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DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.
7l DIESEL 9 -1629
ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL
TABLE OF CONTENTS
page page
ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L P0102-MASS AIR FLOW SENSOR "A"

DIESEL CIRCUIT LOW ........................... 1709
DIAGNOSIS AND TESTING P0103-MASS AIR FLOW SENSOR "A"
PRE·DIAGNOSTIC TROUBLESHOOTING CIRCUIT HIGH .......................... 1715
PROCEDURE ........................... 1634 P0106..MANIFOLD ABSOLUTE PRESSURE
INTERMITTENT CONDITION ............... 1636 SENSOR PERFORMANCE ............... 1720
POOOF-FUEL SYSTEM OVER PRESSURE P0107·MANIFOLD ABSOLUTE PRESSURE
RELIEF VALVE ACTiVATED ............... 1637 SENSOR CIRCUIT LOW .................. 1723
P0016-CRANKSHAFT/CAMSHAFT TIMING P0108-MANIFOLD ABSOLUTE PRESSURE
MISALIGNMENT - BANK 1 SENSOR 1 ..... 1640 SENSOR CIRCUIT HIGH ................. 1730
P0031-02 SENSOR 1/1 HEATER CIRCUIT P0111-INTAKE AIR TEMPERATURE SENSOR
LOW.................................... 1642 1 PERFORMANCE ....................... 1736
P0037-02 SENSOR 1/2 HEATER CIRCUIT P0112-INTAKE AIR TEMPERATURE,
LOW.................................... 1645 SENSOR 1 CIRCUIT LOW ................ 1738
P003A-TURBOCHARGER BOOST CONTROL P0113-INTAKE AIR TEMPERATURE
MODULE POSITION EXCEEDED SENSOR 1 CIRCUIT HIGH ............... 1743
LEARNING LIMIT ........................ 1648 P01l6-ENGINE COOLANT TEMPERATURE
P0046-TURBOCHARGER BOOST CONTROL SENSOR PERFORMANCE ............... 1748
CIRCUIT PERFORMANCE ................ 1651 POll7-ENGINE COOLANT TEMPERATURE
P0049-TURBOCHARGER TURBINE SENSOR CIRCUIT LOW .................. 1751
OVERSPEED ............................ 1654 P0118-ENGINE COOLANT TEMPERATURE
P006E-TURBOCHARGER BOOST CONTROL SENSOR CIRCUIT HIGH ................. 1754
MODULE SUPPLY VOLTAGE CIRCUIT P0128-THERMOSTAT RATIONALITY ........ 1759
LOW.................................... 1659 P0131-02 SENSOR 1/1 CIRCUIT LOW ..... 1760
P006F-TURBOCHARGER BOOST CONTROL P0135-02 SENSOR 1/1 HEATER
SUPPLY VOLTAGE CIRCUIT HIGH ........ 1661 PERFORMANCE. ........................ 1767
P007l-INLET AIR TEMP SENSOR P0137-02 SENSOR 1/2 CIRCUIT LOW ..... 1774
RATIONALITY - ECM ..................... 1663 P0141-02 SENSOR 1/2 HEATER
P0071-AMBIENT AIR TEMPERATURE PERFORMANCE ......................... 1779
SENSOR PERFORMANCE (TIPM) ......... 1665 P0148-FUEL DELIVERY ERROR ........... 1784 _
P0072-INLET AIR TEMP SENSOR VOLTAGE P0169-WATER IN FUEL DETECTED FOR
TOO LOW - ECM ........................ 1669 TOO LONG ............................. 1787
P0072-AMBIENT AIR TEMPERATURE P0191·FUEL RAIL PRESSURE SENSOR
SENSOR CIRCUIT LOW .................. 1673 CIRCUIT PERFORMANCE ................ 1789
P0073-INLET AIR TEMP SENSOR VOLTAGE P0192-FUEL PRESSURE SENSOR LOW .... 1791
TOO HIGH - ECM ........................ 1676 P0193-FUEL PRESSURE SENSOR HIGH ... 1797
P0073-AMBIENT AIR TEMPERATURE P0201-FUEL INJECTOR 1 CIRCUIT/OPEN .. 1803
SENSOR CIRCUIT HIGH (TIPM) .......... 1680 P0202~FUEL INJECTOR 2 CIRCUIT/OPEN .. 1816
P007C-CHARGE AIR COOLER P0203-FUEL INJECTOR 3 CIRCUIT/OPEN " 1828
TEMPERATURE SENSOR CIRCUIT LOW .. 1684 P0204~FUEL INJECTOR 4 CIRCUIT/OPEN " 1840
P007E-CHARGE AIR COOLER P0205-FUEL INJECTOR 5 CIRCUIT/OPEN .. 1851
TEMPERATURE SENSOR CIRCUIT HIGH .. 1689 P0206-FUEL INJECTOR 6 CIRCUIT/OPEN .. 1862
P007E-CHARGE AIR COOLER P0217-COOLANT TEMPERATURE TOO
TEMPERATURE SENSOR CIRCUIT HIGH ................................... 1874
INTERMITTENT/ERRATIC ................ 1694 P0219-ENGINE OVERSPEED .............. 1876
P0087·FUEL RAIL PRESSURE TOO LOW ... 1697 P0251-INJECTION PUMP FUEL VALVE
P008S-FUEL RAIL PRESSURE TOO HIGH .. 1701 FEEDBACK ............................. 1877
POOAF-TURBOCHARGER BOOST CONTROL P0300-MULTIPLE CYLINDER MISFIRE ..... 1884
MODULE PERFORMANCE ............... 1704 P0301·CYLINDER 1 MISFIRE .............. 1887
P0101-MASS AIR FLOW SENSOR IfA" P0302-CYLINDER 2 MISFIRE .............. 1890
CIRCUIT PERFORMANCE ................ 1706 P0303-CYLINDER 3 MISFIRE .............. 1893
9· 1630 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l D I E S E l - - - - - - - - - DR
P0304-CYLINDER 4 MiSFIRE .............. 1896 P0516-BATTERY TEMPERATURE SENSOR

P030S-CYLINDER S MiSFIRE .............. 1899 CIRCUIT LOW ........................... 2021
P0306-CYLINDER 6 MiSFIRE .............. 1902 POS17-BATTERY TEMPERATURE SENSOR
P033S-CRANKSHAFT POSITION SENSOR CIRCUIT HIGH . . . . . .. .. ............... 2024
PERFORMANCE. ........................ 1905 P051 B-CRANKCASE PRESSURE SENSOR
P0336-CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE ........ 2027
PERFORMANCE ......................... 1911 POS1C-CRANKCASE PRESSURE SENSOR
P0340-CAMSHAFT POSITION SENSOR CIRCUIT LOW ........................... 2030
CIRCUIT - BANK 1 SENSOR 1 ............ 1917 P051D-CRANKCASE PRESSURE SENSOR
P0341-CAMSHAFT POSITION SENSOR CIRCUIT HIGH .......................... 2034
PERFORMANCE - BANK 1 SENSOR 1 .... 1923 P0521-ENGINE OIL PRESSURE SENSOR
P0381-WAIT TO START LAMP INOPERATIVE. 1929 PERFORMANCE. ........................ 2038
P0400-EGR SYSTEM FLOW MALFUNCTION. 1931 P0524-ENGINE OIL PRESSURE TOO LOW . 2041
P0401-EGR SYSTEM PERFORMANCE ..... 1933 P0532-AlC PRESSURE SENSOR CIRCUIT
P0402-EGR FLOW EXCESSIVE DETECTED. 1937 LOW .................................... 2044
P0403-EGR CONTROL CiRCUiT/OPEN ..... 1940 POS33-AlC PRESSURE SENSOR CIRCUIT
P0404-EG R POSITION SENSOR HIGH ................................... 2051
PERFORMANCE (DIESEL) ............... 1944 P0541-INTAKE AIR HEATER CONTROL
P0405-EGR POSITION SENSOR CIRCUIT CIRCUIT 1 LOW ......................... 20S6
LOW.................................... 1946 P0542-INTAKE AIR HEATER CONTROL
P040B-EXHAUST GAS RECIRCULATION CIRCUIT 1 HIGH ......................... 20S9
TEMPERATURE SENSOR 1 CIRCUIT P0545-EXHAUST GAS TEMPERATURE
PERFORMANCE. ........................ 1952 SENSOR CIRCUIT LOW - BANK 1
P040C-EXHAUST GAS RECIRCULATION SENSOR 1 .............................. 2062
TEMPERATURE SENSOR 1 CIRCUIT LOW. 1954 P0546-EXHAUST GAS TEMPERATURE
P040D-EXHAUST GAS RECIRCULATION SENSOR CIRCUIT HIGH - BANK 1
TEMPERATURE SENSOR 1 CIRCUIT HIGH. 1957 SENSOR 1 .............................. 2067
P0420-CATALYST EFFICIENCY BANK 1 .... 1961 P0562-BATTERY VOLTAGE LOW ........... 2072
P042E-EXHAUST GAS RECIRCULATION P0563-BATTERY VOLTAGE HIGH .......... 2075
CONTROL STUCK OPEN ................. 1964 P0571':BRAKE SWITCH 1 PERFORMANCE . 2077
P0461-FUEL LEVEL SENSOR 1 P0572-BRAKE SWITCH 1 STUCK ON ...... 2078
PERFORMANCE. ........................ 1965 P0573-BRAKE SWITCH 1 STUCK OFF ..... 2081
P0462-FUEL LEVEL SENSOR 1 CIRCUIT P0580-SPEED CONTROL SWITCH 1
LOW .................................... 1968 CIRCUIT LOW ........................... 2084
P0463-FUEL LEVEL SENSOR 1 CIRCUIT P0581-SPEED CONTROL SWITCH 1
HIGH .................................. 1972 CIRCUIT HIGH .......................... 2088
P0471-EXHAUST PRESSURE SENSOR 1 POS8S-SPEED CONTROL SWITCH 1/2
PERFORMANCE. ........................ 1975 CORRELATION. . . . . . . . . . . . . . . .. . ....... 2093
P0472- EXHAUST PRESSURE SENSOR 1 P0592-SPEED CONTROL SWITCH 2
LOW .................................... 1978 CIRCUIT LOW ........................... 2095
P0473- EXHAUST PRESSURE SENSOR 1 P0593-SPEED CONTROL SWITCH 2
HIGH ................................... 198S CIRCUIT HIGH .......................... 2099
P0480-COOLING FAN 1 CONTROL P0601-INTERNAL MEMORY CHECKSUM
CIRCUIT/OPEN .......................... 1991 INVALlD ................................ 2104
P0483-COOLING FAN SPEED ............. 1995 P0604-INTERNAL CONTROL MODULE RAM . 2105
P0487-EGR AIRFLOW THROTTLE P0606-INTERNAL CONTROL PROCESSOR. 2106
CONTROL CIRCUIT A OPEN .............. 2001 P0607 ECU INTERNAL PERFORMANCE .... 2107
P0488-EGR AIRFLOW THROTTLE P061 A-ETC LEVEL 2 TORQUE
CONTROL CIRCUIT PERFORMANCE ..... 200S PERFORMANCE. ........................ 2108
P0489-EGR CONTROL CIRCUIT LOW ...... 2011 P061C-ETC LEVEL 2 RPM PERFORMANCE. 2110
POS01-VEHICLE SPEED SENSOR 1 P0622-GENERATOR FIELD CONTROL
PERFORMANCE. ........................ 2013 CIRCUIT/OPEN .......................... 2111
POSOS-ENGINE SPEED AT IDLE - DATA P0628-FUEL PUMP CONTROL CIRCUIT
ERRATIC, INTERMITTENT OR LOW ................................ , ... 2114
INCORRECT ............................ 2016 P0629-FUEL PUMP CONTROL CIRCUIT
POS13-INVALID SKIM KEY ................. 2017 HIGH ................................... 2117
P0514-BATTERY TEMPERATURE SENSOR P062C-ETC LEVEL 2 MPH PERFORMANCE .. 2121
PERFORMANCE. ........................ 2019 P0630-VIN NOT PROGRAMMED IN PCM ... 2122
DR - - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS . . 6.7L DIESEL 9 .. 1631
P0633-SKIM SECRET KEY NOT STORED IN P141 A-EXHAUST GAS TEMPERATURE

PCM .................................... 2123 SENSOR 1 AND 2 SIGNALS SWAPPED '" 2206
P063C-GENERATOR VOLTAGE SENSE LOW. 2124 P144E-EGR COOLER BYPASS STATUS
P063D-GENERATOR VOLTAGE SENSE LINE CIRCUIT LOW .................... «. 2208
HIGH ................................ ««.2127 P144F-EGR COOLER BYPASS STATUS LINE
P0642-SENSOR REFERENCE VOLTAGE 1 CIRCUIT HIGH .......................... 2211
CIRCUIT LOW ........................... 2131 P1451-DIESEL PARTICULATE FILTER
P0643-SENSOR REFERENCE VOLTAGE 1 SYSTEM PERFORMANCE ................ 2215
CIRCUIT HIGH .......................... 2134 P1484-CATALYST OVERHEAT DETECTION . 2218
P0646-AlC CONTROL CIRCUIT LOW ....... 2137 P1506-CRANKCASE DEPRESSION
P0647-AlC CONTROL CIRCUIT HIGH ....... 2140 REGULATOR VALVE PERFORMANCE ..... 2221
P0652-SENSOR REFERENCE VOLTAGE 2 P1507-CRANKCASE FILTER RESTRICTION. 2222
LOW.................................... 2143 P1508-CRANKCASE FILTER RESTRICTION-
P0653-SENSOR REFERENCE VOLTAGE 2 REPLACE FILTER ....................... 2223
HIGH .................. «....... «........ 2146 P2000-NOX ADSORBER EFFICI ENCY
P065A-GENERATOR SYSTEM BELOW THRESHOLD - BANK 1 ........... 2224
PERFORMANCE. ........................ 2148 P2002-DIESEL PARTICULATE FILTER
P0698-SENSOR REFERENCE VOLTAGE 3 EFFICIENCY BELOW THRESHOLD ....... 2229
CIRCUIT LOW ........................... 2150 P200C-DIESEL PARTICULATE FILTER OVER
P0699-SENSOR REFERENCE VOLTAGE 3 TEMPERATURE· BANK 1 ................ 2232
CIRCUIT HIGH ......... «................ 2152 P200E-CATALYST SYSTEM OVER
P06A4-SENSOR REFERENCE VOLTAGE 4 TEMPERATURE· BANK 1 ................ 2235
CIRCUIT LOW ................. «......... 2154 P2032-EXHAUST GAS TEMPERATURE
P06A5-SENSOR REFERENCE VOLTAGE 4 SENSOR CIRCUIT LOW- BANK 1 SENSOR
CIRCUIT HIGH .......................... 2156 2 ................... 2238
« •• «.« • • • • • • «.«« • • • •
P0700-TRANSMISSION CONTROL SYSTEM P2033-EXHAUST GAS TEMPERATURE

(MIL REQUEST) ....... «................. 2158 SENSOR CIRCUIT HIGH - BANK 1
P0850-PARK/NEUTRAL SWITCH SENSOR 2 ....................... 2242
,
« ••••••
PERFORMANCE. ........................ 2159 P2080·EXHAUST GAS TEMP SENSOR

P113C·02 SENSOR POWER SUPPLY CIRCUIT PERFORMANCE - BANK 1
CIRCUIT PERFORMANCE ................ 2160 SENSOR 1 .... ow 2246
........................
P125A-POWER ENABLE CONTROL P2084-EXHAUST GAS TEMP SENSOR

CIRCUIT LOW ........................... 2163 CIRCUIT PERFORMANCE - BANK 1
P125B-POWER ENABLE CONTROL SENSOR 2 .............................. 2248
CIRCUIT HIGH .......................... 2166 P2121-ACCELERATOR PEDAL POSITION
P1272-AlC CLUTCH CONTROL CIRCUIT 2 SENSOR 1 PERFORMANCE .............. 2250
LOW .................................... 2169 P2122-ACCELERATOR PEDAL POSITION
P1273-AlC CLUTCH CONTROL CIRCUIT 2 SENSOR 1 CIRCUIT LOW .... « 2258
•••••••••••
HIGH ................................... 2172 P2123-ACCELERATOR PEDAL POSITION

P1274-AlC CLUTCH CONTROL CIRCUIT 2 SENSOR 1 CIRCUIT HIGH ............... 2264
OPEN .................................. 2176 P2127-ACCELERATOR PEDAL POSITION
P1275-AlC CLUTCH CONTROL CIRCUIT 2 SENSOR 2 CIRCUIT LOW ................ 2269
OVERCURRENT ................. «....... 2180 P2128-ACCELERATOR PEDAL POSITION
P1277-STARTER CONTROL CIRCUIT 2 LOW SENSOR 2 CIRCUIT HIGH ............... 2275
(TIPM) .. «« ........... «.................. 2183 P2141-EGR AIRFLOW THROTTLE
P1278-STARTER CONTROL CIRCUIT 2 CONTROL CIRCUIT LOW ................ 2280
HIGH (TtPM) ............................ 2185 P2142-EGR AIRFLOW THROTTLE
P1279-STARTER CONTROL CIRCUIT 2 CONTROL CIRCUIT HIGH ........... 2283 « ••••
OPEN (TIPM) ............................ 2187 P2227-BAROMETERIC PRESSURE SENSOR

P127A-STARTER CONTROL CIRCUIT 2 RATIONALITY ........................... 2285
OVERCURRENT (TIPM) .................. 2189 P2228-BAROMETRIC PRESSURE CIRCUIT
P127C-FUEL PUMP CONTROL CIRCUIT 2 LOW .................................... 2286
LOW (TIPM) ............................. 2192 P2229-BAROMETRIC PRESSURE CIRCUIT
P127D-FUEL PUMP CONTROL CIRCUIT 2 HIGH ............................ 2290 « ••••••
HIGH (TIPM) ............................ 2195 P2262-TURBOCHARGER BOOST

P127E-FUEL PUMP CONTROL CIRCUIT 2 PRESSURE NOT DETECTED-
OPEN (TIPM) ............................ 2199 MECHANICAL ........................... 2294
P0127F-FUEL PUMP CONTROL CIRCUIT 2 P2266-WATER IN FUEL SENSOR CIRCUIT
OVERCURRENT (TIPM) «................. 2203 LOW .................................... 2296
9 ·1632 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
P2267-WATER IN FUEL SENSOR CIRCUIT P268D-CYLINDER 2 INJECTOR DATA

HIGH ................................... 2299 INCOMPATIBLE ......................... 2380
P2269-WATER IN FUEL CONDITION ....... 2302 P268E-CYLINDER 3 INJECTOR DATA
P2299-BRAKE PEDAL POSITION / INCOMPATIBLE ......................... 2381
ACCELERATOR PEDAL POSITION P268F-CYLINDER 4 INJECTOR DATA
INCOMPATIBLE ......................... 2304 INCOMPATIBLE ......................... 2382
P242B-EXHAUST GAS TEMP SENSOR P2690-CYLINDER 5 INJECTOR DATA
CIRCUIT PERFORMANCE - BANK 1 INCOMPATIBLE ......................... 2383
SENSOR 3 - DIESEL. .................... 2306 P2691-CYLINDER 6 INJECTOR DATA
P242C-EXHAUST GAS TEMPERATURE INCOMPATIBLE ......................... 2384
SENSOR CIRCUIT LOW- BANK 1 SENSOR P2AOO-02 SENSOR 1/1 CIRCUIT
3 ....................................... 2308 PERFORMANCE. ........................ 2385
P242D-EXHAUST GAS TEMPERATURE P2A01-02 SENSOR 1/2 CIRCUIT
SENSOR CIRCUIT HIGH - BANK 1 PERFORMANCE. ........................ 2390
SENSOR 3 .............................. 2312 U0001-CAN C BUS ....................... 2395
P242F-DIESEL PARTICULATE FILTER U0101-LOST COMMUNICATION WITH TCM .2396
RESTRICTION - ASH ACCUMULATION .... 2316 U010C-LOST COMMUNICATION WITH
P244A·DIESEL PARTICULLATE FILTER TURBOCHARGER/SUPERCHARGER
DIFFERENTIAL PRESSURE TOO LOW .... 2319 CONTROL MODULE ..................... 2398
P244D-EXHAUST TEMPERATURE TOO U011 A-LOST COMMUNICATION WITH
HIGH FOR PARTICULATE FILTER EXHAUST GAS SENSOR MODULE ....... 2403
REGENERATION-BANK 1 ................ 2321 U0121-LOST COMMUNICATION WITH
P2453-DIESEL PARTICULATE FILTER ANTI-LOCK BRAKE MODULE ............. 2408
PRESSURE SENSOR A CIRCUIT U0141-LOST COMMUNICATION WITH FCM
PERFORMANCE. ........................ 2324 (TIPM) .................................. 2409
P2454-DIESEL PARTICULATE FILTER U1403-IMPLAUSIBLE FUEL LEVEL SIGNAL
PRESSURE SENSOR A CIRCUIT LOW .... 2327 RECEIVED .............................. 2410
P2455-DIESEL PARTICULATE FILTER U1412-IMPLAUSIBLE VEHICLE SPEED
PRESSURE SENSOR A CIRCUIT HIGH .... 2330 SIGNAL RECEiVED ...................... 2411
P2457 -EXHAUST GAS RECIRCULATION U1421-IMPLAUSIBLE IGNITION KEY OFF
COOLING SYSTEM PERFORMANCE ...... 2334 TIME RECEiVED ........................ 2413
P245A-EGR COOLER BYPASS CONTROL *CHECKING THE ACCELERATOR PEDAL
CIRCUIT IOPEN ......................... 2336 SENSOR CALIBRATION .................. 2414
P245C-EGR COOLER BYPASS CONTROL "'CHECKING THE ECM POWER AND
CIRCUIT LOW ........................... 2340 GROUNDS .............................. 2415
P245D-EGR COOLER BYPASS CONTROL *CHECKING THE EXHAUST SYSTEM FOR
CIRCUIT HIGH .......................... 2344 LEAKS .................................. 2416
P2463-DIESEL PARTICULATE FILTER - * PRESSURE LIMITING VALVE TEST ....... 2417
SOOT ACCUMULATION .................. 2347 *ENGINE SURGES ........................ 2418
P2503-CHARGING SYSTEM OUTPUT LOW. 2350 "'ENGINE NO START/HARD START ......... 2420
P2504-CHARGING SYSTEM OUTPUT HIGH. 2353 *ENGINE NOiSE .......................... 2423
P2509-ECM/PCM POWER INPUT SIGNAL *FUEL HEATER THERMOSTAT TEST ....... 2424
INTERMITTENT ......................... 2357 *INJECTOR RETURN FLOW TEST ......... 2425
P254C-PTO SPEED SELECTOR SENSOR "'IN-TANK FUEL LIFT PUMP FLOWI
CIRCUIT LOW ........................... 2360 DIAGNOSTIC TEST PROCEDURE ........ 2427
P254D-PTO SPEED SELECTOR SENSOR *FUEL PUMP RETURN FLOW TEST ........ 2429
CIRCUIT HIGH .......................... 2364 *HIGH PRESSURE FUEL PUMP
P2579-TURBOCHARGER SPEED SENSOR PERFORMANCE TEST ................... 2430
CIRCUIT PERFORMANCE ................ 2367 *INTAKE AIR SYSTEM PRESSURE TEST ... 2431
P2580-TURBOCHARGER SPEED SENSOR "OFF-IDLE ENGINE SPEED LOW DURING
CIRCUIT LOW ........................... 2371 COLD START ........................... 2431
P2609-INTAKE AIR HEATER SYSTEM STANDARD PROCEDURE
PERFORMANCE. ........................ 2376 ECM/PCM PROGRAMMING ............... 2432
P268C-CYLINDER 1 INJECTOR DATA POWERTRAIN VERIFICATION TEST ....... 2437
INCOMPATIBLE ......................... 2379
DR ENGINE - ELECTRICAL DIAGNOSTICS - 6.1L DIESEL 9 - 1633
ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL

