inlet Temperature 4.55 V
C1-30 ECM PWR OUT ECM Power Output 3 B+
3
C1-33 ECM PWR OUT ECM Power Output 1 B+
1
C1-34 J1939-H J1939 Datalink High 2.69 V
C1-36 VREF1 Voltage Reference 1 5.00 V
C1-37 VREF4 Voltage Reference 4 5.00 V
C1-39 NVOLT Nernst Volt 3.02 V
C1-40 VIRGND Virtual Ground 2.59 V
C1-41 SIG GND Signal Ground 0V
C1-42 ECM PWR OUT ECM Power Output 2 B+
2
C1-46 O2SH-L Oxygen Sensor High and Low B+

975
 972 12 APPENDIX B: SIGNAL VALUES

ECM 58-pin C1 Connector

ECM Pin Abbreviation Circuit Name KOEO
C1-47 J1939-L J1939 Datalink Low 2.40 V
C1-49 VREF4 Voltage Reference 4 5.00 V
C1-50 VREF5 Voltage Reference 5 5.00 V
C1-52 PUMPCUR Pumping Current 2.90 V
C1-53 TRIMRES Trim Resistor 2.92 V
C1-54 ECM PWR OUT ECM Power Output 1 B+
1
C1-55 SIG GND Signal Ground 0V
C1-56 ERO Engine Running Output 0.10 V
C1-57 MIL Malfunction Indicator Lamp 3.58 V +/- 0.10 V
C1-58 EFS Engine Fan Speed 5.00 V

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976
 12 APPENDIX B: SIGNAL VALUES 973

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and with
Breakout Harness 00-01467-00 connected between the Engine Control Module (ECM) and vehicle
harness. See “APPENDIX A: PERFORMANCE SPECIFICATIONS” (page 953) for actuator output
voltages, sensor values, and component specifications in a range of conditions.

ECM 98-pin E1 Connector

ECM Pin Abbreviation Circuit Name KOEO
E1-02 TC2WC Turbocharger 2 Wastegate Control B+
E1-03 IAHFS Inlet Air Heater Fuel Solenoid B+
E1-04 EBPV Exhaust Back Pressure Valve B+
E1-05 ECM PWR OUT 2 ECM Power Output 2 B+
E1-07 CCOSS-L Crankcase Oil Separator Speed Low 2.58 V
E1-10 EOP Engine Oil Pressure 0.59 V
E1-12 TC2CIT Turbocharger 2 Compressor Inlet 2.32 V
Temperature
E1-13 CACOT Charge Air Cooler Outlet Temperature 2.46 V +/- 0.50 V
E1-14 ECT1 Engine Coolant Temperature 1 2.21 V

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E1-15 VSS-L Vehicle Speed Sensor Low 2.46 V
E1-16 CKP-L Crankshaft Position Low 2.50 V
E1-17 CMP-H Camshaft Position High 2.64 V
E1-18 IMP Intake Manifold Pressure 0.80 V
E1-19 SIG GND Signal Ground 0V
E1-20 SIG GND Signal Ground 0V
E1-21 SIG GND Signal Ground 0V
E1-22 SIG GND Signal Ground 0V
E1-23 SIG GND Signal Ground 0V
E1-24 ECM PWR OUT 3 ECM Power Output 3 B+
E1-25 FPCV 12V Fuel Rail Pressure Control High B+
E1-26 ECM PWR OUT 3 ECM Power Output 3 B+
E1-27 ECM PWR OUT 3 ECM Power Output 3 B+
E1-28 ECM PWR OUT 2 ECM Power Output 2 B+
E1-29 ECM PWR OUT 2 ECM Power Output 2 B+
E1-31 CCOSS-H Crankcase Oil Separator Speed High 2.58 V
E1-34 FRP Fuel Rail Pressure 0.54 V +/- 0.20 V
E1-35 FDP Fuel Delivery Pressure 0.59 V
E1-36 EOT Engine Oil Temperature 2.40 V
E1-37 IMT Intake Manifold Temperature 2.36 V

977
 974 12 APPENDIX B: SIGNAL VALUES

ECM 98-pin E1 Connector

ECM Pin Abbreviation Circuit Name KOEO
E1-38 IAT Inlet Air Temperature 2.49 V
E1-39 VSS-H Vehicle Speed Sensor High 2.65 V
E1-40 CKP-H Crankshaft Position High 2.61 V
E1-41 CMP-L Camshaft Position Low 2.51 V
E1-42 AAT Ambient Air Temperature 2.67 V at 70°
E1-43 SIG GND Signal Ground 0V
E1-44 SIG GND Signal Ground 0V
E1-45 SIG GND Signal Ground 0V
E1-46 SIG GND Signal Ground 0V
E1-47 ECB1 Engine Compression Brake 1 B+
E1-48 CMV Coolant Mixer Valve B+
E1-49 ECB2 Engine Compression Brake 2 B+
E1-50 ECB2 12V Engine Compression Brake 2 High B+

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E1-52 TC1WC Turbocharger 1 Wastegate Control B+
E1-53 AFTFD-H AFT Fuel Doser High 1.30 V
E1-54 ECM PWR OUT 2 ECM Power Output 2 B+
E1-55 SIG GND Signal Ground 0V
E1-57 ETP Engine Throttle Position 2.82 V
E1-58 VREF4 Voltage Reference 4 5.00 V
E1-61 TC1TOP Turbocharger 1 Turbine Outlet Pressure 0.94 V
E1-63 SIG GND Signal Ground 0V
E1-64 EOL Engine Oil Level 0.10 V
E1-67 IAHRD Inlet Air Heater Relay Diagnostic 6.10 V
E1-68 SIG GND Signal Ground 0V
E1-71 ECT2 Engine Coolant Temperature 2 2.29 V
E1-72 IAHRC Inlet Air Heater Relay Control 0.95 V
E1-73 FRPCV Fuel Rail Pressure Control Valve 8.75 V +/- 0.20 V
E1-74 CFV Coolant Flow Valve B+
E1-75 ETC Engine Throttle Control 7.77 V
E1-76 AFTFD-L AFT Fuel Doser Low 1.32 V
E1-77 EGR-C Exhaust Gas Recirculation Control 7.78 V
E1-79 TC2CIP Turbocharger 2 Compression Inlet 1.15 V
Pressure
E1-81 VREF5 Voltage Reference 5 5.00 V

978
 12 APPENDIX B: SIGNAL VALUES 975

ECM 98-pin E1 Connector

ECM Pin Abbreviation Circuit Name KOEO
E1-82 VREF5 Voltage Reference 5 5.00 V
E1-83 SIG GND Signal Ground 0V
E1-85 VREF2 Voltage Reference 2 5.00 V
E1-86 VREF2 Voltage Reference 2 5.00 V
E1-88 VREF6 Voltage Reference 6 5.00 V
E1-89 VREF3 Voltage Reference 3 5.00 V
E1-94 SIG GND Signal Ground 0V
E1-95 EGRT EGR Temperature 4.66 V
E1-96 IAHRE Inlet Air Heater Relay Enable B+

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979
 976 12 APPENDIX B: SIGNAL VALUES

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980
 13 APPENDIX C: TECHNICAL SERVICE INFORMATION (TSI) 977

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .979

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 978 13 APPENDIX C: TECHNICAL SERVICE INFORMATION (TSI)

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Description product enhancements and field service issues. File

TSIs in this section for supplemental reference.
Technical Service Information (TSI) letters are
periodically published to inform service technicians of

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