DIAGNOSIS AND TESTING
9 - 1634 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE
For a complete wiring diagram Refer to Section 8W.
Diagnostic Test
1. NO RESPONSE
Make sure the scan tool will communicate with the appropriate modules.
Are you currently experiencing a NO RESPONSE condition?
Yes »The NO RESPONSE condition must be properly diagnosed before continuing.
Refer to the appropriate BUS Communication test in Section 8 ELECTRONIC CONTROL MODULES -
ELECTRrCAL DIAGNOSTICS.
No »Go To 2
2. NO START
Is the customer complaint a NO START condition?
Yes »Check the vehicle for any NO START related ECM DTC(s) or Vehicle Theft Security related DTC(s).
If no Theft related DTC(s) are present, refer to the Non DTC Diagnostic Procedures that relate to Fuel
and Starting.
No »Go To 3
3. VEHICLE HISTORY AND

Continue by reading ECM DTC(s) and record the related Freeze Frame data if any DTC(s) are present.
Whether or not any DTC(s) are present you will want to check the following items which may assist in repairing the
customers complaint successfully.
Check the vehicles repair history.
If the vehicle has a repair history that pertains to the customer's current complaint, review the repair.
Inspect the vehicle for any aftermarket accessories that may have been installed incorrectly.
Check for any TSB(s) related to the customer's complaint or DTC(s).
If a TSB applies, follow the instructions per the TSB.
Choose the following scenario that best applies.
The TSB repaired the customers complaint.
Testing complete.
A DTC is present, no TSB applies, or the TSB didn't repair the customers complaint.
Go To 4
No DTCes) are present.
Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS" 6.7l DIESEL 9 -1635
4. WIRE HARNESS INSPECTION

Clear the DTC(s).
Attempt to duplicate the customer complaint.
Whether the customer complaint can be duplicated or not, make a quick wire harness inspection related to the
DTC(s) that were previously cleared.
Check the Engine Control Module connectors, the suspected component connection, in-line connectors, wire har-
ness splices, ECM power and ground circuits, and any related fuses.
If the DTC(s) are fuel or air related, check the fuel level and quality.
Were any repairs made that fixed the customer's complaint?
Yes »Testing complete.
No »Refer to the diagnostic test procedure related to the DTC.
9 ·1636 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
INTERMITTENT CONDITION
POSSIBLE CAUSES
IINTERMITIENT CONDITION
Diagnostic Test
1. INTERMITTENT CONDITION
NOTE: The conditions that set the DTe are not present at this time. The following Jist may help in identi-
fying the intermittent condition.
WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands
near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in
personal injury or death.
Reter to any Technical SeNice Bulletins (TSBs) that may apply.
Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the scan tool parameters related to the DTC while
wiggling the wire harness. Look for parameter values to change and/or a DTC to set.
Turn the ignition off.
Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed,
pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals.
Perform a voltage drop test on the related circuits between the suspected faulty component and the ECM.
Inspect and clean all ECM, engine, and chassis grounds that are related to the most current DTC.
If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits.
For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the
actuation.
For intermittent Evaporat;ve Emission trouble codes perform a visual and physical inspection of the related parts
including hoses and the Fuel Filler cap.
For intermittent Misfire DTC's check for restrictions in the Intake and Exhaust system, proper installation of Sensors,
vacuum leaks, and binding components that are run by the accessory drive belt.
Use the scan tool to perform a System Test jf one applies to failing component.
A co-pilot, data recorder, and/or fab scope should be used to help diagnose intermittent conditions.
Were any problems found during the above inspections?
Yes »Perform the necessary repairs.
Perform POWERTRAIN VERIFICATION TEST (DIESEL) (Refer to 9 - ENGINE - STANDARD PROCE-
DURE).
No »Test Complete.
DR ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 -1637
POOOF-FUEL SYSTEM OVER PRESSURE RELIEF VALVE ACTIVATED
I.IIOR·
FUEL
RAIL
FUEL
PA••IURI
RAIL
SENSOR SENSOR 5VOLT
SIGNAL GROUND SUPPLY
'I 1
3
K9IS F855
18 18
BRIOR PKIVL
" (
I
• 10"
I
• 11Ja
\ \
K181 K916 F855
18 18 18
BRIYt. BR/oR PKiVL
~
"Li -sENsoR
"ti - JCi
FUE7'"" :- -SVolT-I·ODULE.
I RAil GROUND SUPPLY EII.I.
SENSOR I CO~TROL
I SIGNAL I '
I I
!... __________ I
°l
-= "
~ooo~
iii
10
'00000
l~ 00000 00000 II
30 00000 00000 21
00000 0 00000
40
~O.
00000
00000
00000
00000
31 = = =
, 41 "
eo \.... .A ~ 51
L.J '-' I •••OR·
FUEL RAIL
PREll URI
MODULE· IDI.IEL)
ElIIIE
CONTROL ct
(I.ILI

9 -1638 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The ECM will turn on the MIL lamp immediately after this diagnostic runs and fails. The ECM will turn off the MIL
lamp after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
Engine running
• Set Condition:
Fuel pressure deviation from setpoint occurs at a rate higher than a calibrated amount.
Possible Causes
PRESSURE LIMITING VALVE

LIFT PUMP
HIGH PRESSURE PUMP
EXCESSIVE INJECTOR DRAINS
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1 a PRESSURE LIMITING VALVE

Ignition on, engine not running.
Using the electronic scan tool, view the pressure limiting valve counter and pressure limiting valve timer.
Is the counter value higher than 50 or the timer value higher than 5 hours?
Yes »Change the pressure limiting valve. When valve replacement is complete, use the scan tool to reset the
pressure limiting valve counter and timer. This command is in the PCM Misc Functions.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. LIFT PUMP
Perform In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure
Does the lift pump pass the In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure ?
Yes »Go To 3
No »Replace Lift Pump. Go to 6
3. HIGH PRESSURE PUMP PERFORMANCE

Perform High Pressure Fuel Pump Performance Test.
Is the fuel flow above the specification?
Yes »Go To 4
No »Replace appropriate component as per High Pressure Fuel Pump Performance Test tree. Go to 6
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 • 1639
4. HIGH PRESSURE PUMP RETURN

Perform Fuel Pump Return Flow Test
NOTE: Part of this test requires that the Pressure Limiting Valve leakage is checked. This work was already
performed in step 2.
Is the drain flow measured less than 1000 ml/minute at idle?
Ves »Go To 5
No »Replace fuel injection pump. Go to 6
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 . ENGINE - STANDARD PROCE-
DURE)
5. FUEL INJECTOR RETURN FLOW

Perform Injector Return Flow Test
NOTE: Step 6 requires Fuel Injector Return Flow to be measured. That test can be performed at the same
time as the High Pressure Pump Return test.
Is the fuel flow below the specification?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
No »Replace appropriate component per Injector Return Flow test. Go to 6
Perform POWERTRAIN VERlFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
6. PRESSURE LIMITING VALVE

Remove the banjo bolt from the pressure limiting valve drain on the fuel rail.
Install fuel system test fitting #9012 into the drain.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container.
Operate the engine at idle and watch for fuel flow into the container.
Operate the engine at idle and actuate the high pressure safety valve test with the scan toot
Watch for fuel flow into the fuel container.
Does fuel flow into the container under either operating conditions?
Yes »Change the pressure limiting valve. When valve replacement is complete, use the scan tool to reset the
pressure limiting valve counter and timer. This command is in the PCM Misc Functions.
Perform POWERTRAIN VERIFICATION TEST - 6.7L). (Refer to 9 - ENGINE ~ STANDARD PROCE-
DURE)
No »Repair complete.
Perform POWERTRAIN VERIFICATION TEST - 6.7L). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
9 .. 1640 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT - BANK 1 SENSOR 1
SENSOR· SENSOR·
CAMSHAFT CRANKSHAFT
POSITION CKP POSITION
CMP SENSOR 5 VOLT 5 VOLT CKP SENSOR
SIGNAL GROUND SUPPL Y SUPPLY SIGNAL GROUND
K44 K916 F855 K824 K24 K925

18 18 18 18 18
DBiGY BR/OR PKIYL DBJBR BRIlB BRIOR
•
I SD44 •
I S173
I I
K916 F855
18 18
BRIOR PKIYl
37
rCMP - C1 ,Jet ,Jet
SENSOR- - 5VOLT - - - - - -
26
svoLT -
C1 31
CKP -
C1
-
44 C1
CKP- - MODULE·
SIGNAL GROUND SUPPL Y SUPPLY SIGNAL SENSOR ENOIME
I GROUND COIIITROL
I
'--------------------------
10
~8"CK
~
20 11
3D 21
50 41
60 5' 3 1
SENSOR· SENSOR·
MODULE· CAMSHAFT CRANkSHAFT
ENGiINE POSITION
POSITIOIII
CONTROL C1 (DIESEL) (DIESEL)
(S.lL)
.1.4HU

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 .. 1641
Theory of Operation
The crankshaft position and camshaft position sensors are hall effect type sensors. The ECM provides a 5-volt sup-
ply to the position sensor and a return circuit. As the teeth on the crankshaft speed ring or the lobes on the cam-
shaft gear passes past the position sensor, a signal is generated on the position sensor signal circuit. The ECM
interprets this signal and coverts it to an engine speed. A missing tooth on the crankshaft gear is used to determine
the position of the engine by the ECM .
• When Monitored:
While Engine is running. The ECM monitors the position of the missing tooth on the crankshaft speed sensor
target and the camshaft speed sensor target. It the two positions do not match, the ECM then determines that
there is a mechanical mis-alignment between the two sensors .
• Set Condition:
The ECM illuminates the MIL light immediately when the diagnostic runs and fails. The ECM will turn off the
MIL after the diagnostic runs and passes in 4 consecutive drive cycles. If the fault is active the engine will run
derated and hard starVrough idle is possible.
Possible Causes
DAMAGE TO THE ESS OR EPS

MECHANICAL MISALIGNMENT OF THE ESS OR EPS
MECHANICAL MISALIGNMENT OF THE CAMSHAFT AND CRANKSHAFT GEARS
Diagnostic Test
1.. DAMAGE TO THE ESS OR EPS

Visually inspect the condition of the tone wheel, ESS, and EPS for damage.
Are any of the components damaged?
Yes »Repair or replace any damaged component.
DURE)
No »Go To 2
2. MECHANICAL MISALIGNMENT OF THE ESS OR EPS

Verify the speed indicator ring is properly positioned relative to the locating pin in the front face of the crankshaft.
Is the speed indicator ring properly installed?
Yes »Go To 3
No »Repair the speed ring indicator ring installation.
DURE)
3. MECHANICAL MISALIGNMENT OF THE CAMSHAFT AND CRANKSHAFT GEARS

Check the mechanical alignment of the camshaft gear to the crankshaft gear. Refer to service manual for assis-
tance.
Are the gear teeth in proper alignment?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
No »Repair the gear alignment.
DURE)
9 - 1642 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL·
P0031-02 SENSOR 1/1 HEATER CIRCLIIT LOW
l,uTU
L- - - - - -IWODULI.
- - - - - - - - - - - - - - - - - 11.DULI.
I
~
(+) - - .., ElECTRONICS
TOULLY I
.ITIIRUED I IUI.IE
B
I I FUSED IGNITION I I POWI!R I DIAGNOSTIC DIAGNOSTIC COITKOL
I SWITCH OUTPUT I I PORT lOW PORT HIGH I
I DATA LINK DATA LINK GROUND GROUND GROUND J
II L (RUN.STA~ -.J
___T_____ _I -;-, Ct - - -;j-:C2 -47~C! -48YC! -57YCI
Z902 Z902 Z902
20 yea 16 16 16
F96D BK BK BK
20
PICA.G
EXCEPT
SHIFT ON SHIFT ON
THE FLY THE Fl Y
• ______ • sn. . - - - . - - - . S1I4
I 1 I
F~O F~O D132 0133 Z902
20 20 18 18 10
PK.tG PKA.G WT WTlOR BK
I
r- -
~ - - ...., I.DULE.
. ,lr cu•
"'1114
I FUSED IGNITION 11iTI-LOCI F960

SWITCH OUTPUT lRAIES 18
I (RUN·START)
'-- _ _ _ ....J
I ('WAL) PKA.G
I
10 ~ - - - 7~ - - - B~ Ci ••
I I I
F960 0132 0133
20 20 20
PKA.G WT WTlOR
9A 3A llA
10DULE·
FUSED IGNInON DIAGNOSTIC DIAGNOSTIC
01 UISOR
SWITCH OUTPUT PORT lOW PORT HIGH
(I.n DI!lEL)
(RUN·START) DATA LINK DATA LINK
02111 02111 02111 02112 02112 021n

02111 HEATER HEATER PUMP CELl 02112 HEATER HEATER PUMP CELL
PUMP 021/1 CONTROL CONTROL CURRENT 02111 CURRENT 021/2 CONTROL CONTROL CURRENT 02112
GROUND CURRENT RETURN RETURN SUPPLY TRIM SIGNAL PUMP RETURN REllIRN SUPPLY TRIM SIGNAL
lOT 7T 14 T 16 T IT 15 T 6T 51 121
8
1 21 13
1 4T
Z902 K89 K902 K79 K99 Kl03 K41 K734 K904 K8D K299 K733 K141
20 20 20 20 20 20 20 20 20 20 20 20 20
t.
BK BRA.G BRlDG BRA.B BRA.G BRltB DBlB BRllG DBI1JG BRITN BRNH BR DBJYL
12 11
Z902
20
BK J J J J JJ
02112
CURRENT
02112
RETURN
02112
HEATER
021f2
HEATER
02112
PUMP CELL
02112
SIGNAL
IUIOR·
OIYCIEl1}2
I
• IU.
PUMP CONTROL CONTROL CURRENT II.7L DIESEL)
RETURN SUPPLY TRIM
1J 6,
02111 021/1 02 III 02111 02 111 02 l1t SII SOR·
PUMP RETURN HEA TER HEA TER PUMP CELL SIGNAL OXYlEl1/1
CURRENT CONTROL CONTROL CURRENT II.7L DII!II!L)
RETURN SUPPLY TRIM
Z902
10
BK
I
... lt14
.n.... t

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 1643
Theory of Operation
The engine aftertreatment system monitors the 02 content in the diesel engine exhaust. The ECM monitors the
exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the
system. This diagnostic monitors the status message broadcast by the Smart 02 sensor module for the upstream
02 sensor's internal heater circuit. The ECM will set the fault if it rece"ives a FMI (Failure Mode Indicator) message
from the Smart 02 Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails.
The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles.
• When Monitored:
This diagnostic runs when the engine is running.
• Set Condition: ,
The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the Sm~rt 02 Module.
Possible Causes
HEATER CIRCUIT IN 02 SENSOR

02 SENSOR MODULE
INTERMITTENT CIRCUIT BETWEEN THE MODULE AND SENSOR
Always perform the Pre.. Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
Diagnostic Test
1. AFTERTREATMENT WIRING HARNESS
Disconnect the Oxygen sensor and the Smart 02 Sensor Module from
the Aftertreatment Wiring Harness.
NOTE: Check connectors - Clean/repair as necessary, inspect for
signs of Water intrusion in the connector.
Measure the resistance of the (K99) 02 heater supply circuit between
the 02 sensor harness connector and the Smart 02 sensor module har-
ness connector.
Measure the resistance of the (K79) 02 heater return circuit between
ness connector.
Is the resistance less. than 10 Ohms?
Yes »Go To 2 16
SENSOR·
OXYG!N1/1
No »Replace Aftertreatment Wiring Harness. I'.7L DlUI!L)
Perlorm POWERTRAIN VERIFICATION TEST - 6.7L.

(Refer to 9 - ENGINE - STANDARD PROCEDURE)
16 9
MODULE.()2
SENSOR
(8.7L DIESEL) 81b4007c
9 .. 1644 ENGINE - ELECTRICAL DIAGNOSTICS -.,6.7L DIESEL - - - - - - - - - DR
2. OXYGEN SENSOR AND SMART MODULE

Measure resistance of the 02 sensor heater between the (K99) 02
heater supply and (K79) 02 heater return circuits.
Is the resistance 3.2 +/. 0.8 ohms at ambient temperature?
Yes »Replace Smart 02 Sensor Module.
Perform POWERTRAIN VERIFICATION TEST • 6.7L.
No » Replace the sensor
Perform POWERTRAIN VERIFICATION TEST - 6.7L.
16 CCClCCCCCl 9
MODULEo02
SENSOR
(8.7L DIESEL) 81b4007~
4
SINSQR.
OXYGEN 1ft
(I.7L DIESEL)
(COMPONENT 8IDE!)
81b4OOab
DR ENGINE • ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 - 1645
P0037-02 SENSOR 1/2 HEATER CIRCUIT LOW
Illn II
I L-- - - - - -1.oluLe-
~ _
I rB(t) l ELECTRONICS
ITOTALLY
I.TI!IRIT!I
1'- - - - - - - - - - - - - - - - , 101'''1!·
I I FUSED IGNITION ! I,own I DIAGNOSTIC DIAGNOSTIC I :::~R~L
I I SWITCH OUTPUT I , I PORT LOW PORT HIGH I
,,,,. _ OATA~ _ _ ~ATAlIN~ _G~N~ _G~N~ _G~N~ J
I ___
L ~N.STA~ ..J
T_____ _ I
51 C2 31 ct 47 '( C2 48 '( C2 57 '( C2
20'( ca 1902 1902 1902
lfi 16 16
F960 OK BK BK
20
PKA.G
------.111. .---.---.It.4
I I
F96C D132 0133 Z902
20 18 III lD
PK.tG WT WTlOR BK
,.... -
I
32.,l
- -
FUSED IGNITION
SWITCH OUTPUT
-. IOIUL!·
)IITI.a..CI
111I!1
'" t
F9UO
Ct.
I u.
....
18
I (RUN.START)
...... _ _ _ -.J
IIAWAL) PUG
10~ - - - CUI
I 1 Y 8 I
F960 0132 0133
20 20 20
PK.tG WT WTroR
9A 3A 11)"
FUSED IGNITION DIAGNOSTIC OIAGNOSTlC
IODULI!·
Ot 1IIIOR
SWITCH OUTPUT paRTLOW PORT HIGH
(RUN.START) DATA LINK DATA LINK II.n DIEIEL}
02111 02111 02111 02112 02lfl 0211'2

02111 HEATER HEA TER PUMP CEll 02112 HEATER HEATER PUMP CELL
PUMP 021/1 CONTROl CONTROL CURRENT 02 111 CURRENT 02112 CONtROl CONTROL CURRENT 02 112
GROUND CURRENT RETURN RETURN SUPPLY TRIM SIGNAL PUMP RETURN RETURN SUPPLY TRIM SIGNAL
10'( 1'( 14 T lOT 1'( 15 T 61 ~ T 12 T 8 T 2 T 13 T T 4

1902 K89 K902 K7S K9. Kl03 K41 K134 K904 K80 K299 K7J3 K141
20 20 20 20 20 20 20 20 20 20 20 20 20
"t
BK BRIlG BRJDG BRItB BR4.G 8R1lB DBILB BRn:lG DBI1lG BRITN BRIWT BR DBlYl
JJ j j jj
Ct"
Z902
20
BK
02112 02112 02112 021fl 02112 02 In 1.1.01·
CURRENT RETURN HEATER HEATER PUMP CELL SIGNAL OIYI!I 1/2
I
.1114
PUMP CONTROL
RETURN
CONTROL
SUPPLY
CURRENT
TRIM
IUL DII!Ul)
02111 02111 02111 02111 02 111

PUMP CELL
02 111
SIGNAL
,.1.01-
OIYIEI 1/1
PUMP RETURN HEA TER HEA TER
CURRENT CONTROL CONTROL CURRENT II.n DIIIll)
RETURN SUPPl '( TRIM
Z9n2
10
BK
I
.II.. IU4
. "...11
For a complete wiring diagram Reter to Section 8W.

9 -1646 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
exhaust gases for oxygen content and varies the richllean fuel mixture of the intake air fuel mixture to adjust the
system. This diagnostic monitors the status message broadcast by the Smart 02 sensor module for the downstream
02 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message
from the Smart 02 Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails.
The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles .
• When Monitored:
• Set Condition:
The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the Smart 02 Module.
Possible Causes
HEATER CIRCUIT IN 02 SENSOR

02 SENSOR MODULE
INTERMITIENT CIRCUIT BETWEEN THE MODULE AND SENSOR
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE ..
Diagnostic Test
1. AFTERTREATMENT WIRING HARNESS

Measure the resistance of the (K99) 02 heater supply circuit between
ness connector.
Measure the resistance of the (K79) 02 heater return circuit between
ness connector.
Is the resistance less than 10 Ohms?
Yes »Go To 2
No »Replace Aftertreatment Wiring Harness.
16
MODULE-02
SENSOR
(6.7L DIESEL)
81b400b3
DR - - - - - - - - - ENGINE .' ELECTRICAL .DIAGNOSTICS ~ 6.7L DIESEL 9 ·1&47

Is the resistance 3.2 +/- 0.8 ohms at ambient temperature?
Perform POWERTRAIN VERIFICATION TEST - 6.7L. 2
No »Replace the sensor
16 cocccocc 9
MODULE..()2
SENSOR
(1.7L DIESEL.) 81b400af
2 6
4
SENSOR-
OXVOENtl2
(I.7L DIESEL)
(COMPONENT SIDE)
81b400b7
9 .. 1648 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l DIESEL DR
P003A-TURBOCHARGER BOOST CONTROL MODULE POSITION EXCEEDED
LEARNING LIMIT
-I . I - I
IIATT AO
r MODULE·
I
I
@ FUSE
TOTALLY
IIITI....O
I POWER
I 42 ,
I lOA I
I_I __ J
T'
IEMlOR·
TURBO TURBO TURIO
SPEED SPEED SPEED
SENSOR SENSOR
A209
SIGNAL GROUND
10 ACTUATOR·VGT
j
RD VGT VGT (1.1L)
ACTUATOR ACTUATOR SMART
VGT HIGH LOW POWER
2 elM
'I ACTUATOR
GROUND
21
DATA
UNK
3
1
DATA
LINK
41
RELAY
FEED
11
A209 K540 K541 K972 0130 0131 Fl48
10 18 18 18 18 1B 16
RD BRIGY BRNT DBITN BRNT WTt1..G PKIOR
I
.---.---.I11S
I I I
1TO
A209 A209 A209 OTHER
16 16 16 MODULES
RO RD RO
491 C2 50 1C2 601 C2 42 C1 43 Ct 33 Ct 38 Ct 39 C1

I fuSED - fuSED - FUSED - -TURBO - - TURaO- - - VGT - - - VGT - - - VGT - -, laDULE·
I B(+) B(t) B(t) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR IEIilGINE
SENSOR SENSOR GROUND HIGH LOW I COJITROL
I SIGNAL GROUND DATA DATA
I LINK LINK I
- - - - - - - - - - - - - - - - - - - - - - ______ 1
ACTUATOR·VQT SEll lOR.

,1.7L) TURIO SPEED
,G·1L1
10 10
20 II 20 11
~6 21 JO 21
40 31 40 31
41 10 41
60 51 60 51
IODULE. MODULE·
EIIGIIIE EIIGtlE
CONTROL C1 COIITROL C2
,1.1L) ,e.lL)
111241 ••
Theory of Operation
The variable geometry turbocharger (VGT) is electronically activated by the VGT actuator. The VGT actuator is a
smart device and receives information via the J1939 datalink from the ECM. The VGT actuator performs its own
diagnostics and reports failures back to the ECM ':Ising the J1939 datalink. The ECM then decodes the error mes-
sage and converts it to a fault code. The ECM lights the MIL lamp immediately after the diagnostic runs and fails.
The ECM turns off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
Ignition on.
• Set Condition:
The VGT actuator reference position was not detected during a learn span, true position is not known.
Possible Causes
INCORRECT ACTUATOR INSTALLATION

VGT ACTUATOR
TURBOCHARGER
Diagnostic Test
1. OTHER DTC'S
With the scan tool, read DTC's
Is U010C active?
Yes »Repair UD1 DC first.
DURE)
No »Go To 2
2. INCORRECT ACTUATOR INSTALLATION

Check vehicle history for previous VGT actuator replacements.
Has the acuator just been replaced?
Yes »Remove actuator and install in the correct position.
No »Go To 3
3. VGT ACTUATOR
Disconnect the VGT acutator harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Remove the VGT actuator from the turbocharger.
Is the VGT acuator drive gear broken/damaged?
Yes »Replace the VGT actuator.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 4
9 -1650 ENGINE - ELECTRICAL ,DIAGNOSTICS - 6.7L D I E S E l - - - - - - - - - DR
4. TURBOCHARGER
Inspect the sector gear on the turbocharger for damage or broken teeth.
Move the sector gear lever on the turbocharger bearing housing up and down from stop to stop.
Check for smooth movement between the stops.
NOTE: The actuator lever must move evenlY and crisply as it is moved.
Does the nozzle slide evenly from stop to 'stop and are the gear teeth undamaged?
Yes »Replace the VGT actuator
Perform POWERTRAIN VERIFICATION TEST· B.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
No »Replace the turbocharger assembly.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer. to 9 • ENGINE - STANDARD PROCE-
DURE)
DR - - - - - - - - - ENGINE .< ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 . 1651
P0046-TURBOCHARGER BOOST CONTROL CIRCUIT PERFORMANCE
r
l
IIA"AG
F I -I MODULE·
TOTALLY
IIIITEGRATED
J
I
@ FUSE
42
I
I
PO ER
•
I 30A I
l_l __ J
'r
A209
10
TURBO
SPEED
SENSOR
SIGNAL
TURBO
SPEED
SENSOR
GROUND
SENSOR·
TURBO
SPEED
ACTUATOR·"T
RD VGT VGT (6.1L)
21 Ci",
VGT
ACTUATOR
HIGH
DATA
LOW
DATA
POWER
RELAY
r
GROUND LINK LINK FEED
21 3
1 4[ IT
A20S K540 K541 K9n D130 D131 F348
1D 18 18 18 18 18 16
RD BRIGY BRNT DBITN BRNT WUG PKIOR
I
. - - - . - - - . S185
I I I
1
TO
16 16 16 MODULES
RD RO RD
- -
491 C2 501 C2 601 C2
- - - - - - - - - -
42
-
.., MODULE·
C1
- -
43
-
C1
- - -
33
- -
C1
- -
38
-
C1
- - -
39
-
Ct
I FUSED FUSED FUSED TURBO VGT I ENGllIE
TURBO VGT VGT
B(+) B(t) 8(+) SPEED SPEED ACTUATOR ACTUATOR CONTROL ACTUATOR
I SENSOR SENSOR GROUND HIGH lOW I
I SIGNAL GROUND ~~~: ~~:: I
I J
...... - - - - - - - - - - - - - - - - - - - - - - - - - - -
ACTUATOR·vaT SElSOR·
II.lL, TURBO SPEED
(1.1L)
r1
-=
~~'OOo~ 00000
00000 00000 11
30 00000 00000
4C
00000
00000
<0 00000
00000
11
31 3'
50
00000 00000 41 41
,0 II 51
L.I
LJ --
MODULE· MODULE·
ElGIN! ElIGINE
CONTROL Ct CONTROL C2
(1.1L, IS.lL)
.t.t4te.

9 -1652 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The variable geometry turbocharger (VGT) is electronically activated by the Electronic Turbo Actuator. The Elec-
tronic Turbo Actuator is a smart device and receives information via the J1939 datalink from the ECM. The Elec-
tronic Turbo Actuator performs its own diagnostics and reports failures back to the ECM using the J1939 datalink.
The ECM then decodes the error message and converts it to a fault code. The ECM lights the MIL lamp after the
diagnostic runs and fails in two consecutive drive cycles. The ECM will turn off the MIL lamp immediately after this
diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
Ignition on.
• Set Condition:
The Electronic Turbo Actuator does not receive a valid J1939 message from the ECM for 1 second.
Possible Causes
INTERMITTENT J1939 CONNECTION

(F348) SMART POWER RELAY FEED INTERMITfENT
(K972) ACTUATOR GROUND INTERMITTENT
ECM
ELECTRONIC TURBO ACTUATOR
Diagnostic Test
1. OTHER DTC'S
Is U010C active?
Yes »Repair U01 Dc first.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. ECM
Turn ignition off.
Disconnect the Electronic Turbo Actuator harness connector.
After 30 seconds, monitor the system response with the scan tool.
Is U010C active?
Yes »Go To 3
No »Replace ECM
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 -1653
3. INTERMIITENT CONNECTION
Turn ignition off.
Reconnect the Electronic Turbo Actuator harness connector.
After 30 seconds, monitor the system response with the electronic scan tool.
Is P0046 active?
Yes »Go To 4
DURE)
4. ECM CONNECTION
Turn ignition off.
Disconnect the ECM harness connector.
NOTE: Check connectors· Clean/repair as necessary.
Were their any dirty or damaged pins'?
Yes »Repair/Replace as necessary.
DURE)
No »Go To 5
5. INTERMIITENT CONNECTION
Turn ignition off.
Reconnect the Electronic Turbo Actuator harness connector.
Reconnect the ECM harness connector.
After 30 seconds, monitor the system response with the electronic scan tool.
Is P0046 active?
Yes »Replace the Electronic Turbo Actuator.
DURE)
DURE)
9 .. 1654 ENGINE ". ELECTRICAL DIA:GNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
P0049-TURBOCHARGER TURBINE OVERSPEED
IBATTA. I
r -F -I MODULE·
l
I
I
I
$ FUSE
42
30A
I
TOTALLY
IllnEGRATED
I POWER
I_I __ J
T3 A20Q
TURBO
SPEED
SENSOR
TURBO
SPEED
SENSOR
SENSOR·
TURIO
SPEED
SIGNAL GROUND
10 ACTUATOR·VGT
RD VGT VGT (S.1L)
1 ') ')
VGT HIGH LOW POWER
1 em ACTUATOR DATA DATA RELAY
I
21 3
1 41
A209 K540 K541 K972 0130 Dl~1 F348
10 18 18 18 lB 18 16
RD BR/GY BRNT OB/TN BRNT WTfLG PK/OR
I
. - - - . - - - . S1&5
I I I
1TO
16 16 16 MODULES
RD RD R_D
_.~~)~2_ ~lc2 _ !.l~ _ ~2.:...C~ _43....::~ _ _33_ c..:. __3B,,~ _ _39 A':!...
I FUSED FUSED FUSED TURBO TURBO VGT VGT VGT'" MODULE·
81+) B(t) B(t) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR EIIGIIIE I
I SENSOR SENSOR GROUND HIGH lOW COIITROL I
I LINK LINK I
- - - - - - - - - - - - - - - - - - __________ 1
.• ACTUATOR·YGT
'
SEnOR·
IS.1L) TURIO SPEED
,1.7L)
~
,.., ,..,
r~~ 0
~
~(rIOO:1l ~~
10 ! 10 I
00000 00000
20
30
40
,00000
'00000
·00000
!llooooo
00000
00000
00000
00000
~I
21
31
20
30
40
Ii
, 00000
00000
~I 00000
OOO~
00000
0 00000
00000
00000
I
~
;
II
)1
31
I . 00000 00000
~o 41 50 l~OOOO 00000
~ I) 41
50 51 SO 51
1-" '-'
'-' '-'
MODULE· IODULE·
ENGIIIE EIIGIIIE
COIITROL C1 COIITROL C2
,1.7L) (S.7L)
11 •• 4' ..

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 -1655
Theory of Operation
The turbocharger speed sensor is a variable reluctance speed sensor. It consists of a coil of wire and an iron core.
The target on the turbocharger shaft is a ground flat in the center of the shaft. As the flat on the turbocharger shaft
spins past the speed sensor, a signal is generated. The ECM interprets this signal and converts it to a turbocharger
speed reading. If this fault becomes active the ECM will light the MIL light immediately. The ETC lamp will also be
illuminated at this time. During this time the ECM uses an estimated turbocharger speed. An engine power derate
may be experienced. The ECM turns off the MIL when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
When the key is on and the ECM detects a valid turbocharger speed.
• Set Condition:
ECM detects turbocharger speed greater than a calibration limit.
Possible Causes
OTHER DTC'S
(K540) TURBO SPEED SENSOR SIGNAL
(K54) TURBO SPEED SENSOR RETURN
TURBOCHARGER SPEED SENSOR
ENGINE HARNESS
ECM POWER SUPPLY AND GROUNDS
AFTER MARKET INSTALLED ACCESSORIES
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 .. ENGINE ..
Diagnostic Test
1. OTHER DTC'S
With the scan too', read DTC's
Are any DTC's present for Inlet air pressure or boost pressure?
Yes »Troubleshoot other DTC's first.
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go to 2
2 . INTERMITTENT CONDITION
Start the engine.
Using the accelerator pedal, accelerate the engine speed to high idle (1000/0) and hold the engine speed at high idle
for at least 20 seconds
Does DTC P0049 become active?
Yes »Go To 3
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
9 ·1656 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
3. TURBOCHARGER SPEED SENSOR

Turn Ignition off.
Disconnect the engine harness from the turbocharger speed sensor.
Measure the resistance from the (K540) turbocharger speed signal cir-
cuit to the (K54) turbocharger speed return circuit at the sensor. 2
Is the resistance between 600 and 1600 ohms?
Yes »Go To 4
No »Replace the Turbocharger speed sensor.
Perform POWERTRAIN VERIFICATION TEST - B.7L.
3
SENSOR-
TURBO SPEED
(e.1Ll
81a241ec

Measure the resistance from the (K540) turbocharger speed signal cir-
cuit to ground at the turbocharger speed sensor connector.
Is the resistance greater than 100k ohms?
Yes »Go To 5
No »Replace the Turbocharger speed sensor.
SENSOR-
TURBOSPI!I!D
(6.1Ll
81a241fO
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 1657
5. ENGINE HARNESS
Reconnect the turbocharger speed sensor connector.
Measure the resistance of the (K540) turbocharger speed sensor signal
[OJ
circuit at the ECM harness connector to the (K54) turbocharger speed
sensor return circuit at the ECM harness connector.
NOTE: The resistance of the turbocharger speed sensor circuit
must not be more than 10 ohms greater than the resistance of the
turbocharger speed sensor. The turbocharger speed sensor resis-
tance value was read in Step 3.
Is the resistance within 10 ohms of the sensor resistance?
Yes » Go To 6
No » Repair the high resistance in the engine harness. 10
20
(Refer to 9 - ENGINE - STANDARD PROCEDURE) 40
50
60
MODULEa
ENGINE
CONTROLC1
(6.7L) 81a241f4
6. SHORT TO GROUND
circuit at the ECM harness connector to ground.
Ves »Go To 7
No »Repair the short to ground.
10
20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROL C1
(6.7L.)
81a241f8
7. CIRCUITS SHORTED TOGETHER

circuit in the ECM harness connector to all other circuits in the ECM
harness connector except the (K54) turbocharger speed sensor return
circuit.
42
Yes »Go To 8
No »Repair the short circuit in the ECM harness connector.
10
20 11
30 21
40 31
50 41
eo 51
MODULE-
ENGINE
CONTROLC1
(6.7L) 81a241fc
8. ECM
Reconnect ECM harness connectors.
Start the engine.
Allow the engine to idle
Using the accelerator pedal, accelerate the engine speed to high idle (1000/0) and hold the engine speed at high idle
for at least 20 seconds.
Yes »Replace the ECM
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6.7l DIESEL 9 • 1659
P006E-TURBOCHARGER BOOST CONTROL MODULE SUPPLY VOLTAGE CIRCUIT

LOW
IIAn AI I
r
I
F ODULI .
-I-TOULL'
I INTEGRATED
I @ FUSE IPOWER
I 42 I
I 30A
I_I __ J
'I""
III lOR·
TUR80 TURBO TURIO
SPEED SPEED SPEED
SENSOR SENSOR
A209
SIGNAL GROUND
10 ICTU I TOR·vaT
,j
RD 1 " 2 ' veT VOT ".lL)
VGT HIGH LOW POWER
ACTUATOR DATA DATA RElAY
Ct. GROUND LINK LINK FEED
2T 3T 1{
A20g K540 K541 K972 om F348
10 18 18 18 18 16
~ ~MY 8RNT oelfN BRNT PKIOR
I
.---.---.ltlS
I I I
1TO
. 16 16 16 MODULES
RD RD RO
rFuSED -
I
49101
B(t)
50101
FuSED - rusEO -
B(+)
60102
B(+)
42,Ot
-TURBO -
SPEED
-
43,01
TiiRBO- -
SPEED
-
33,01
ACTUATOR
3L,Ct
VGT - - - VGT - - - VGT - ,
ACTUATOR
39...,C1
ACTUATOR
_ODULE·
I :::~IR~L
SENSOR SENSOR GROUND HIGH LOW I
I SIGNAL GROUND DATA DA TA
I_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _LINK
_ _ _ _ LINK
__ JI
1 (~/~Io~) 3
ICTUIlOR·va, SElSOR.
11.7L) TURIO SPEED
II.n,
~
....,
10 /~'ooo;' ~oooo" 1 10 ~
00000 ~ooo~ 1
20 00000 00000 11 20 00000 00000 11
00000 00000 21 10 00000 00000 21
lO
40
00000
00000
0 00000
00000 31 40
00000
00000
0 00000
00000 31
00000 00000 ~1 50 00000 00000 41
50
A \.. 51 60 51
GO
'-' LJ ~ ~
_OOULI· MODULE·
ElailE EIIGIIIE
COITROL ot CONTROL C2
(I.U, Is.lLl IUUt ••
9 .. 1660 ENGINE - Ii.LECTRICAL,01AGNOSJICS -. 6.7L. DIESEL - - - - - - - - - DR
For a complete wiring di~ram Reter.~ Sectlon~8W. ,,"",G ....
Theory of Operation
diagnostics and reports failures back to the ECM using the J1939 datalink. The ECM then decodes the error mes-
sage and converts it to a fault code. The ECM will not light a MIL lamp for this fault. Wh~n this fault is active the
VGT will still continue to respond to commands from the ECM .
• When Monitored:
Ignition on.
• Set Condition:
Supplied voltage to the VGT actuator dropped below 10 :yolts.
Possible Causes
I
INFORMATION ONLY
Always perform the Pre-Diagnostic Troubleshooting proc,dure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING) ,
Diagnostic Test
1. INFORMATION ONLV
Turn the ignition on.
With the scan tool. read DTC's.
Is P006E active?
Ves »The VaT actuator power supply has dropped below 10 volts. This fault code is for information only and
will not light the MIL lamp. Erase DTC.
No »Repair complete. erase DTC's.
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 1661
P006F-TURBOCHARGER BOOST CONTROL SUPPLY VOLTAGE CIRCUIT HIGH
r -I I -
!lAn AD
~ .ODULI·
I
I
@ FUSE
'TOULLY
IllTEaUTED
I POWER
I 42 I
, lOA
I_I--J IE.SOR·
T'
A209
TURBO
SPEED
SENSOR
SIGNAL
TURBO
SPEED
SENSOR
GROUND
TURIO
IPEED
ACTUATOR.vaT
10
j
RD VGT VGT (l.lLl
VGT HIGH LOW POWER
ACTUATOR DATA DATA RELAY
2 CilO GROUND LINK LINK FEED
2T 3T 4'( IT
A209 K540 K541 K972 0130 0131 F3U
10 18 18 10 18 18 16
RO BRIGY BRNT DBITN BRNT WTILG PKIOR
I
. - - - . - - - . S1U
I I I
1TO
16 16 16 MODULES
~ ~ ~
49lci 50lci 60lci 42 Ct 43 Ct 33 Ct 38 C1 39 C1

I fusEi)'" - fuSED - fuSED - -TURBO - - ruReO- - - VGT - - - VGT - - - vaT - , .ODULE·
, B(+) B(+) B(+) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR ElailE I
SENSOR SENSOR GROUND HIGH LOW COITROL I
, LINK LINK'
____________________________ J
ACTUATOR·YIIT SEIIOR·
(l.lL) TURIO BPEED
,1.lL)
('""'1 r'\
" "
10
20
00000
00000
~
00000 II
10
20
00000
00000
"'00000
00000 11
00000 00000 00000 00000 21
30
40
00000 0 00000
11
31
30
40
00000
00000
0 00000
00000 31
00000 00000
00000 00000 50 00000 00000 41
50 ~1
SO ~ 51 SO ~ 51
~ LJ ~ LJ
MODULE· MODULE·
ElailE ElailE
CONTROL C1 CONTROL C2
(l.lL) II.lL) 11114...

9 -1662 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
diagnostics and reports failures back to the ECM using the J1939 datalink. The ECM then decodes the error mes-
sage and converts it to a fault code .
• When Monitored:
Ignition on .
• Set Condition:
The internal VGT actuator temperature has exceeded 257°F (125°C)
Possible Causes
iINFORMATION ONLY
Diagnostic Test
1. DTC P006F PRESENT

Turn Ignition on.
Is P006F active?
Yes »The VGT actuator internal temperature has exceeded the maximum limit. Verify generator, batteries,
Smart Power Relay and TIPM connections are tight and free of dirVcorrosion. This fault code is for infor-
mation only and will not light the MIL lamp.
No »Repair complete erase DTC's
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 1663
P0071-INLET AIR TEMP SENSOR RATIONAI.lTY - ECM
r-----.
, 10DULE.
I
I
BOOST
PRESSURE
E.I.I.
I CONTROL
I SENSOR I
' - ~GNAl _..J
19 TCi r- - - -IElIOR·
K37 1 ITEIPERATUREI
18 I PREIIURE·
DR I .1 LET
-
11 IE,IOR-
I
I
INLET
AIR
I
I
1
BOOST - - - - -
ITIIPERATU REI PRESSURE I
J
PRESSURE
SENSOR I PREIIURE..AP I_ ~eNSE _ J
I SIGNAL f
I SENSOR HOl T I
I- -
GROUND SUPPLY
------ I
.y 21
K916 F855
K616
18 18
BRIOR PKNL 18
BAAL
I I
• 1"4 • Ina
• I I
K916 F855
18 18
BRIOR PKNl
r
. 1., 381.,
SENSOR - -SVOlT - - - - - - - -
20
-;L~ -
.,
- , 10DULE·
I GROUND SUPPLY AIR I E••IIIE
I PRESSURE I CONnOL
SENSE
l ___________________ 1
,..., ~
10 ~0006 00006 I
20 00000 00000 II
30 00000 00000 21
40
50
00000
00000
0 00000
00000
31
41
80 00000 00000 Sl
"- .A
lEI lOR· ~ LJ
'EIPERATURE/
PREIIURI·
lAP 10DULE·
,1.fL) EI ••IE
COITROL CI
(1.7L)
.."...
Theory of Operation
This DTC is set in the ECM. The inlet air pressure is part of the Inlet Temperature/Pressure Sensor which is located
in the top of the air cleaner box. The Inlet Air Temperature Sensor performance looks at the outputs of four tem-
perature sensors and compares them under cold start conditions. Following a start to run delay time, the outputs of
the inlet air, engine coolant, intake air temperature and battery temperature sensors will be compared. If the engine
coolant, intake air and battery temperature sensors agree and the inlet air temperature does not agree. the inlet air
temperature sensor is declared irrational. This diagnostics also checks for a change in sensor value over a period
of time. This is to verify the sensor is not stuck. The ECM will illuminate the MIL lamp after this diagnostic runs a
fails in two consecutive drive cycles. The ECM will turn off the MIL lamp once the diagnostic runs and passes in four
consecutive drive cycles .
• When Monitored:
While the engine is running .
• Set Condition:
The ECM does not read a change in value from the sensor over time. The ECM value after a cold soak for the
inlet air temperature sensor varies from other engine temperature sensors.
Possible Causes
INLET AIR TEMPERATURE SENSOR
INTERMITIENT CONDITION
Diagnostic Test
1. INLET AIR TEMPERATURE SENSOR

Remove the temperature sensor and reconnect the wiring to the sensor.
With the scan tool in Sensors, Monitor the inlet Air Temperature.
While heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
Does the reading from the sensor increase at least -150 C (50 F. on the scan toot?
Yes »Go To 2
No »Replace the Inlet Air Temperature/Pressure sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)

After an 8 hour cold soak, hook up scan tool and monitor inlet air temperature, battery temperature, intake air tem-
perature and coolant temperature.
NOTE: Ensure inlet air temperature is above 20° F when performing this test.
NOTE: Ensure there is no external heat source, such as a block heater, operating during this test or within
the 8 hour cold soak.
Does the inlet air temperature sensor read differently from the other sensors?
Yes »Replace the Inlet Air Temperature/Pressure sensor.
DURE)
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom (Diagnostic Procedure).
DR ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 1665
P0071-AMBIENT AIR TEMPERATURE SENSOR PERFORMANCE (TIPM)
For a complete wiring diagram Refer to Section aw .
• When Monitored:
Engine off time is greater than 480 minutes. Ambient temperature is greater than 4 0 C (38 0 F).
• Set Condition:
After a calibrated amount of cool down time the TIPM compares the ECT Sensor, IAT Sensor, and the Ambient
Air Temp Sensor values.
Possible Causes
(G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

(G31) AAT SIGNAL CIRCUIT OPEN
(G930) AAT RETURN CIRCUIT OPEN
(G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND
(G31) AAT SIGNAL CIRCUIT SHORTED TO THE (G930) AAT RETURN CIRCUIT
AMBIENT AIR TEMPERATURE SENSOR
TOTALLY INTEGRATED POWER MODULE
DIAGNOSIS AND TESTING).
Diagnostic Test
1. ACTIVE DTC
NOTE: Diagnose any CAN - C Communication DTCs before continuing.
Start the engine.
" Allow the engine to reach normal operating temperature.
With a scan tool, select View DTCs.
NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the
conditions in which the fault originally set by reviewing the Freeze Frame data.
Is the DTC Active or Pending at this time?
Yes »Go To 2
AND TESTING)
9 • 1666 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
2. (G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

Disconnect the C5 TIPM harness connector.
Disconnect the MT Sensor harness connector.
NOTE: Visually inspect both the component and the TIPM connec-
tors. Look for damaged, partially broken wires, and backed out or
corroded terminals.
Measure the voltage on the (G31) AAT Signal circuit in the AAT Sensor
harness connector.
Is the voltage above 5.2 volts?
Yes »Repair the short to voltage in the (G31) MT Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST ~ 6.7L.
No »Go To 3
8132b439
3. AAT SENSOR VOLTAGE ABOVE 4.6 VOLTS

Connect the C5 TIPM harness connector.
With a scan tool, read the AAT voltage.
Ves »Go To 4
No »Go To 7
4. AAT SENSOR
Connect a jumper wire between the (G31) MT Signal circuit and the
(G930) Sensor ground circuit in the AAT Sensor harness connector.
With a scan tool, read the AAT voltage. -@IB}
Is the voltage below 1.0 volt with the jumper wire installed?
1 2 ::~
Yes »Replace the AAT Sensor.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L.
No »Go To 5 2
NOTE: Remove the jumper wire before continuing. "
8I!NIOR·
AMBlENT
AIR
TEMPERATURE
8132b444
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 -1667
5. (G31) AAT SIGNAL CIRCUIT OPEN

Measure the resistance of the (G31) AAT Signal circuit from the AAT
Sensor harness connector to the C5 TI PM harness connector.
Is the resistance below 5.0 ohms?
Ves »Go To 6
8
No »Repair the open in the (G31) AAT Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. 1
)'~'
1~BI..ACK
10
AM8IENTAlR
TEMPERATURe
8164bOdb
6. (G930) SENSOR GROUND CIRCUIT OPEN

Measure the resistance of the (G930) AAT return circuit from the AAT
Sensor harness connector to the C5 TI PM harness connector.
Ves »Go To 9
[]
No »Repair the open in the (G930) AAT return circuit.
Perform the POWERTRAIN VERIFICATION TEST - B.7L.
9
10
1iIIODUt.£.
TOTALLY
WTEGIlATID
POWI!""
8164bOfO
9 - 1668 ENGINE - -ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
7. (G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND

-@lID
Measure the resistance between ground and the (G31) AAT Signal cir-
cuit in the AAT Sensor harness connector. [QJ ~:~
Is the resistance below 100 ohms?
1
\~
Yes »Repair the short to ground in the (G31) AAT Signal circuit.
No »Go To 8 2
SENSOR-
AMBIENT
AIR
TEMPERATURE
8132b45d
8. (G3l) AAT SIGNAL CIRCUIT SHORTED TO THE (G930) SENSOR GROUND CIRCUIT
Measure the resistance between the (G31) AAT Signal circuit and the
(G930) AAT return circuit in the AAT Sensor harness connector.
-&JID
Yes »Repair the short between the (G930) AAT return circuit and ~'o~
the (G31) AAT Signal circuit.
1 2
Perform the POWERTRAIN VERIFICATION TEST - B.7L.
,
No »Go To 9
SENSOR.
AMBIENT
AIR
TEMPERATURE 8132b459
9. TOTALLY INTEGRATED POWER MODULE

NOTE: Before continuing, check the TIPM harness connector terminals for corrosion, damage, or terminal
push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and
Ground circuits.
Were there any problems found?
Yes »Repair as necessary.
Perform BODY VERIFICATION TEST VER - 1. (Refer to 8 - ELECTRICAUELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE)
No »Replace the Totally Integrated Power Module per Service Information.
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS·,- 6",7l DiESel:. g- ··1669
P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW - ECM . 'f I,
r---~-
I 1I0DULE·.,
I BOOST E.I.IE
I PRESSURE I OOITIOL
I SENSOR I
_ ..!GMAL _ ...J
ltTei
r- - - -II!IIOI.
K37 I I fEIPERITURE/
18 I'II"URE.
BR I IILlf
-
11
BOOST - - - -
I INLET
I AIR
I
I
1
-IEIIOR.
I TEIIPERATURE/ PRESSURE I
I
PRESSURE
~ENSOR' " I PRESIURE..IP I.:..::~f~_J
I SIGNAL I
I SENSOR 5VOL T I
I GROUND SUPPLY I
--------
41 2T
K916 F855
18 K616
18
PKf{L 18
BRroR
BRftL
•
I 1044
I
• sua
I I
K916 F855
18 18
eRroR PKf{l
lslet "let
SEHSOR
et
r------------------, INLET 1I0DULI!·
5IJOLT
20
I GROUND AIR EI.IIE

SUPPLY . I
I PRESSURE CONTROL I
l ___________________
SENSE 1
.-. .-.
10 ~OOO~ 00000 !
II
20 00000 00000
30 00000 00000 21
,1·'· ; 40
lO
00000
00000
0 00000
00000
31
41
00 OOOO~ 00000 51
\,... ...)
IEIIOR· ~ ......
TEll PERITU RE!
'RES.URE·
,I.n,
IIAP IIODULE·
ElI'IE
COIITROL Ct
CI.lL,
I1IJtNt
For a complete wiring diagram Refer to Section aw.

9 -1670 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
in the top of the air cleaner box .
• When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
• Set Condition:
The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.
Possible Causes
SENSOR OUT OF SPEC

HARNESS SHORTE~ (SENSOR SIDE)
(F855) 5-VOLT SUPPLY OPEN
HARNESS SHORTED (ECM SIDE)
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE·
Diagnostic Test
1. INLET AIR TEMP SENSOR OUT OF SPEC

Disconnect the Inlet Air Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the temperature sensor.
Is the resistance between 300 and 90k ohms?
Yes »Go To 2
No »Replace the sensor.
DURE)
Reconnect the Inlet Air Temp Sensor harness connector.
With the scan tool, erase DTCs.
With the scan tool, read DTCs.
Did the DTC return?
Yes »Go To 3
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 -1671
3. HARNESS SHORTED (INLET AIR TEMPERATURE SENSOR SIDE)

Disconnect the inlet Air Temp sensor harness connector.
Measure the resistance between the engine ground and the (K615)
temperature sensor signal circuit at the sensor connector.
Is the resistance more than 100 k ohms?
Ves »Go To 4
No »Repair or replace the Engine harness shorted.
Periorm POWERTRAIN VERIFICATION TEST - 6.7L.
SENSOR-
(Refer to 9 - ENGINE - STANDARD PROCEDURE) INLET AIR
TEMPERATURE
(DeIHL)
813cc716
4. HARNESS SHORTED (ECM SIDE)

Measure the resistance between the (K615) signal circuit and all other circuits at the ECM harness connector.
Yes »Go To 5
No »Repair or replace the ECM harness shorted.
DURE)
5. (F855) 5-VOLT SUPPLY CIRCUIT

Measure the voltage between the (F855) supply circuit and the (K690)
return circuit in the Air Temp sensor harness connector. D
Is the voltage between 4.5 and 5.5 volts?
Yes »Go To 6
No » Go To 7
SENSOR·
INLET AIR
TE...ERATURE
(DIESEL)
813cc1aa
9 ·1672 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
6. ECM
Reconnect the Air Temp sensor harness connector.
While monitoring with scan tool, disconnect the Air Temp sensor harness connector.
Did the DTC P0073 set?
Yes »Refer to the INTERMITTENT CONDITION DIESEL Symptom (Diagnostic Procedure) (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
No »Replace the ECM.
DURE)
7. (F855) 5-VOLT SUPPLY OPEN

Disconnect the ECM harness connectors.
Replace and program the Powertrain Control Module per the Service Information. Refer to 8 - ELECTRICAUELEC-
TRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE for the appropriate service procedure.
Measure the voltage at the (F855) 5-volt supply circuit at the ECM harness connector.
Yes »Fix or repair the (F855) 5-volt supply circuit shorted to voltage.
DURE)
No »Replace and program the Engine Control Module per the Service Information. Refer to 8 - ELECTRI-
CAUELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE for the appropriate ser-
vice procedure.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 -1673
P0072-AMBIENT AIR TEMPERATURE SENSOR CIRCUIT LOW
r- - - - - - - - - - - - .ODULE·
I !TOTALLY
I r- - - - - - - 1ELECTRONICS I ~II~:::ATED
I I I
I I AAT AAT I I
I L SIGNAL RETURN
L __- _~-_-_-~_~_ _ _ _ ,
B CS 9 YC5
G930
20
.., EXCEPT VrlTN
REMOTE I REMOTE
S~
I
• S1S4
~
I
I
631 6930
20 20
VTilG VTlTN
AAT AAT SElSOR-

SIGNAL RETURN '.BIElLl AIR
fE.PERATURE
BLACK
BLACK
10
SElSOR·
A.IIEIIT AIR
TE.PERATURE ."DULE·
TOTALLY
IITEGRATED
POWER C5

• When Monitored:
The ignition key on .
• Set Condition:
Ambient Temperature Sensor is less than 0.078 of a volt at the PCM for 2.8 seconds. One Trip Fault. Three
good trips to turn off the MIL.
Possible Causes
(G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND

(G31) AAT SIGNAL CIRCUIT SHORTED TO THE (G930) AAT RETURN CIRCUIT
Diagnostic Test
1. AAT SENSOR VOLTAGE BELOW 0.078 OF A VOLT
With a scan tool, read the Ambient Air Temperature Sensor voltage.
Is the voltage below 0.078 of a volt?
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
2. CHECKING AAT SENSOR

Disconnect the Ambient Air Temperature Sensor harness connector.
With a scan tool. read the AAT Sensor voltage.
Yes »Replace the Ambient Temperature Sensor.
DURE)
No »Go To 3
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS" 6.7L DIESEL 9 -1675
3. (G31) AAT SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the C5 Totally Integrated Power Module (TIPM) harness
~ID
connector.
Measure the resistance between ground and the (G31) AAT Signal cir-
cuit in the AAT Sensor harness connector.
[QJ :)o~
1
~
Yes »Repair the short to ground in the (G31) AAT Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST - B.7L
No »Go To 4
SENSOR-
AMBIENT
AIR
TEMPERATURE
8132b45d
4. (G31) AAT SIGNAL CIRCUIT SHORTED TO THE (G930) SENSOR GROUND CIRCUIT
Measure the resistance between the (G930) AAT return circuit and the
(G3l) AAT Signal circuit in the AAT Sensor harness connector.
Is the resistance below 5.0 ohms? ~ID
Yes »Repair the short between the (G930) AAT return circuit and :lo~
the (G31) AAT Signal circuit.
1 2
Perform the POWERTRAIN VERIFICATION TEST - B.7L
,
No »Go To 5
Sl!NSOR·
AMBIENT
AIR
TEMPERATURE 8132b459

Ground circuits.
MODULES· STANDARD PROCEDURE)
No »Replace and program the TIPM per Service Information.
9 - 1676 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH - ECM
r - - - ......
I IIODULE·
I BOOST EIIIG'IIIE
I PRESSURE I CONTROL
I SENSOR I
...... ~GNAL _ ..I
19 Tel r- - - -1E •• OR.

K37 ITEIIPERATUREI
18
I I PRESSURE·
BR I 'III LET
-
11
BOOST - - - - - SElSOR·
I
I
INLET
AIR
I
I
1 I TEIPERATUREI PRESSURE I
I
PRESSURE
SENSOR I PAESSUAE..'P I_ ~ENSE _ J
IV
I SIGNAL I
I SENSOR 5 VOL T II
I- -
GROUND SUPPLY
------
·'1 21
K916 F8S5
18 . 18 K616
PKfYl 18
BR/OR
BRfYL
•
I 1044
I
• 8173
I I
K916 FOS5
18 18
BR/OR PKJYl
"1 1
r - -Ct - - "- Ct- - - - - - - - - -10 -ct - - -, IODULE·
SENSOR 5VOL T INLET I EIIIGIII1E
I GRO UND SU PPL Y AIR COIITROL
I PRESSURE I
SENSE
L__ -----------------I
-_..__. _ - - - - _ . _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
~,
n n
10 I"~'ooo~ Yaoooo I
20 00000 00000 II
30 00000 00000 21
4 40
50
00000
00000
0 00000
00000
31
41
60 00000 00000 51
~ ~
lEI 'OR· ~
'-'
TEll PERATU REI
PAESSURE·
lAP IODULE·
,1.lL, EIIIOIIE
CO.TROL CI
,1.lL)
II"'"
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9· 1677
Theory of Operation
in the top of the air cleaner box .
• When Monitored:
With ignition on and battery voltage greater than 10.4 volts .
• Set Condition:
The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.
Possible Causes
DTC RETURNS
- INLET AIR TEMPERATURE SENSOR

(K615) SIGNAL CIRCUIT OPEN
(K916) RETURN CIRCUIT OPEN
(K615) SIGNAL CIRCUIT SHORTED
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 .. ENGINE -
Diagnostic Test
1. DTC RETURNS
With the scan tool, record all Freeze frame data.
Did the DTC return?
Ves »Go To 2

Disconnect the Inlet Air Temp sensor harness connector.
Measure the resistance of the Inlet Air temp sensor
Ves »Go To 3
No »Replace the Inlet air temperature sensor.
Periorm POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
9 .. 1678 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. RESISTANCE CHECK
Reconnect the Inlet Air Temp sensor harness connector.
Measure the resistance between the (K615) inlet air temperature sensor signal circuit and (K916) return circuit at
the ECM connector.
Yes »Go To 6
No »Go To 4
4. INLET AIR TEMPERATURE SIGNAL CIRCUIT OPEN

Measure the resistance of the (K615) inlet air temperature sensor signal circuit between the sensor harness con-
nector and the ECM harness connector.
Yes »Go To 5
No »Repair or replace the harness.
DURE)
5. RETURN CIRCUIT OPEN

Measure the resistance of the sensor (K916) return circuit between the sensor harness connector and the ECM
harness connector.
Yes »Go To 6
DURE)
6. SIGNAL CIRCUIT SHORTED

Check for a short circuit from the (K615) signal circuit to all other circuits at the ECM harness connector.
Yes »Go To 7
No »Repair or replace the harness for a short to ground in the signal circuit.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6. 7l DIESEL 9 -1679
7. ECM
-@»
•. ::~
While monitoring with scan tool, use a jumper wire and connect the
sensor (K615) signal circuit to the sensor (K916) return circuit at the
sensor connector.
Did the DTC P0072 set? '
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symp- 8ENSOR-
tom (Diagnostic Procedure). (Refer to 9 - ENGINE - DIAG- INLlTAJR
TEMPERATURE
NOSIS AND TESTING) (OI.'IJ.)
No »Replace the ECM. 813d49a2
P0073-AMBIENT AIR TEMPERATURE SENSOR CIRCUIT HIGH (TIPM)
r- - - - - - - - - - - -IODULE.
I 1t0ULLY
r- - - - 1ElECTRONICS IINTEIRATED
I PDWER
I AAT AAT I I
I L SIGNAL RETURN I I
L __- _-_-,l-_~ ____ I
B C5 9 '( CJ
6930
2D
EXCEPT VTrrN
REMOTE REMOTE I
S~
I t 11.4
~
I
G31 6930
20 20
VTJlG VTlTN
AAT AAT IEN'OR·

SIGNAL RETURN
AIIIENT AIR
TEIPERATURE
1D
HUOI·
II.IEIIT IIR
TEIPERITURE IODULE·
TOTALLY
IIilTEGRATED
POWER C5
II .....

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 ·1681
• When Monitored:
With the ignition on. Battery voltage greater than 10 volts.
• Set Condition:
The Ambient Temperature Sensor voltage is greater than 4.98 volts at the ECM for 2.8 seconds. One Trip
Fault. Three good trips to turn off the MIL.
Possible Causes
(G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

(G31) AAT SIGNAL CIRCUIT OPEN
(G930) AAT RETURN CIRCUIT OPEN
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE -
Diagnostic Test
1 . AAT SENSOR VOLTAGE ABOVE 4.98 VOLTS

With a scan tool, read the Ambient Air Temperature Sensor voltage.
Yes »Go To 2
AND TESTING)
2. AAT SENSOR
Disconnect the Ambient Air Temperature Sensor harness connector.
Connect a jumper wire between the (G31) AAT Signal circuit and the -&lID
::~
(G930) AAT return circuit in the AAT Sensor harness connector.
1 2
With a scan tOO', read AAT Sensor voltage.
Is the voltage below 1.0 volt with the jumper wire installed?
Yes
No
»Replace the Ambient Air Temperature Sensor.
Perform the POWERTRAIN VERIFICATION TEST • 6.7L.
»Go To 3
6seNSOR.
AM..ENT
AIR
2
NOTE: Remove the jumper wire before continuing. TEIltF£RATURE
8132b444
9 .. 1682 ENGINE ".. ELECTRICAL DIAG'NOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. (G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

Measure the voltage on the (G31) MT Signal circuit in the MT Sens9r
harness connector.
Is the voltage above 0 volts?
Yes »Repair the short to battery voltage in the (G31) AAT Signal
circuit.
Perform the POWERTRAIN VERIFICATION TEST • 6.7L.
(Refer to 9 • ENGINE - STANDARD PROCEDURE)
No » Go To 4
SENSOR-
AMBIENT
AIR
TEllPERATURE
8132b439
4. (G31) AAT SIGNAL CIRCUIT OPEN

Tum the ignition off.
Measure the resistance of the (G31) AAT Signal circuit from the MT
Sensor harness connector to the C5 TIPM harness connector.
Yes »Go To 5
No »Repair the open in the (G3l) AAT Signal circuit. 8
10
8164bOdb
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9· 1683
5. (G930) AAT RETURN CIRCUIT OPEN

Measure the resistance of the (G930) AAT return circuit from the AAT
Sensor harness connector to the C5 TIPM harness connector.
Yes »Go To 6
No »Repair the open in the (G930) AAT return circuit.
... Perform the POWERTRAIN VERIFICATION TEST - 6.7L.
9
~~~
,®, 10
AIII.IENTAIR
TEIIP£IlAT\JRE
MOOULE·
TOTALLY
IIl11!:GMTI!D
POWERC&
8164bOfO

Ground circuits.
No »Replace the Totally Integrated Module per Service Information.
9 • 1684 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P007C-CHARGE AIR COOLER TEMPERATURE SENSOR CIRCUIT LOW
r -------- IIODULE.
EIGINE
I BOOST CHARGE AIR ICONTROL
PRESSURE COOLER OUTLET I
I SENSOR TEU PERA TURE
__ ____ _ _ ---.JI
L SIGNAL SENSOR
19lC1 11 lei
K37 K735
18 18
BR BRltG
11 31
SEllaR·
BOOST CHARGE AIR
PRESSURE COOLER OUTLET
TEl PERATU REI
SENSOR TEM PERA TURE PREIIURE·I"
SIGNAL SENSOR
SENSOR 5VOLT
GROUND SUPPLY
K916 F855
18 18
BRJOR PKIYL
I 1044
•
I
• ItJ~
K916 F855
I
18 18
BRIOR PKIYL
r-
,,1 et
SENSOR - -
,.let
5VOLT lIODULE-
ENGIIE
I GROUND SUPPl Y I CONTROL
I I
L _______ J
rl M
// v ~,
10
ooooo~ 00000 11
20 00000 00000
)0 00000 00000 21
40 00000
00000
<0 00000
00000
31
50 41
60 00000 00000 51
~ \\.
~ V
L...I '-' SElSOR·
TEl PERATU REI
IODULE· PRESSURE·
ENGINE lAP
COITROL C1 ,I.n,
(I.n,
II If....

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 ·1685
Theory of Operation
The intake manifold temperature sensor is a variable resistor sensor and is used to measure the temperature of the
air entering the intake manifold of the engine. The ECM supplies 5-volts to the. intake manifold temper~tllre signal
circuit. The ECM monitors the change in voltage caused by changes in the resistance of the sensor to determine
the intake manifold temperature. The intake manifold temperature 'sensor is a combination sensor that also reads
pressure. It is located on the intake manifold. The Mil lamp is illuminated immediately when 1he -diagnostic runs and
fails. During this time the customer may notice periods of white smoke as-well'as the fan running more -often. The
MIL lamp is turned off once the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
The ECM monitors the change in signal voltage and converts this to a temperature value .
• Set Condition:
The ECM illuminates the MIL light immediately when the diagnostic runs and fails. During this time it uses an
estimated value for Inlet Air Temperature. The ECM will tum off the MIL after the diagnostic runs and passes
in 4 consecutive drive cycles.
Possible Causes
INTAKE AIR TEMP SENSOR OUT OF SPEC

(K21) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT
WIRING HARNESS SHORTED
(F855) 5-VOLT SUPPLY CIRCUIT OPEN
ECM
~Iwaysperform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to, 9 • ENGINE -
1. INTAKE AIR TEMP SENSOR OUT OF SPEC

Disconnect the Intake Air Temperature sensor harness connector.
Measure the resistance of the Intake Air Temp sensor.
Yes »Go To 2
No »Replace the Intake Air Temperature Sensor/MAP sensor.
Perform POWERTRAIN VERIFICATION TEST - S.7L. (Reter to 9 • ENGINE - STANDARD PROCE-
DURE)
Reconnect t"e circuit.
Turn the ignition on.'
With the scan tool, erase OTCs.
With the. scan tool, read DTCs.
Did the DTC reappear?
Yes »Refer ~o the rNTERMITIENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
No »Go To 3
3. (K21) SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT

Measure the resistance between the engine ground and the (1<21) tem-
[QJ
perature sensor signal circuit at the sensor harness connector.
Yes »Go To 4
No »Repair the (K21) temperature sensor signal circuit.
SENIOR-
THlPERAlUREI
PRnSURE-
MAP
(ULI
8A.TTI!RY-
HI!IM1M!
(DIEII!L LEn SATTl!RY)
..,.
IICIIULE·
IiNGIlNi
(;0_C1
fI."-) 81888400
4. WIRING HARNESS SHORTED

Measure the resistance between the (K21) signal circuit and all other
circuits at the ECM harness connector.
Yes »Go To 5
[OJ
No » Repair as necessary.
10
20
30
"
21
40 31
50 41
eo 51
MODULE-
ENGINE
CONTROLC1
(8.7L)
81a8e4cf
5. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K916) RETURN CIRCUIT

Reconnect the ECM harness connector connected.
Measure the voltage between the (F855) 5-volt supply circuit and the
(K916) return circuit the sensor harness connector. D
Yes »Go To 7
-- No »Go To 6
SENSOR·
TEMPERATUREI
PRESSURe·
MAP
(6.7L)
81a8e4d3
6. (F855) 5-VOLT SUPPLY CIRCUIT OPEN

Measure the voltage at the (F855) 5-volt supply circuit of the sensor
harness connector.
Yes »Repair the open (F855) 5-volt supply circuit.
No »Go To 7
SENSOR·
TEMPERATURE!
PRESSURE·
MAP
(UL)
81a8e4d7
9 .. 1688 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
7. ECM
Reconnect the intake air temp sensor harness connector.
While monitoring with scan tool, disconnect the temperature sensor
Yes »Clear DTC's, repair complete.
DURE)
Perform POWERTRAIN VERIFICATION TEST - B.7l. (Refer to 9 - ENGINE ~ STANDARD PROCE-
DURE)
P007E-CHARGE AIR COOLER TEMPERATURE SENSOR CIRCUIT HIGH
r - - - - - - - - -, EII8111E MODULE·
I BOOST CHARGE AIR I CONTROL

PRESSURE COOLER OUTLET I
I SENSO R TEM PERA TU RE
L _ ~GNAL _ _ SENSOR _ --.J
19IC1 HIe,
K37 K1J5
18 18
BR 8RJt.G
11 31 SElSOR·
BOOST CHARGE AIR
PRESSURE COOLER OUTlET
TEMPERATURE/
SENSOR TEMPERATURE PRESSURE·IAP
SIGNAL SENSOR
SENSOR 5 VOL T
GROUND SUPPLY
KS16 FRS5
18 18
BRIOR PKNL
I
• S044
I
• 5113
K916
I
F8S5
ta 18
BRIOR PKNL
r-
..1
SENSOR - -
c. 3.1vOLTc.
5 lIiODULE.
I GROUND SUPPLY I CONTROL

EIIGIIIE
I I
L _______ J
rl .-.
//. v "y..
oooo~
1j
2C
00000 11
00000 00000
,0 00000 00000 21
40 00000
00000
0 00000
00000
31
50 41
60 00000 00000 51
A ~ .I
~ I...J '-' SElSOR·
TEll PERAtURE/
MODULE· PRESSURE·
EIIGIIIE IIAP
CONTROL C1 (1.7L)
(1.1L)
IUff.a.

Theory of Operation
The ambient air temperature sensor is used by the ECM to monitor ambient air temperature. This is used to sense
the air temperature outside the vehicle. The ECM provides a 5-volt reference voltage to the sensor. The ECM mon-
itors the change in signal voltage and converts this to a temperature value. The circuit voltage to the ECM is above
a calibrated threshold for a certain period of time. The ECM illuminates the MIL light immediately when the diag-
nostic runs and fails. During this time it uses an estimated value for Intake Air Temperature. The ECM will turn off
the MIL after the diagnostic runs and passes in 4 consecutive drive cycles
• When Monitored:
• Set Condition:
Possible Causes
INTAKE AIR TEMPERATURE SENSOR

ECM
Diagnostic Test
1. DTC RETURNS
Did the DTC return?
Yes »Go To 2
2. INTAKE AIR TEMPERATURE SENSOR

Disconnect the Intake Air Temp sensor harness connector.
Measure the resistance of the Intake Air Temp sensor
Yes »Go To 3
No »Replace the Intake air temperature sensor.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - &.7L DIESEL 9· - 1691
3. RESISTANCE CHECK
Reconnect the Intake Air Temp sensor harness connector.
Measure the resistance between the' (K21) inlet air temperature sensor
[OJ 48
signal circuit and (K916) return circuit at the ECM connector.

Yes » Go To 6 10
20 11
No » Go To 4 30 21
40 31
50 41
eo 51
MODULE-
ENGINE
CONTROLC1
(6.7L)
81a8eSdO
4. (K21) INTAKE AIR TEMPERATURE SIGNAL CIRCUIT OPEN

Measure the resistance of the (K21) inlet air temperature sensor signal
3
circuit between the sensor harness connector and the ECM harness
connector.
Yes » Go To 5
No » Repair or replace the harness.

SENSOR-
TEMPERATUREJ 11
PRESSURE-
MAP
10
20 11
30 21
31
50 41
eo 51
MODULE-
ENG..E
CONTROLC1
(i.7L)
81a8e5d4
9 - 1692 ENGINE .. ELECTRICAL DIAGNOSTjCS - 6.7L DIESEL - - - - - - - - - DR
5. (K916) RETURN CIRCUIT OPEN

Measure the resistance of the (K916) sensor return circuit between the
sensor harness connector and the ECM harness connector.
4
Yes »Go To 6
Perform POWERTRAIN VERIFICATION TEST - 6.7L.'
4
SEN8OR·
TEMNRATUIlE/
PRESSURE·
MAP
(8.'1t.)
11
21
31
41
51
MODULE·
ENOINE
CONTROLC1
(1.l'L, 81a8e5d8
6. (K21) SIGNAL CIRCUIT SHORTED

Check for a short circuit from the (K21) signal circuit to all other circuits
at the ECM harness connector.
Is the resistance more than 100 k ohms? g " ~ .,
, ,
,
Yes »Go To 7 11
No »Repair or replace the harness for a short to ground in the
(K21) signal ctrcuit.
Perform POWERTRA1N VERIFICATION TEST - 6.7L.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) 1D
20 11
!IO 2'
-40 31
IiO ~,
IIQ 51
MOOULE.
ENGINE
CONTROLC1
ILl'L)
81a8eSdc
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS' - 6.7L DIESEL g.. : 1693
7. ECM
sensor (K21) signal circuit to the sensor (K916) return circuit at the sen-
sor connector.
Old the OTC P0112 set?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symp-
tom (Diagnostic Procedure). (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING)
4
No » Replace the ECM.
SENSOR·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) TEMPERATUREI
PRESSURE·
MAP
(1.7l)
81a8e5e1
9 .. 1694 ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P007E-CHARGE AIR COOLER TEMPERATURE SENSOR CIRCUIT INTERMITTENTI
ERRATIC
I - - - - - - - - -, IODULE·
ENGINE
I BOOSTCHARGE AIR COITROL I
PRESSURE
COOLER OUTLET I
I SENSOR
TEMPERATURE
L SIGNAL
__ ____ SENSOR
_ _ ---1I
19 lei 111 C1
K31 1(135
18 18
BR BRIlG
11 31 SENSOR·
BOOST CHARGE AIR
PRESSURE COOLER OUTLET TEIPERATUREI
TEMPERA TU RE
PRESSURE·lllP
SENSOR
SIGNAL SENSOR
SENSOR 5 VOL T
GROUND SUPPLY
K916 F855
18 18
BRiOR PKNl
I S044
•
•
I 8t73
K916
I
FB55
18 18
BRIOR PKNl
r-
,.let - "m>LT
SENSOR
let lIiODULE.
ENGINE
I GROUND SUPPLY ICONTROL
I I
L_ _____ J
r1 n
I/- roooco,;:,\"
/00006
00000 00000
M 00000 00000
40 00000
00000
<0 00000
00000
31
<Ii
00000 00000
~
A ~ :,;
L..I LJ SElSOR·
TEMPERATURE/
MODULE· PRESSURE·
EIGINE
CONTROL C1
M"
IS.lL)
('.7L)
DR - - - - - - - - - ENGINE - ELECTRICAl DIAGNOSTICS .. 6.7L DIESEL 9 - 1695
The ambient air temperature sensor are used by the electronic control module (ECM) to monitor the CAC temper-
ature. The ambient air temperature sensor is a thermistor and changes resistance based on the temperature being
measured. The ECM provides a 5-volt reference voltage to the sensor. The ECM monitors the change in signal
voltage and converts this to a temperature value. There are two parts to this fault code, a key on check and a
ratipoality check. After an 8 hour cold soak, at, key ON the readings for the CAC temperature, battery temperature
and CAC temperature and coolant temperature are all compared. If the temperatures differ more than a calibrated
amount, then the appropriate sensor fault code would be recorded. The key on monitor is disabled for ambient
temperatures below 20 0 F. This monitor looks for all the sensors to be grouped on one temperature or, in the case
that the monitor fails, three sensors grouped at one temperature and one outlier. In the case that all four sensor
values ·are. distributed over a range of temperatures this diagnostic will not run. A block heater is one possible cause
of such a distribution. The rationality check is referred to as a dither. The dither looks at the temperature reading
from the sensor over time and ensures that it changes. This monitor is used to detect a IIstuck" sensor. If the sensor
reading does not change over a calibrated time limit, the fault will be recorded. Both the key-on and dither portions
of this rationality error require that the diagnostic fails in two consecutive drive cycles before the MIL lamp is lit.
During this time the ECM uses an default value for the ambient air temperature. The ECM turns off the MIL lamp
when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
Key on engine off and while engine is running .
• Set Condition:
At key on engine off, the CAC temperature sensor reads differently than the battery temperature and ambient
air temperature sensors. Or while the engine is running the ECM does not read a change in value from the
CAC temperature sensor over time.
Possible Causes
CAC TEMPERATURE SENSOR
Diagnostic Test
1. CAC TEMPERATURE SENSOR
With the scan tool in Sensors, Monitor the CAC Temperature.
Does the reading from the sensor increase at least -15 0 C (5° F) on the scan tool?
Yes »Go To 2
No »Replace the CAC temperature sensor.
DURE)
9 -1696 ENGINE - ELECTRICAL DIAGNOS'rICS - 6.7L DIESEL - - - - - - - - - DR
2. CAC TEMPERATURE SENSOR

After an 8 hour cold soak, hook up scan tool and monitor CAC temperature, battery temperature, CAC temperature
and coolant temperature.
NOTE: Ensure ambient air temperature is above -6.7 C (20 F) when performing this test.
0 0
Does the CAC temperature sensor read differently from the other sensors?
Yes »Replace the CAC temperature sensor.
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 1697
P0087-FUEL RAIL PRESSURE TOO LOW
SElSOR·
FUEL
RAIL
PRESSURE
FUEL
RAIL
SENSOR SENSOR 5VOLT
11
1<918
18
'I
F855
18
BRIOR PKNl
I I
• S044 • 8113
I I
K181 1(916 F855
18 18 18
BRNL BRIOR PKJYl
r
"leI . lei ,,1 •.-I
FuEL - -sENsoR - -5 Viii: T MODULE·
I RAil GROUND SUPPL Y I :::~EOL
I SENSOR
SIGNAL I
1 1
1
- - - - - ______ 1
SElSOR·
FUEL RAIL
PRES8URE
IDIEIEL)
li.I.1I
For a complete wiring diagram Refer to Section 8W,

9 .. 1698 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The ECM will turn on the MIL lamp immediately after this diagnostic runs and fails. The ECM will turn off the MIL
lamp after the diagnostic runs and passes in 4 consecutive drive cycles.
• When Mon itored:
Engine running
• Set Condition:
Actual fuel pressure differs from set point more than a calibrated amount for a calibratable amount of time.
Possible Causes
POOOF PRESENT
OTHER DTC'S
EXTERNAL FUEL LEAKS
LOW LIFT PUMP FLOW
HIGH PRESSURE PUMP
INJECTOR LEAKAGE
FUEL PRESSURE LIMITING VALVE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Reter to 9 - ENGINE -
Diagnostic Test
1. POOOF PRESENT
With the scan tool, read DTC's.
Yes »Troubleshoot POOOF first.

Periorm POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. OTHER DTC'S
Are any other injectornuel pressure related DTC's present?
Yes »Troubleshoot other injector/fuel pressure related DTC's first.
No »Go To 3
3. EXTERNAL FUEL LEAKS

Put on personal protective equipment.
Operate engine at idle when looking for fuel leaks.
Use the scan tool to operate engine at a variety of engine speeds.
Any external leaks detected?
Yes »Repair or replace component with external fuel leak.
DURE)
No »Go to 4
DR - - - - - - - - - ENGINE - -ELECTRICAL DIAGNOSTICS - 6~'1l DIESEL 9 - 1699
4. IN TANK LIFT PUMP

Perform In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure.
Does the lift pump pass the In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure?
Ves »Go To 5
No »Replace Lift Pump
Perform POWERTRAIN VERIFICATION TEST- 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
5. HIGH PRESSURE PUMP

Perform Fuel Pump Return Flow Test in this section.
NOTE: Part of this test requires that the Pressure Limiting Valve leakage is checked. This work was already
performed in step 4.
NOTE: This test can be performed at the same time as the Injector Return Flow test that is listed in step 8
by measure the flow that is normally wasted.
Is the drain flow measured less than 1000 mllminute at idle?
Ves »Go To 6
No »Replace fuel injection pump
DURE)

Perform High Pressure Fuel Pump Performance Test in this section.
Is the fuel flow above the specification?
Ves »Go To 7
No »Replace appropriate component as per High Pressure Fuel Pump Performance Test tree.
DURE)
7. INJECTOR RETURN FLOW TEST

Perform the Injector Return Flow Test in this section.
Does the injector drainage meet the test specification?
Ves »Go To 8
No »Repair cause of high injector leakage
DURE)
8. FUEL PRESSURE LIMITING VALVE

Using the scan tool, view the pressure limiting valve counter and pressure limiting valve timer.
Is the counter value higher than 50 or the timer value higher than 5 hours?
Ves »Change the pressure limiting valve. When valve replacement is complete, in scan tool go to PCM Misc
Functions and Reset Two-Stage Dump Valve Accumulators.
The fuel pressure limiting valve popping is sometimes a symptom of another fuel system problem.
DURE)
Go To 9
No »Go To 9
9 - 1700 ENGINE· ELECTRICAL' DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
9. FUEL PRESSURE LIMITING VALVE

Turn keyswitch off. Remove the banjo bolt from the pressure limiting valve drain on the fuel rail. Install fuel system
test fitting #9012 into the drain. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel
hose into a container. Perform the tests listed below to determine if the pressure limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool.
Watch for fuel flow into the fuel container.
Does fuel flow into the container under either operating conditions?
Yes »Change the pressure limiting valve. When valve replacement is complete. use the scan tool to reset the
pressure limiting valve counter and timer. This command is in the PCM Mise Functions.
DURE)
No »Refer to the INTERMITIENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
DR ENGINE • ELECTRICAL DIAGNOSTICS \.1&·.7L DIESEL 9 .' 1701
POOSS-FUEL RAIL PRESSURE TOO HIGH
8EI'OR·
FUEL
ItAIL
FUEl 'REIIURI
RAIL
SENSOR SENSOR 5 VOLT
'[ '[
2''''
K916 F955
18 18
BRJOR PKNl
I
.1144
I
• sna
I I
KID 1 K916 FB55
18 18 18
BRlVl BRtoR PKNL
r
Jet Jet
"7t,E~ - -sENsoR -
"L~
-SVOLT-rMODULE.
I RAIL GROUND SUPPLY .I.IIE
I SENSOR I
CDITRDI.
SIGNAL I
I I
I_ _ _ _ _ _ _ _ _ _ _ 1
.I!NIOR·
FUEL RAIL
PRI.SURE
(DI.I.L,

9 -1702 ENGINE ·,ELECTRICAL DIAGNO.SJICS - 6.7L DIESEl:. - - - - - - - - - DR
Theory of Operation
The ECM wiU turn on the MIL lamp immediately after the diagnostic runs and fails. During this time the ETC lamp
will also illuminate. The ECM will turn off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive
cycles .
• When Monitored:
Engine running .
• Set Condition:
Fuel pressure is above a calibrated value for a calibrated amount of time.
Possible Causes
OTHER DTC'S
LIFT PUMP
FUEL CONTROL ACTUATOR
CHECK VALVE DAMAGED OR BLOCKED
FUEL PRESSURE SENSOR
LOW PRESSURE FUEL SYSTEM SUPPLY
HIGH PRESSURE FUEL SYSTEM LEAKS
HIGH INLET RESTRICTION
Diagnostic Test
1. OTHER DTC'S
Are any other injectorlfuel pressure related DTC's present?
Yes »Troubleshoot other injector/fuel pressure related DTC's first.
No »Go To 2
2. LIFT PUMP
Perform u'*IN_ TANK FUEL LIFT PUMP FLOW TEST - DIESEL"
Did vehicle pass the ·IN-TANK FUEL LIFT PUMP FLOW TEST· DIESEL?
Yes »Go To 3
No »Repair the Lift pump.
DURE)
3. FUEL CONTROL ACTUATOR

Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.
NOTE: The fuel control actuator will only click when cycled off.
Do you hear a click from the actuator when you cycle the actuator off with the scan tool?
Yes »Go To 4
No »Replace the fuel control actuator.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 -1703
4. CHECK VALVE DAMAGED OR BLOCKED

Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?
Yes »Repair the cause of the damaged or blocked check valve or replace the valve.
DURE)
... No »Go To 5
5. Fuel Pressure Sensor

Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM.
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
Yes »Repair Complete.
DURE)
No »Replace the fuel pressure sensor.
DURE)
9 - 1704 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L _DIESEL - - - - - - - - - DR
POOAF-TURBOCHARGER BOOST CONTROL MODULE PERFORMANCE
IBATT 10 I
r
I
F -I MODULE·
TOTALLY
I INTEGRATED
I ~ FUSE I POWER
I 42 I
I 30A
I_I __ J
'r
A209
10
flO
TURBO
SPEEO
SENSOFl
SIGNAL
1v
TURBO
SPEED
SENSOR
GROUND
2
SENSOR·
TURBO
SPEED
ACTUATOR·YGT
VGT VGT (S.lL)
,1
VGT HIGH LOW POWER
em ACTUATOR DATA DATA RElAY
r
A209
10
K540
18
K541
18
2T
K972
18
JT
D130
18
4T
0131
18
F348
16
flO BRIGY BRNT DBITN BRNT WTIlG PKIOR
I
e---e---e
I I I
S165
1TO
16 16 16 MODULES
RD RD RO
491 C2 501 C2 601 C2 42.- C1 43, C1 33 C1 38 C1 39,., Ct

I FuSED - fuSED - "'FUSED - -TURBO - - TURBO- - - VGT - - - VGT - - - VGT - -, MODULE·
I B(+) 8(+) B(t) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR I :::~R~L
SENSOR SENSOR GROUND HIGH lOW I
I LINK LINK I
~ ___________________________ J
a
I r-I I
4 1 1
~DgD~ 3
ACTUATOR·VGT SENSOR·
11.7L) TURBO SPEED
IS.7L)
,-_____ n __ ------=-:--.. ~ ~
~
rn~i 16000o'~ ~
10 I 10 I
00000
a
20 00000 00000 , II )0 00000 00000 I'
00000 00000 ~o ,00000 00000 2'
30
0 2'
10
a
i 00000 00000 I '00000 00000
40 00000 I l' 40 00000 J'
50 00000 ~~ 4' :0 00000 00000 .,!'.
60 S', ,0 ~ S'
~ ~
MODULE· MODULE·
EMGIIE ENGINE
CONTROL Ct CONTROL C2
(1.1L) IS.7L,

DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 -1705
Theory of Operation
The variable geometry turbocharger (VGT) is electronically activated by the Electronic Turbo actuator. The Electronic
Turbo actuator is a smart device and receives information via the J1939 datalink from the ECM. The Electronic
Turbo actuator performs its own diagnostics and reports failures back to the ECM using the J1939 datalink. The
ECM then decodes the error message and converts it to a fault code. This fault code is logged when the Electronic
Turbo actuator detected an internal error within the Electronic Turbo actuator. The Electronic Turbo actuator will stop
controlling the turbocharger when this fault code is active. The ECM lights the MIL lamp after the diagnostic runs
and fails in two consecutive drive cycles. The ECM turns off the MIL lamp after the diagnostic runs and passes in
4 consecutive drive cycles
• When Monitored:
Ignition on.
• Set Condition:
The Electronic Turbo actuator has detected an internal error in the VGT smart device.
Possible Causes

INTERMITTENT CONNECTION
Diagnostic Test
1. OTHER DTC'S
Is U010C active?
Yes »Repair U010C first.
DURE)
No »Go To 2
2. ELECTRONIC TURBO ACTUATOR

Turn ignition off.
Disconnect the Electronic Turbo actuator harness connector.
NOTE: Check connectors .. Clean/repair as necessary.
Are there dirty or damaged pins?
Yes »Repair/Replace as necessary.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE STANDARD PROCE-
DURE)
No »Replace the Electronic Turbo actuator
DURE)
P0101-MASS AIR FLOW SENSOR "A" CIRCUIT PERFORMANCE
I.ATT AI I
"'T -:. -
I r-- -,.ODULE>
,I @ rUSE
TOTALLY
IIIITEORATED
I POWER
I ~~A I
~r. ___ ~
10
l C3
A11B
18
ROKlR
I
•I • 1024
I
A11S All8
18 18
flO/OR ROtOR
lA 2J.
FUSED FUSED RELAY·
SMART SMART •• ART
B(+) B(+)
POWER POWER POWER
RElAY RELAY
RETURN FEED
5, 4, >
lEI lOR·
IAIIAIR
FLOW
K348 F348
18 16
1 ''''
BR PKKlR
•
•• 37
1 1
;r-- - - - - - I
.: !; 1 C1ao
K916
18
BRIOR
F348
15
t
PK/oR I
• S042
10 C112
I
FM8 FM8 K916
16 16 19
PKKlR PKlOR BRIOR
I I I
• - - - - - - - . 8040 • 1044
I • MIT
K348 Kgjfi K157 •• AIT
18 10 18
BR BRIOR BRKlR
43 J. C2 48 J. C, 21 J. C1
r-------------------------~.~~
SMART SENSOR MASS AIR EIIGIIIE
I POWER GROUND flOW I COIITROL
RElAY
I RETURN SENSOR I
L ________________________ _
SIGNAL ~
//;,
rl r-l
,V ~ 3
[~D~Dll Ii
10 I
20
00000 ""00000 II
00000 00000
3D 00000 00000 21
40 00000
00000
<0 00000
00000
11 2 5
so 41 4 1
51) 00000 00000 51
~ "/ 1
~
L.J L.J
SElSOR·
IODULE· lASS AIR FLOW
EIlOlle RELAY·
(l.lL)
CONTROL at SIART
(1.1L) POWER
,1.1L DIESEL)
.... ..
~.,

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 -·170~
Theory of Operation
The Mass Air Flow Sensor is a frequency based device. A constant voltage is applied to a heated wire. This wire is
positioned in the air stream and is heated by the electr!cal current that the voltage produces. As air flows across it,
it cools down. The heated wire or film is a positive temperature coefficient (ptc) resistor. This means that it's resis-
tance drops when it's temperature drops. The drop in resistance allows more current to flow through it in order to
maintain the programmed temperature. This current is changed to a frequency which is sent to the ECM and inter-
preted as air flow. Adjustments for air temperature and humidity are taken into consideration since they also affect
the temperature of the heated wire or film. This diagnostic has two parts, a key on monitor and a monitor that runs
in operating conditions when the EGR valve is closed. The key on monitor diagnostic fails if the Mass Air Flow
Sensor reads a non-zero value at key on, engine off. The engine running monitor compares an estimated charge air
flow value to the Mass Air Flow sensor reading. This monitor only runs when the EGR valve is commanded closed.
During this time the MAF sensor value should equal the charge air flow estimate. The ECM will light the MIL lamp
if this diagnostic runs and fails in two consecutive drive cycles. The ECM will turn off the MIL lamp when the diag-
nostic runs and passes in four consecutive drive cycles .
• When Monitored:
Ignition on .
• Set Condition:
Flow detected is greater than allowable threshold at key on/engine off. While running and EGR flow equals
zero the Mass Air Flow sensor value does not equal the charge air flow estimate.
Possible Causes
TURBOCHARGER, EGR OR INTAKE AIR SYSTEM RELATED DTC'S

MAF SENSOR
AIR FILTER
AIR INTAKE LEAK
ENGINE HARNESS OR CONNECTORS
DIAGNOSIS AND TESTING) :
Diagnostic Test
1. OTHER DTC'S
Are any other DTC'S present?
Yes »Repair all other DTC's first.
DURE)
No »Go To 2
2 . MAF SENSOR
With the scan tool in Sensors, read the Mass Air Flow sensor.
Does the Mass Air Flow sensor read 0 +/- 2Ib/min?
Yes »Go To 3
No »Replace MAF sensor.
DURE)
9 .. 1708 ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
3. REPLACE AIR FILTER

Remove lid from air fitter box.
Remove air filter and inspect for excessive debris or filter media damage.
Ensure the filter was installed properly.
Was the air filter damaged or full of debris?
Yes »Replace air filter.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 .. ENGINE .. STANDARD PROCE-
DURE)
No »Go To 4
4. MAF SENSOR DIRTY

Turn the Ignition off.
Remove MAF sensor from air box.
Is it free from debris?
Yes »Go To 5
No »Clean sensor using low pressure air and reinstall, repair complete.
Perform POWERTRAIN VERIFICATION TEST ,- 6.7L. (Refer to 9 - ENGINE .. STANDARD PROCE-
DURE)
5. AIR LEAK IN INTAKE SYSTEM

Check for an air intake leak.
Any leak between the air box to the intake manifold could cause this fault.
Were there any air intake leaks?
Yes »Replace air filter.
Perform POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 - ENGINE .. STANDARD PROCE-
DURE)
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 .. ENGINE .. DIAGNOSIS
AND TESTING)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.1l DIESEL 9 • 1109
P0102-MASS AIR FLOW SENSOR "A" CIRCUIT LOW
IIAn '0 I
I
I
I
$
T -:.. - - -
r--
FUSE
IDDULE·
ITOTALL'
IIITEQUTED
I POWER
I !!A I
~.r ___ ~
tft yC3
A.ll8
18
RDIOR
I
• - - - - - - - . S024
I I
Al1R AI18
19 18
RDIOR RDIOR
1~ 2~
FUSED FUSED
RELAY·
SMART SMART .IIRT
B(+) B(f)
POWER
RELAY
RETURN
POWER
RELAY
FEED
POWER
21
5,
B
8EII'OR.
lUll AIR
4'( FLOW
K348 Fa4S
18 13
BR PKIOR 3T l
v
, 11 441
26
, K916
I' C130 III
" 37 ,,,-- - - BRIOR
F348
16
PK/oR I
10 + C1t2
• S042
!
F3U F348 K916
16 16 18
~m ~/oR BR/OR
I I I
• - - - - - - - . 8040 • 1044
I
K348 1(916 1(151 " AIT
18 18 18
BR BR/OR BRIOR
43 ~ C2 48 ~ Ct 21 ~ C1
r SMART - - - - - - - - - - - - - - - - - - SENSOR- - MASSMR - , 'DDULE·
I POWER GROUND flOW I EI •• NE
I RElAY SENSOR I COITROL
L _________________________
RETURN SIGNAL ~
11
21
31
41
SI
SElSOR·
IODULE· IASI llR FLOW
EI ••NE RELA'· (&.711
CONTROL Ct S'1RT
(G.U, POWER
,1.1L DIESEL)
.......,.c

9 - 1710 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - DR
Theory of Operation
positioned in the air stream and is heated by the electrical current that the voltage produces. As air flows across it,
immediately after this diagnostic runs and fails. The ECM will turn off the MIL lamp when the diagnostic runs and
passes in four consecutive drive cycles .
• When Monitored:
When the key is on .
• Set Condition:
The frequency detected is below what is allowable for the sensor.
Possible Causes
OTHER DTCS
(F348) SMART POWER RELAY FEED CIRCUIT SHORTED TO (K916) RETURN CIRCUIT
(K157) SIGNAL CIRCUIT SHORTED TO (K916) RETURN CIRCUIT
(F348) SMART POWER RELAY FEED CIRCUIT OPEN
(K157) SIGNAL CIRCUIT SHORTED TO GROUND
(F348) SMART POWER RELAY FEED CIRCUIT SHORTED TO GROUND ECM
MAF
ECM
Diagnostic Test
1. OTHER DTC'S
Are there any EGR Airflow Control Valve, turbocharger actuator, or Smart Power Relay faults?
Yes »Troubleshoot other DTCs first.
NOTE: The mass air flow sensor, EGR Airflow Control Valve and turbocharger actuator get a 12V power
supply from the Smart Power Relay.
No »Go To 2
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 • 1711
2. (F348) SMART POWER RELAY FEED CIRCUIT AND (<<916) RETURN CIRCUIT SHORTED
Disconnect the Mass Air Flow Sensor harness connector.
Measure the voltage between the (F348) smart power relay feed circuit 2
and (K916) return circuit of the Mass Air Flow sensor harness connec-
tor.
Is voltage equal to battery voltage?
Yes »Go To 3
No »Go To 4
4
SENSOR-
MASS AIR FLOW
IUL)
81a8c7b3
3. MAF SENSOR
Reconnect the disconnected Mass Air Flow sensor harness connector.
Does the DTC P0103 set?
Yes »Replace the MAF sensor.
Perform POWEATRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 4
4. (F348) SMART POWER RELAY FEED CIRCUIT AND (K916) RETURN CIRCUIT SHORTED
Disconnect the C1 ECM harness connector.
Measure the resistance between the (F348) smart power relay feed cir-
cuit and (K91B) return circuit in the sensor harness connector.
Is the resistance greater than 100k Ohms?
Yes »Go To 5
No »Repair the short circuit.
Perform POWERTAAtN VERIFICATION TEST - B.7L.
SENSOR.
IIAS8 AIR FLOW
(a,7L)
81a8c7b7
9 - 1712 ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
5. (K157) SIGNAL CIRCUIT AND (K916) RETURN CIRCUIT SHORTED

Measure the resistance between the (K157) signal circuit and (K916)
return circuit in the sensor harness connector.
Yes »Go To 6
SENSOR·
MASS AIR FLOW
(t.7L)
r---. r---.
I/.
/ooooo~ Vooooo
:\'
it
00000 00000
00000 00000 21
00000 (0) 00000 31
00000 00000 .1
00000 00000 51
~
\...,' L..J L..J
MODULE·
ENGINE
CONTROLC1
(UL)
81a8c7bb
6. (K157) SIGNAL CIRCUIT OPEN

Measure the resistance of the (K 157) signal circuit between the sensor
harness connector and the ECM harness connector.
Is the resistance less than 10 ohms?
Yes »Go To 7
No »Repair the open signal circuit.
21
10
20
30
40
50
eo
MODULE·
ENGINE
CONTROLC1
(8.7L) 81a8c7eO
DR - - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 1713
7. (K157) SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the (K157) signal circuit in the sensor
harness connector and battery negative.
Yes »Go To 8
No »Repair (K157) signal circuit shorted to ground.
SENSOR.
MASS AIR FLOW
1
~7y
81a8c7e4
8. (F348) SMART POWER RELAY FEED CIRCUIT SHORTED TO GROUND

cuit in the sensor harness connector and battery negative.
Yes »Go To 9
No »Repair (F348) smart power relay feed circuit shorted to
ground.
81a8c7ec
9 ·1714 ENGINE - ELECTRICAL DIAGNOSTICS, - 6.7L DIESEL - - - - - - - - - DR
9. ECM
Reconnect the disconnected Mass Air Flow sensor harness connector.
With the scan tool, read DTC·s.
Yes »Test complete, system response is normal.
Perform POWERTRAIN VERIFICATION TEST - B.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P0103-MASS AIR FLOW SENSOR "A" CIRCUIT HIGH
IBATT AO I
-
F
-IIODUlE.
I
I
@ FUSE
TOULLY
I INTEGRATED
I POWEA
I 37 I
15A
~r. ___ ~
10 iC3
All8
18
RDIOR
I
•I •
I
S024
All8 AllS
18 18
RD/OR RO/OR
11 2~
FUSED FUSED
RELAY·
SMART SMART SIAAT
B(+) B(+)
POWER POWER POWER
RELAY
RETURN
RELAY
FEED
21
BT
SENSOR.
IIASS AIR
5'( 4'( FLOW
K348 F348
18 10 v
BR PKIOR 3 1
,
I ' 37 "I'-- -
1 1 - - -
,: ~~I 1
-
cno
K9l6
18
BRiaR
F348
16
PKIOR I 5042
10 t C112
•
I
F34B F348 K916
16 16 1B
PK/OR PKIOR BRiaR
I I I
• - - - - - - - . S040 • S044
K348
I , Mff
K916 K157
I ' AfT
18 18 18
BR BR/OR BR/OR
43 C2 ~ 481Cf 21 Cf1
ISMART- - - - - - - - - - - - - - - - - - SENSOR- - MASSAIR iIODULE·
I POWER GROUND flOW I ENGINE
I RELAY SENSOR CONTROL
L RETURN
________________________ SIGNAL
_ ~
I
1/
" "
:\\
R
~
IV I
20
00000 V-ooooo II
00000 00000
30 00000 00000 11
-a 00000
00000
© 00000
00000
31
50 41
60 00000 00000 51
A ~ ./
\.:
w w
SEilS OR·
MODULE· IIASS AlA FlaW
ENGINE AELAY·
IS.7L)
CONTAOl Cf SIART
(1.7L1 POWER
(S.7L DIESEL)
'U'eJoe

Theory of Operation
positioned in the air stream and is heated by the electrical current that the voltage produces. As air flows across it,
immediately after this diagnostic runs and fails. The ECM will turn off the MIL lamp when the diagnostic runs and
passes in' four consecutive drive cycles .
• When Monitored:
When the key is on .
• Set Condition:
The frequency detected is above what is allowable for the sensor.
Possible Causes
OTHER DTC'S
MAF SENSOR
(K157) SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM
Diagnostic Test
1. OTHER DTC'S
Are there any EGR Airflow Control Valve, turbocharger actuator, or Smart Power Relay faults?
Ves »Troubleshoot other DTCs first.
NOTE: The mass air flow sensor, EGR Airflow Control Valve and turbocharger actuator get a 12V power
supply from the Smart Power Relay.
No »Go To 2
2. (F348) SMART POWER RELAY FEED CIRCUIT AND (K916) RETURN CIRCUIT SHORTED
Ignition on. engine not running.
D
Measure the voltage between the (F348) smart power relay feed circuit 2
and (K916) return circuit of the Mass Air Flow sensor harness connec-
tor.
Yes »Go To 3
No »Go To 4
SENIOR.
MASS AIR FLOW
(&'7L)
81a8c7b3
3. MAF SENSOR
While monitoring the scan tool, connect a jumper wire between the
(K157) sign~1 circuit and the (K916) return circuit of the Mass Airflow
sensor harness connector.
Yes »Replace the MAF sensor. 3
No »Go To 4
SENSOR-
MASS AIR FLOW
(8.7L)
81d111e7
9 - 1718 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D,IESEL - - - - - - - - - DR
4. (K157) SIGNAL CIRCUIT SHORTED TO VOLTAGE

Turn the ignition. off.
Measure voltage between the (K157) signal circuit of the sensor har-
ness connector and battery negative.
Is the voltage less than 1 volt?
Yes »Go To 5
4
No »Repair the (K157) signal circuit shorted to voltage.
IlAT1'IItY·
NI!.CIATIVI
1tlI-'LIFT IlATTlIIWl
,.., r1
/', ~
ooooo~ 00000
11
00000 00000
00000 00000 21
00000
00000
0 00000
00000 .,
31
00000 00000 11
" ......
MOOOLE.
'--'
'/
ENOINE
CONTROlC1
(Ul) 81a8c7f4
5. (K157) SIGNAL CIRCUIT SHORTED TO (F348) SMART POWER RELAY FEED

cuit and (K157) signal circuit in the sensor harness connector.
Is the resistance greater than 10k Ohms? 2
Yes »Go To 6
No »Repair the short circuits.
4 1
SENSOR·
MASS AIR FLOW
(6.7L) 81d111ec

Measure the resistance between the (K916) return circuit in the sensor
harness connector to the (K916) return circuit in the ECM harness con-
nector.
Is the resistance less than 10 ohms? 3
Yes »Go To 7
No »Repair the open (K916) return circuit.
11
21
31
"51
MODULE.
ENG"E
CONTROLC1
(I.7L) 81a8c7fc
7. ECM
Reconnect the C1 ECM harness connector.
While monitoring the scan tool, connect a jumper wire between the
(K157) signal circuit and the (K916) return circuit of the sensor harness
connector.
3
Does the OTC P0102 set?
tom. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
SENSOR-
MASS AIR FLOW
(6.7L)
81d111e7
9 • 1720 ENGINE • ELECTRICAL DIAGNOSTICS . 6.7L DIESEL - - - - - - - - - - DR
P0106-MANIFOLD ABSOLUTE PRESSLIRE SENSOR PERFORMANCE
SENSOR·
TEMPERATURE/
PRESSURE·I'P
BOOST INTAKE AIR
PRESSURE TEM PE RA TU RE
SENSOR 5 VOL T SENSOR SENSOR
GROUND SUPPLY SIGNAL SIGNAL
'IK916
'I
F855
18
1' 3'
18
BRJOR PKIYL
I
• SDU •
I S173
I I
K916 F855 K37 K21
18 18 18 18
BRIOR PKlYl BR DBIl G
I
,J.t
SENSOR - - -
"l.t
SVOlT - - -
"l.t
B008T- - -
1I1.t
INTAKEAIR -IIODULE.
I GROUND SU PPL Y PRES SUR E TEM PERA TU RE I Ee·oINITIll E L

SENSOR SENSOR RO
IL __________________
SIGNAL SIGNAL
~
I
I)
10000~ J6000'~,
20 00000 00000 'I
JC ggggg 0 ggggg 21
40 00000 00000 J1
,0 00000 00000
.A \...
SUSOR·
TEl PERATU RE/
PRESSURE·
IODULE·
I" EIIIGI.E
(G.lL)
COIITROL Ct
(G.7L)
IUJII4.

DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS" 6.7l DIESEL 9 .. 1721
Theory of Operation
The boost pressure sensor is used to measure exhaust gas pressure in the intake manifold. The Electronic Control
Module (ECM) provides a 5-volt supply to the intake manifold pressure sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The boost pressure sensor provides a signal to the ECM
on the boost pressure sensor signal circuit. This sensor signal voltage changes based on the pressure in the intake
manifold. The ECM will detect a low signal voltage at operating conditions such as during an idle or a deceleration.
The ECM will detect a high signal voltage during high engine load operating conditions. There are two parts to this
fault code, a key on check and a rationality check. At key ON, the readings for the boost pressure, exhaust gas
pressure, and barometric pressure are compared. This fault code occurs if the boost pressure reading is different
from the other two. This diagnostic is run 5 seconds after key on. During normal engine operation, other air handling
sensor values are used to estimate a boost pressure. If the difference between the value read from the boost pres-
sure sensor and the estimation is above a calibrated threshold for a calibrated period of time then an error is
recorded. The key-on portion of the rationality will light the MIL immediately after the diagnostic runs and fails. The
rationality portion has to fail in two consecutive drive cycles for the MIL to become illuminated. The ETC lamp will
also be illuminated. During this time the ECM uses an estimated boost pressure. The ECM turns off the MIL when
the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
While the key is on .
• Set Condition:
The boost pressure recorded at key on is not within a calibrated range from the inlet air pressure sensor.
Possible Causes
EGR AIRFLOW THROTTLE CONTROL VALVE

BOOST PRESSURE SENSOR
Always perform the Pre.. Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 .. ENGINE ..
1. EGR AIRFLOW THROTTLE CONTROL VALVE

Remove the boot from the EGR airflow throttle control valve.
Using a mirror, look at the butterfly valve on the inside of the EGR airflow throttle control valve.
Start the vehicle, let idle for 10 seconds and key off.
NOTE: If functioning properly the EGR airflow throttle control valve will cycle closed immediately after the
engine is shut down.
Did the EGR airflow throttle control valve cycle closed immediately after the engine was shut down?
Ves »Go To 2
No »Replace the EGR airflow throttle control valve.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
2. BOOST PRESSURE SENSOR

Turn ignition switch on. Wait 5 seconds after ignition switch is turned on.
Using the scan tool, read DTC's
Is P0106 stored?
Ves »Go To 3
No »Replace the Boost Pressure sensor.
PROCEDURE)
9 -1722 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
3. BOOST PRESSURE SENSOR

Erase the DTC with the scan tool.
Start the engine and let it idle for 1 minute.
With the scan tool, monitor the boost pressure reading.
Does the value fluctuate slightly, indicating the sensor Is not stuck?
Yes »Repair complete
DURE)
No »Replace the Boost pressure sensor.
Perform POWERTRAtN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P0107-MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT LOW
IEUOR·
TIl PIRITU REI
PRESIURE·IIP
BOOST INTAKE AIR.
PRESSURE TEMPERATURE
SENSOR 5 VOLT SENSOR SENSOR
GROUND . SUPPLY SIGNAL SIGNAL
K916 f855
18 18
BRIOR PKlYL
I
• S044
I
• sna
I I
K916 F855 Kl7 K21
18 18 18 18
BRIOR PKlYl SR DBA.G
r .sENsOR
lei - "lei
- - 5VoLT - - -
"lei
8005T- -
11
-I :::I:~E.
- iNrAKEAIR
I COITROL
lei
I GROUND SUPPl Y PRESSURE
~~OR
TEMPERATURE
~~OR
IL _ _ _ _ _ _ _ _ _ _ _
SIGNAL
_____ __ I
SiGNAL ~
,.., ,..,
10 ".. """I
00000 00000
2a 00000 00000 II
00000 00000
30
40
00000
00000
0 00000
00000
21
31
00000 00000 41
SO
IEIISOR. ~ ~
TEl 'EUTU REI

PREIIURI. 10DULE·
lIP EIlClIIIE
(I.U, COIITROL C1
".lL)

Theory of Operation ' ..' \
~, ".
The Electronic Control Module (ECM) provides a 5-volt supply to the intake manifold pressure sensor on the sensor
supply circuit. The ECM also provides a ground on the sensor return circuit. The intake manifold pressure sensor
provides a signal to the ECM on the intake manifold pressure sensor signal circuit. This sensor signal voltage
changes based on the pressure in the intake manifold. The ECM will detect a low Signal voltage at operating con·
ditions such as during an idle or a deceleration. The ECM will detect a high signal voltage during high engine load
operating conditions. When the fault is active, the ECM illuminates the MIL light immediately when the diagnostic
runs and fails. During this time a default value is used of the intake manifold pressure reading. The ECM will turn
off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles. This fault may cause a derate
in power output.
• When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
• Set Condition:
When the fault is active, the ECM illuminates the MIL light immediately when the diagnostic runs and fails.
During this time a default value is used of the intake manifC?t~ pressure reading..
Possible Causes
OTHER DTC'S
(K37) SIGNAL CIRCUIT SHORTED TO (K916) SENSOR RETURN CIRCUIT
(F855) 5..VOLT SUPPLY CIRCUIT SHORTED TO (K916) SEN~OR RETURN CIRCUIT
MAP SENSOR
(K37) MAP SENSOR SIGNAL CIRCUIT OPEN
(K37) MAP SENSOR SIGNAL CIRCUIT SHORT TO GROUND
ECM
DIAGNOSIS AND TESTING)",
Diagnostic Test
1. OTHER DTC'S
With the scan tool, read the Engine DTC's.
Is there a 5-volt Supply DTC set?
Yes »Repair 5-volt Supply DTC.
DURE)
No »Go To 2
2. P0108 SET
Is P0108 Active?
Yes »Go to 3
AND TESTING)
3. HIGH VOLTAGE
Disconnect the MAP sensor harness connector.
NOTE:' Check connectors - Clean/repair as necessary.
Measure the voltage between the (F855) 5-volt supply circuit and sen-
sor (K916) return circuit of the MAP sensor harness connector.
Yes »Go To 4
No »Go To 5
TEMPERATUREJ
PRESSURE-
MAP
(1.7L)
81aBd090
4. MAP SENSOR
While monitoring the scan toolt jumper the (F855) 5-volt supply circuit to
the (K37) signal circuit in the MAP sensor harness connector.
Did the P0108-MAP SENSOR VOLTAGE TOO HIGH, DTC set?
Yes »Replace the MAP sensor. 2
No »Go To 5
HNSOR-
TEIllPERAT\JREJ
PRESSURI!-
MAP
(1.7L)
81aBdObO
5. (K37) SIGNAL CIRCUIT SHORTED TO (K916) SENSOR RETURN CIRCUIT

Disconnect the ECM harness 60 pin connector.
sensor return circuit in the MAP sensor harness connector.
Is the resistance greater than 100 K Ohms?
No »Repair (K37) signal circuit shorted to (K916) sensor return
circuit or replace harness.
Yes »Go To 6 SENSOR·
TEMPERATURE!
PRESSURE-
MAP
(6.1l)
r-1 ,...,
/ ::\
'0
00000": V'ooooo
20 11
00000 00000
30 00000 00000 21
4(l 00000 (Q) 00000 31
50 00000 00000 41
110
00000 00000 51
A ~
" L....J
MODULE.
L....J
ENGINE
CONTROLC1 81a8d0b4
6. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K916) SENSOR RETURN CIRCUIT

Measure the resistance between the (F855) 5-volt supply circuit and
(K916) sensor return circuit in the MAP sensor harness connector.
No »Repair (F855) 5-volt supply circuit shorted to (K916» sensor
return circuit or replace harness.
Yes »Go To 7
4
SENSOR-
TEMPERATURE!
PRESSURE-
MAP
(6.7L)
81a8dObc
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 .. 1727

Measure the resistance of the (K37) signal circuit between the MAP
Yes »Go To 8
No »Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST * B.7L.
10
20 11
30 21
40
150
'1
.(1
l1li n
MODULE·
I!NGI"
COHTROt..C1 81a8c8a4

Measure the resistance of the (F855) 5-volt supply circuit between the
MAP sensor harness connector and the ECM harness connector.
Yes »Go To 9 2

Perform POWERTRAIN VERIFICATION TEST • B.7L.
(Refer to 9 - ENGINE· STANDARD PROCEDURE)
SENSOR·
TEMPERATURE/
PREDURE-
10
20
30
40
150
00
MOOUt..&
INOIH!!
CONTROt..C1 81a8c8a8
9· 1728 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
9. MAP SENSOR SIGNAL (K37) CIRCUIT SHORTED TO GROUND

Measure the resistance between the MAP Sensor Signal (K37) circuit
and the Battery negative terminal.
Is the resistance above 100k ohms?
Yes »Go To 10
No »Repair the MAP Sensor (K37) Signal circuit for a short to
ground.
4
SENSOR·
TEMPERATUREI
PRESSURE·
MAP
(6.7L)
BATTERY·
_TIlle
/DIEIIEL LEFT IlATlER't) 81a8dOca
10. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K916) RETURN CIRCUIT OR GROUND
Measure the resistance between the (F855) 5-volt supply circuit in the
sensor harness connector and battery negative.
Is the resistance above 100k ohms?
Yes »Go To 11 2
No »Test Complete.
IlATTeIt't·
IfiQATl\I&
/DEIEL LEI'T BATTER't) 81a8d1a4
11. ECM
While monitoring the scan tool, jumper the (F855) 5-volt supply circuit to
the (K37) signal circuit in the map sensor harness connector.
Did the P010S-MAP SENSOR VOLTAGE TOO HIGH, DTC set? 2
Yes »Test Complete.
No » Replace and program the ECM in accordance with the Ser-
vice Information.
'"
SENSOR.
TEMPERA1UREI
PRESSURE·
MAP
(8.7L)
81a8dObO
9 - 1730 ENGINE • ELECTRICAL DIAGNOS1"ICS - 6.7L DIESEL - - - - - - - - - DR
P0108-MANIFOlD ABSOLUTE PRESSURE SENSOR CIRCUIT HIGH
....------------------------,8EUOR.
TEMPERATURE/
PRESIURE·I"
BOOST INTAKE AIR
PRESSURE TEMPERA TURE
SENSOR 5VOL T SENSOR SENSOR
'IK916
18
'I
F855
18
BRIOR PKIYL
I I
.8na
• 1044
I I
K916 F855 m K21
18 18 18 18
BRroR PKNL BR OBI1.6
.. 101 "leI
I sENsoR - - - 5vOLT - - -
"leI
8008r- - -
"leI
"iNTAKE AIR -IIODULEa
EIO'IE
I GROUND SUPPLY PRESSURE TEMPERATURE I CO.TROL
SENSOR SENSOR
IL _ _ _ _ _ _ _ _ _ _ _
SIGNAL
_____ __ I
SIGNAL ~
n ,.,
10
I'~ooo~ 00000'
1
'0 00000
00000
00000
00000
11
21
30
40
00000
00000
0 00000
00000 31
SO 00000 00000 : 41
..... .....
• • IOR·
TEMPERATURE/
PREISURE· MODULE·
M"
('.7L)
EI •• IE
CONTROL C1
,I.IL)

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 -1731
Theory of Operation
The Electronic Control Module (ECM) provides a 5-volt supply to the intake manifold pressure sensor on the sensor
supply circuit. The ECM also provides a ground on the sensor return circuit. The intake manifold pressure sensor
provides a signal to the ECM on the intake manifold pressure sensor signal circuit. This sensor signal voltage
changes based on the pressure in the intake manifold. The ECM will detect a low signal voltage at operating con-
ditions such as during an idle or a deceleration. The ECM will detect a high signal voltage during high engine load
operating conditions. The ECM illuminates the MIL light immediately when the diagnostic runs and fails and a
default value is used for the intake manifold pressure reading. The ETC lamp will also be illuminated. The ECM will
turn off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles. This fault may cause a
derate in power output
• When Monitored:
With the ignition on and battery voltage greater than 10.4 volts .
• Set Condition:
Possible Causes
OTHER DTC'S
(K37) SIGNAL CIRCUIT SHORTED TO BATTERY
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY
MAP SENSOR
(K916) OPEN RETURN CIRCUIT
(K37) SIGNAL CIRCUIT SHORT TO SUPPLY
(F855) 5-VOLT SUPPLY CIRCUIT SHORT TO BATTERY
INTERMITTENT
ECM
Diagnostic Test
1. OTHER DTC'S
Is there a 5-volt Supply DTC set?
Ves »Repair all 5-volt Supply DTC's first.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE~
DURE)
No »Go To 2
2. P108 SET
Yes »Go To 3
AND TESTING)
3. HIGH VOLTAGE
Disconnect the MAP sensor harness connector.
Measure the voltage between the (F855) 5~volt supply circuit and
(K916) sensor return circuit of the MAP sensor harness connector.
Yes »Go To 4
No »Go To 5 4
S!NeOR·
TEIlPERA1\JRE/
PRESSURE·
MAP
(e.fL)
81aBd09O
4. MAP SENSOR
While monitoring scan tool, use a jumper wire to connect the (K916)
return circuit with the (K37) signal circuit at the sensor connector.
Did the P0107-MAP SENSOR VOLTAGE TOO LOW, DTC set?
Yes »Go To 5 4
No »Replace the MAP sensor.

SENSOR·
TEMPERA1\JREf
PRESSURE·
MAP
(l.fL)
81a8&459
DR - - - - - - - - - ENGINE· ELECfRICAl D"AGNOSTICS • 6.7L DIESEL 9 -1733
5. (K37) SIGNAL CIRCUIT SHORTED TO BATTERY

Measure the voltage between the (K3-7) signai circuit at the MAP sensor
harness connector and Battery Negative.
Is the voltage greater than 1 volt?
Yes »Repair (K37) signal circuit shorted to battery.
No »Go To 6
81a8e45d
6. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY

~
,j
,
:
- ,". -
...
Measure the voltage between the (F855) ,5-volt supply cirouit 'at the :. :
MAP sensor harness connector and Battery negative.
-&lID :
~'o~
~,
Yes »Repair (F855) 5-volt supply circuit shorted to Battery or ., 2

replace harness.
Perform POWERTRAIN VERIFICATION TEST - ,6.7L.
No »Go To 7
4
SENSOR-
TEMPERATUREI
PRESSURE-
MAP
,e,n.)
81a8&465
9 - 1734 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
7. (K37) SIGNAL CIRCUIT SHORT TO S-VOLT SUPPLY

Measure the resistance between the (K37) signal circuit of the sensor -&lID
harness connector and the (F855) 5·volt supply circuit of the sensor 2 1 ~.~
harness connector.
~,'
No »Go To 8
Ves »Repair or replace the engine harness.
Perform POWERTRAIN VERIFICATION TEST - B.7L. 4
(Refer to 9 • ENGINE· STANDARD PROCEDURE)
SENSOR·
TEMPERATURE/
PRESSURE·
MAP
(UL)
r-I r-I
'/:/ooooo~ ~
10
20
rooooo II
00000 00000
30 00000 00000 21
.0 00000 (0) 00000 31
50 00000 00000 41
eo 00000 00000 51
~
,~ .A ./
L..J L..J
MODULE·
INGINI
CONTROLC1 81a88469
8. (F855) SENSOR RETURN CIRCUIT OPEN

Measure the resistance between the (K91B) sensor return circuit in the
MAP sensor harness connector with the (K91B) sensor return circuit in
the ECM harness connector.
[]4
4~
Yes »Go To 9
(Refer to 9 • ENGINE - STANDARD PROCEDURE) SENSOR·
TIIPERATUREI
PRESSURE-
MAP
(Ul)
10
20 n
30 21
40
tIO .,
31
60 51
MODULE·
ENCJlNE
CONTROLC1
(8.1l) 81a8c8b2
DR - - - - - - - - - ENGINE - ELECIRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 1735
While monitoring scan toolt connect a jumper wire between the (K37)
signal circuit of the sensor harness connector and the (K916) return cir-
4
cuit of the sensor harness connector.
Does the scan tool show P0107-MAP Sensor Voltage Too Low
DTC?
tom (Diagnostic Procedure).
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
No » Replace and program the ECM in accordance with the Ser- 81!NSOR·
TEMPERATUIIlEI
vice Information.
PRE8IURE·
Perform POWERTRAIN VERIFICATION TEST - 6.7l. MAP
(Refer to 9 - ENGINE - STANDARD PROCEDURE) JUL,
81a8e459
9 • 1736 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
P0111-INTAKE AIR TEMPERATURE SENSOR 1 PERFORMANCE
SElSOR·
TEl PERATURE!
PREIIU RE·IIAP
BOOST INTAKE AIR
PRESSURE TEMPERA TU RE
SENSOR 5VOL T SENSOR SENSQR
K916 F855
18 18
BRIOR PKlYl
I
• SO ...
I
• St73
I I
K916 FS55 K:!7 K2t
18 18 18 18
BRIOR PKIYL BR DBILG
I
,JCt
SENSOR
3J Ct
- - - 5"VoLT - - -
1
" C1
800ST- - -
1
11 C1
INrAKEAIR -IIODULE.
ENGIIiE
I GROUND SUPPL Y PRESSURE TEMPERATURE I CONTROL
SENSOR SENSOR
IL _ _ _ _ _ _ _ _ _ _ _
SIGNAL
_____ __ I
SIGNAL
~
SElSOR·
TEl PERATU REI
PRESSURE· IODULE·
1&' EIGINE
ll.UI CONTROL C1
(1.1L)
IHlla ••
For a complete wiring diagram Reier to Section 8W.

DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 1737
The ambient air temperature sensor are used by the electronic control module (ECM) to monitor the intake air tem·
perature. The ambient air temperature sensor is a thermistor and changes resistance based on the temperature
being measured. The ECM provides a 5·volt reference voltage to the sensor. The ECM monitors the change in
signal voltage and converts this to a temperature value. There are two parts to this fault code, a key on check and
a rationality check. After an 8 hour cold soak, at key ON the readings for the intake air temperature, battery tem-
perature and intake air temperature and coolant temperature are all compared. If the temperatures differ more than
a calibrated amount, then the appropriate sensor fault code would be recorded. The key on monitor is disabled for
ambient temperatures below 20° F. This monitor looks for all the sensors to be grouped on one temperature or, in
the case that the monitor fails, three sensors grouped at one temperature and one outlier. In the case that all four
sensor values are distributed over a range of temperatures this diagnostic will not run. A block heater is one pos-
sible cause of such a distribution. The rationality check is referred to as a dither. The dither looks at the temperature
reading from the sensor over time and ensures that it changes. This monitor is used to detect a "stuck" sensor. If
the sensor reading does not change over a calibrated time limit, the fault will be recorded. Both the key-on and
dither portions of this rationality error require that the diagnostic fails in two consecutive drive cycles before the MIL
lamp is lit. During this time the ECM uses an default value for the ambient air temperature. The ECM turns off the
MIL lamp when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
At key on engine off, the intake air temperature sensor reads differently than the battery temperature and
ambient air temperature sensors. Or while the engine is running the ECM does not read a change in value
from the intake air temperature sensor over time.
Possible Causes
Diagnostic Test

With the scan tool in Sensors, Monitor the Intake Air Temperature.
Does the reading from the sensor increase at least -15 C (5° F) on the scan tool?
0
Yes »Go To 2
No »Replace the intake air temperature sensor.
DURE)

After an 8 hour cold soak, hook up scan tool and monitor intake air temperature, battery temperature, intake air
temperature and coolant temperature.
NOTE: Ensure ambient air temperature is above -6.7° C (20° F) when performing this test.
Does the intake air temperature sensor read differently from the other sensors?
Yes »Replace the intake air temperature sensor.
DURE)
P0112-INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
SElSOR·
TEIPUATUREJ
PREIIURE·I"
BOOST INTAKE AIR
PRESSURE TEMPERA TURE
SENSOR 5VOLT SENSOR SENSOR
K916
18
'I
F855
18
BR/OR PKlYl
I I
• 8113
• 8044
I I
K916 F855 K37 K21
18 18 18 18
BRIOR PKIVL BR DBIlG
"1..
I" sENsoR - - - 5
,,1..
VOLT - - -
"1..
iNTAKE AIR
800ST- - -
11
:::I~~E.
1. -I
GROUND SU PPl Y PRESSURE
TEMPERATU RE 1COITROL
1 SENSOR
SENSOR
1L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
SIGNAL
_ _ J1
SIGNAL
,...., ,.,
10
00000 00000
20 00000 00000 II
00000 00000 21
30
40
00000
00000
0 00000
00000 31
SO 00000 00000 : 41
~ ~
8E180R·
...
TEl PERlTU REI
PRESSURE·
II.lL)
10DULE·
EMa'IE
CONTROL C'
(I.7L,
......
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 -1739
Theory of Operation
The intake manifold temperature sensor is a variable resistor sensor and is used to measure the temperature of the
air entering the intake manifold of the engine. The ECM supplies 5-volts to the intake manifold temperature signal
circuit. The ECM monitors the change in voltage caused by changes in the resistance of the sensor to determine
the intake manifold temperature. The intake manifold temperature sensor is a combination sensor that also reads
pressure. It is located on the intake manifold. The MIL lamp is illuminated immediately when the diagnostic runs and
fails. During this time the customer may notice periods of white smoke as well as the fan running more often. The
MIL lamp is turned off once the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
The ECM monitors the change in signal voltage and converts this to a temperature value .
• Set Condition:
The ECM illuminates the MIL light immediately when the diagnostic runs and fails. During this time it uses an
estimated value for Inlet Air Temperature. The ECM will turn off the MIL after the diagnostic runs and passes
in 4 consecutive drive cycles.
Possible Causes
INTAKE AIR TEMP SENSOR OUT OF SPEC

(K21) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT
ECM
1. INTAKE AIR TEMP SENSOR OUT OF SPEC

Disconnect the Intake Air Temperature sensor harness connector.
Measure the resistance of the Intake Air Temp sensor.
Yes »Go To 2
No »Replace the Intake Air Temperature Sensor/MAP sensor.
DURE)
Reconnect the circuit.
With the scan .tool. erase DTCs.
With the scan tool. read DTCs.
Did the DTC reappear?
No »Go To 3
9 .. 1740 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL - - - - - - - - - DR
3. (K21) SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT

Turn the fgnition off.
Disconnect the 'ECM harness connector.
Measure the resistance between the engine ground and the (K21) tem-
Yes »Go To 4
No »Repair the (K21) temperature sensor signal circuit.
'I!NSOR-
T1!MPIAA'NREI
IATT'I!AY-
..... ~ MIGAlM!
(DIEHl. LI" IAmlRY)
...
00000 r;ooo~
00000 00000
00000 00000
0
50
00000
00000
00000
00000
00000
00000
....
'" ~ ---d
...... ~
~.
ENGINE
CONlJlOLC1
"'11..1 81a8e4cb

Measure the resistance between the (K21) signal circuit and all other
circuits at the ECM harness connector.
Yes » Go To 5
No » Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST - 6.7L 11
10
20 11
30 21
40 31
so 41
eo 51
MODULE·
ENGINE
CONTROLC1
(Ul)
81a8e4cf

Reconnect the ECM harness connector connected.
Measure the voltage between the (F855) 5-volt supply circuit and the
(K916) return circuit the sensor harness connector.
Is the yoltage between 4.5 and 5.5 Yolts?
Yes »Go To 7
No »Go To 6
TEMPERATUREI
PRESSURE-
MAP
fUL)
81a8e4d3

Measure the voltage at the (F855) 5-volt supply circuit of the sensor
harness connector.
Is the voltage between 4.5 and 5.5 Yolts?
Yes »Repair the open (F855) 5-volt supply circuit.
No »Go To 7
SENSOR·
TEMPeRATUIlEI
PRESSURE·
MAP
(1.7l)
81a8e4d7
7. ECM
Reconnect the intake air temp sensor harness connector.
While monitoring with scan tool, disconnect the temperature sensor
Did the DTe P0113 set?
Yes »Clear DTC's, repair complete.
DURE)
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 .. 1743
P0113-INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
SEI'OR·
TEM PERATU REI
PRESSURE·I"
800ST INTAKE AIR
PRESSURE TEM PERA TU RE
SENSOR 5 VOLT SENSOR SENSOR
K916
18
'I
F05S
18
BRIOR PKlYL
I
• 1044
I
• ena
I I
K916 F855 K37 K21
18 18 18 18
BRIOR PKlYl BR DBJLG
"1 Ct 381 Ct 191 Ct 11 1

1-SOOOR - - - SVoLY- - - - B008T- - - iNrAKEAIR -IIODULI.
Ct
I GRO UND SUPPl Y PRESSURE TEMPERA TURE I EI QUI E

SENSOR SENSOR CDIITIOL
IL _ _ _ _ _ _ _ _ _ _ _ SIGNAL
_____ _ _ JI
SIGNAL
M M
10
20
oooo~ 00000'
1
11
00000 00000
30 00000 00000
40
00000
00000
0 00000
00000
21
31
sa 00000 00000 41
IEleOI· ~ .....
TEIPEtITUR!1
'lEISURE· 10DULE·
I" EIIIIIE
II.lL)
,I.n,
OOilTIOL01

9 ·1744 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The ambient air temperature sensor is used by the ECM to monitor ambient air temperature. This is used to sense
the air temperature outside the vehicle. The ECM provides a 5-volt reference voltage to the sensor. The ECM mon-
itors the change in signal voltage and converts this to a temperature value. The circuit voltage to the ECM is above
a calibrated threshold for a certain period of time. The ECM illuminates the MIL light immediately when the diag-
nostic runs and fails. During this time it uses an estimated value for Intake Air Temperature. The ECM will turn off
the MIL after the diagnostic runs and passes in 4 consecutive drive cycles
• When Monitored:
• Set Condition:
Possible Causes

ECM
Diagnostic Test
1. DTC RETURNS
Did the DTC return?
Yes »Go To 2
No »Refer to the INTERMITIENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -

Disconnect the Intake Air Temp sensor harness connector.
Measure the resistance of the Intake Air Temp sensor
Yes »Go To 3
No »Replace the Intake air temperature sensor.
DURE)
3. RESISTANCE CHECK
Reconnect the Intake Air Temp sensor harness connector. 48
Measure the resistance between the (K21) inlet air temperature sensor
signal circuit and (K916) return circuit at the ECM connector.
Yes » Go To 6
No » Go To 4
11
21
31
41
51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a8e5dO
4. (K21) INTAKE AIR TEMPERATURE SIGNAL CIRCUIT OPEN

Measure the resistance of the (K21) inlet air temperature sensor signal
3
circuit between the sensor harness connector and the ECM harness
connector.
Yes » Go To 5
No » Repair or replace the harness.
SENSOR·
TEMPERATUREI 11
PRESSURE-
11
21
JI
.(1
51
MODULE·
ENGINE
CONTROL C1
(UL)
81a8e5d4

Measure the resistance of the (K916) sensor return circuit between the
4
Yes »Go To 6
SENSOR·
10
:za 11
30 21
40 l1
50 4'
80 51
MODUL!.
ENGINE
CONTROLC1
(UL) 81a8e5d8

Check for a short circuit from the (K21) signal circuit to all other circuits
at the ECM harness connector.
Yes »Go To 7 11
No »Repair or replace the harness for a short to ground in the
(K21) signal circuit.
3D 11
30 21
40 J1
60 41
110 51
MODULE.
ENGINE
CONTROLC1
(8.7L)
81a8eSdc
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 - 1747
7. ECM
sensor (K21) signal circuit to the sensor (K916) return circuit at the sen-
sor connector.
Ves »Refer to the INTERMITTENT CONDITION - DIESEL Symp-
NOSIS AND TESTING)
4
SENSOR·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) TEMPERATURE!
PRES8URE-
MAP
(B.7L)
81a8e5e1
9 .. 1748 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
P0116-ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE
• - - - - - - - - - • 8045
I
K914
18
8EIIOR.
W
B1
ENGIIE
COOLIIT
TEMPERATURE
K2 K914
18 18
~roR ~m,
1- -
"lci
Ec,- -
.,lCi
- - - - - - SENSOO - tIlODULE.
I SIGNAL GROUND IENGIIE
I I CONTROL
I I
I _______________ J
10 t
20 11
30 21
40 31
50 41
aD 51
SE••OR· MODULE·
EllailiE !II alII E
COOL'NT CONTROL C1
TEll PEAATU RE II.lLl
(DIESEL)

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 .. 1749
Theory of Operation
The coolant temperature sensor is a variable resistor sensor and is used to measure the temperature of th,e coolant
of t",e engine. The ECM suppUes 5-volts to" the coolant temperature signal circuit. The 'ECM monitors the 'change in
vortage caused by changes 'in the resistance of the sensor to determine the coolant temperature. The er'glne cool-
ant temperature sensor is located near the thermostat housing. There are two parts to this fault code, a key on
check and a rationality check. After an 8 hour cold soak, at key ON the readings for the inlet air temperature, battery
temperature. intake air temperature and coolant temperature are all compared. If the temperatures differ more than
a calibrated amount. then the appropriate sensor fault code would be recorded. The key on monitor is disabled for
ambient temperatures below 20°F. This monitor looks for all the sensors to be grouped on one temperature or, in
the case that the monitor fails, three sensors grouped at one temperature and one outlier. In the case that all four
sensor values are distributed over a range of temperatures this diagnostic will not run. A block heater is one pos-
.sible cause of such a distribution. The rationality check is referred to as a dither. The dither looks at the temperature
reading from the sensor over time and ensures that it changes. This monitor is used to detect a "stuck" sensor. If
the sensor reading does not change over a calibrated time Umit, the fault will be recorded. Both the key-on and
dither portions of this rationality error require that the diagnostic fails in two consecutive drive c.ycles befors the MIL
lamp is lit. The ETC lamp will also be illuminated. During this time the ECM uses an default value for the intake air
temperature. The ECM tums off the MIL lamp when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition: '
The ECM does not read a change in value from the sensor over time.
Possible Causes
LOW COOLANT LEVEL

COOLANT TEMPERATURE SENSOR
THERMOSTAT
Diagnostic Test
1. LOW COOLANT LEVEL

With the engine cold, verify the level of coolant in the radiator.
Is the radiator full of coorant?
Yes »Go To 2
No »Fill the radiator with coolant- refer to the owners manual for assistance.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGINE - STANDARD PROCE·
DURE)
2. COOLANT TEMPERATURE SENSOR

Monitor scan tool, while heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
0
Does the reading from the sensor increase at least -15 C (5° F on the scan toor?
Yes »Go To 3
No »Replace the coolant temp sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE STANDARD PROCE-
DURE)
9 ·1750 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - DR
3. THERMOSTAT
WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands
near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in
personal injury or death.
Start the engine.
Allow the engine to reach normal operating temperature.
Does the thermostat open properly at the correct temperature?
Yes »Go To 4
No »Replace the Thermostat.
DURE)

After an 8 hour cold soak, hook up scan tool and monitor inlet air temperature, battery temperature, intake air tem-
perature and coolant temperature.
NOTE: Ensure ambient air temperature is above 20°F when performing this test.
Does the coolant temperature sensor read differently from the other sensors?
Yes »Replace the coolant temperature sensor.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE· DIAGNOSIS
AND TESTING)
P0117-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
. - - - - - - - - - • 1045
I
KR14
18
BRNH
Ai
rn
:::~IO:'
COOUNT
nlPERlTURE
BT
K2 K914
18 18
VOOR B~T
151 C1 471 Ct
r - - ECT- - - - - - - - SENSOR - • MODULE·
I SIGNAL GROUNO I EI.II.
I I COITROL
I I
I _______________ J
,.., r1
10
10
oooo~ ~oooo'" 1
00000 00000 11
30 00000 00000 21
40
50
00000
00000
0 00000
00000
31
41
eo 00000 00000 51
~ \..
~ ~
SEIIOR· MODULE·
.IIIIE EI.IIE
COOUNT COITROL C1
TEl PIRI TU RE (1.7L,
(DIESEL)
I''''
Theory of Operation
The coolant temperature sensor is a variable resistor'sensor and is used to measure the temperature of the coolant
of the engine. The ECM supplies 5-volts to the coolant temperature signal circuit. The ECM monitors the change in
voltage caused by changes in the resistance of the sensor to determine the coolant temperature. The engine cool·
ant temperature value is used by the ECM for the engine protection system and engine emissions control. The
engine coolant temperature sensor is located near the thermostat housing. This fault is lit if the ECM detects that
the coolant temperature signal voltage is less than a calibratable voltage for a calibratable amount of time. When
the fault is active the customer may complain of white smoke and the fan will stay ON. There is NO engine pro-
tection for high engine coolant temperature if this fault is active. The ECM illuminates the MIL lamp after the diag-
nostic runs and fails once. The ETC lamp will also be illuminated. During this time a default value is used for the
coolant temperature reading. The ECM will turn off the MIL lamp after the diagnostic runs and passes in 4 consec-
utive drive cycles .
• When Monitored:
• Set Condition:
Possible Causes

(K2) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND OR (K914) RETURN CIRCUIT
ECM
Diagnostic Test

Disconnect the Coolant Temp sensor harness connector.
Measure the resistance of the Temp sensor.
Yes »Go To 2
No »Replace the Coolant Temperature sensor.
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
Reconnect the coolant temp sensor connected.
Did the DTC reset?
Yes »Go To 3
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 ·1753
3. (K2) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the engine ground and the (K2) tem-
Yes »Go To 4
No »Repair or replace the short harness.
SENSOR·
ENGiNe
COOLANT
TEMPERATURE
(DIESEL) 813e2e8f

Measure the resistance between the (K2) signal circuit and all other cir-
cuits at the ECM harness connector.
Is the resistance more than lOOk ohms?
Yes »Go To 5 15
No »Repair or rep/ace shorted wiring harness

10
~o 11
30 21
40 31
50 41
60 ~,
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a8c854
5. ECM
Reconnect the ECM harness connectors.
Reconnect the ECT harness connector.
While monitoring the scan tool, Disconnect the temperature sensor harness connector.
PROCEDURE)
ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
P0118-ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH
. - - - - - - - - - • 1045
I
K914
18
8EISOR.
EIIIIIE
COOLAIT
TIIPERATURE
D ~4
18 18
VTIOR BRNH
r - -
15101
Eel - - - - - - - -
.,1 CI
'S'ENSOR - ..., IODULE·
I SIGNAL GROUND I IIIIIIE
I ICOITROL
I I
I _______________ J
n CL
10 /oooo~ '00000'" 1
20 00000 00000 11
30 00000 00000 21
40
50
00000
00000
0 00000
00000
31
41
£0 00000 00000 51
"- \...
~ ~
IE.'OR· IODULE·
E.Ullln ElUUNI!
COOL'N' COILTROl Ct
TEI'IRATUII ,1.lL)
(DIESEL)
••etdIf

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l D1ESEL 9 -1755
Theory of Operation
The coolant temperature sensor is a variable resistor sensor and is used to measure the temperature of the coolant
voltage caused by changes in the resistance of the sensor to determine the coolant temperature. The engine cool-
engine coolant temperature sensor is located· near the thermostat housing. This fault is lit if the ECM detects that
the coolant temperature signal voltage is less than a calibratable voltage for a calibratable amount of time. When
the fault is active the customer may complain of white smoke and the fan will stay ON. There is NO engine pro-
tection for high engine coolant temperature if this fault is active. The ECM illuminates the MIL lamp after the diag-
nostic runs and fails once. The ETC lamp will also be illuminated. During this time a default value is used for the
coolant temperature reading. The ECM will turn off the MIL lamp after the diagnostic runs and passes in 4 consec-
utive drive cycles .
• When Monitored:
• Set Condition:
Possible Causes

(K914) SENSOR RETURN CIRCUIT OPEN
(K2) SIGNAL CI RCUIT SHORTED
ECM
Diagnostic Test

Disconnect the coolant temperature sensor harness connector.
Measure the resistance of the coolant temperature sensor.
Yes »Go To 2
No »Replace the coolant temperature sensor.
DURE)
Reconnect the disconnected coolant temp sensor harness connector.
Did the DTC return?
Yes »Go To 3
9 • 1756 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l D I E S E l - - - - - - - - - DR
3. HIGH RESISTANCE IN CIRCUIT

Turn the ignition off. .
Measure the resistance between the' (K2}. temperature sensor signal
and (K914) return circuit at the ECM harness connector with the coolant
temp sensor harness connected.
Yes »Go To 6
No »Go To 4
SENSOR·
I!NGINI
COOLANT
TEMPERATURE
(DUEL)
81a8c85e

Disconnect the coolant temperature sensor harness connector.
Measure the resistance of the (K2) coolant temperature sensor signal
circuit between the coolant temperature sensor connector and the ECM
connector.
Yes »Go To 5 B
No »Repair or replace the open (K2) signal circuit.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) SENSOR·
ENGINE
COOlANT 15
TEIIFERATURE
(DIESEl.,
10
20 11
» 21
40 31
50 41
eo S1
MODULE·
ENGINE
CONTROLC1
(1.7L) 81a8c863
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 ·1757
5. (K914) SENSOR RETURN CIRCUIT OPEN

Measure the resistance of the (K914) coolant temperature sensor return
circuit between the coolant temperature sensor connector and the ECM
connector.
Yes »Go To 6
No »Repair or replace the open (K914) sensor return circuit. 8

(Refer to 9 - ,ENGINE - STANDARD PROCEDURE)
-. ENGINE
COOI.ANT
'1'BIIPeRATURE
(DluaL)
10
20 11
30 21
40 i1
110 41
$I S1
MODULE-
ENGItE
CONTROLC1
(I.7L) 81a8c867

Measure the resistance of (K2) signal circuit to all other circuits at the
ECM harness connector.
Is the resistance more than 100k ohms?
15
Yes »Go To 7
No »Repair or replace the (K2) coolant temperature sensor sig-
nal ci rcuit.
10 11
30 21
.w 31
50 41
80 61
MODULE·
I:NGINE
CONTROLC1
('.7L,
81a8c86b
7. ECM
sensor (K2) signal circuit to the (K914) sensor return circuit at the sen-
sor connector.
Perform POWERTRAIN VERIFICATION TEST - 6.7L SENSOR·
(Refer to 9 • ENGINE - STANDARD PROCEDURE) ENGINE

COOLANT
TEMPERATURE
(DIESEL)
813e3f1 &
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 -1759
P0128-THERMOSTAT RA-riONALITY
• When Monitored:
• Set Condition:
The coolant temperature does not rise by a calibrated amount over a calibrated amount of time.
Possible Causes
COOLING FAN
THERMOSTAT
Diagnostic Test
1. COOLING FAN
NOTE: Refer to the no trouble code test Fan Operation Test to ensure the fan is operating properly_
Is the cooling fan operating properly?
Ves »Go To 2
No »Repair the cooling fan.
DURE)

Operate the engine for 10 minutes while monitoring the coolant temperature with the scan tool.
Did the coolant temperature change over time while the engine was running?
Ves »Go To 3
No »Replace the coolant temperature sensor.
DURE)
3. THERMOSTAT
NOTE: Refer to the no trouble code test Thermostat Test to ensure the thermostat Is operating properly.
Is the thermostat operating properly?
No »Replace the thermostat.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
9 • 1760 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P0131-02 SENSOR 1/1 CIRCUIT LOW
- - - - -IMODILE.
TOTALLY - - - - - - - - - - - , MODULE·
"1 ElEC TRONICS I
INTIGRATID IIGIII
I DIAGNOSTIC I COITROL
FUSED IGNITION I I POWER DIAGNOSTIC
I
SWITCH OUTPUT I I PORT lOW
I DATA LINK
PORT HIGH
DA~IN~ _GROUN~ _GROUN~ _G~N~ J
~N.STA~..J I -----
51 C2 31 C2 1,1 yet 48 yet 57 ye2
20 YC~ Z9D2
16
Z902
16
Z902
16
BK BK BK
SHIFT ON
THE FlY
• 1175 . - - - . - - - . 1114
I I
F960 Dm D133 Z902
20 20 18 18 10
PKA.G PK4.G WT WTlOR OK
r- -
I
32,.l
- -
FUSED IGNITION
SWITCH OUTPUT
--. MODULE.
I
AlTI-LOCI
IRAIEI
'" t F960
.m
I
.Gtt4
18
I (RUN-START) IllWALI PKA.G
1..-_
10 w- - -
I
-7 v
I
B v
I
Ctl.
F960 D132 D133
20 20 20
PUG WT WTIOR
SA 3A 11A
FUSED IGNITION DIAGNOSTIC DIAGNOSTIC
IODULI·
02 SElSOR
SWfTCH OUTPUT PORT LOW PORT HIGH
rUL DllIEL)
(RUN·START) DATA LINK DATA LINK
021/1 02111 021{1 02112 02111 0211:1

02111 HEATER HEATER PUMP CEll 02112 HEATER HEATER PUMP CElL
PUMP 021/1 CONTROL CONTROl CURRENT 021/1 CURRENT 02112 CONTROL CONTROL CURRENT 021/2
GROUND CURRENT RETURN RETURN SUPPLY TRIM SIGNAL PUMP RETURN RETURN SUPPlY TRIM SIGNAL
1°T 71 14T 16 T IT 15 T 61 5T 121 aT 2T 13 T 4T

Z902 Kft9 1<902 K79 K99 Kl03 K41 1<734 K904 1<80 1<299 1<733 K141
20 20 20 20 20 20 20 20 20 20 20 20 20
t.,"
8K 8RflG BRIDG 8RA.B 8RA.G BRflB D8ILS BR4)G D810G BRITN BRNJT 8R DBIYL
12
Z962
20
8K J J J J JJ
021n
CURRENT
021/2
RETURN
02112
HEATER
021r.l
HEATER
021/2
PUMP CELL
02112
SIGNAL
IEISOR·
onCEI iJ2
I PUMP CONTROL CONTROL CURRENT (1.1L DIESELl
• S1I. RETURN SUPPLY TRIM
02111 02111 02111 021/1 021(1 02111 IEIIOR·

PUMP RETURN HEATER HEATER PUMP CEll SIGNAL OIYGEI tit
CURRENT CONTROL CONTROL CURRENT (ULDIElELI
RETURN SUPPLY TRIM
Z902
to
BK
I
.a.GH4
.n.... '

Theory of Operation
02 sensor circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the Smart
02 Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn
off the MIL lamp diagnostic runs and passes in four consecutive drive cycles .
• When Monitored:
This diagnostic runs when the engine is running .
• Set Condition:
The ECM will set the fault if it receives a FMf (Failure Mode Indicator) message from the Smart 02 Module.
Possible Causes
(K99) 02 1/1 HEATER SUPPLY CIRCUIT OPEN

(K79) 02 1/1 HEATER RETURN CIRCUIT OPEN
(K89) 02 1/1 PUMP CURRENT CIRCUIT OPEN
(K902) 02 1/1 RETURN CIRCUIT OPEN
(K103) 02 1/1 PUMP CELL CURRENT TRIM CIRCUIT OPEN
(K41) 02 1/1 SIGNAL CIRCUIT OPEN
02 SENSOR MODULE
Diagnostic Test
1. (K99) 02 1/1 HEATER SUPPLY CIRCUIT OPEN

Measure the resistance of the (K99) 02 1/1 heater supply circuit
between the 02 sensor harness connector and the Smart 02 sensor
module harness connector.
2
Yes »Go To 2
Perform POWERTRAIN VERIFICATION TEST - 6.7L
SENSOR-
(Refer to 9 - ENGINE - STANDARD PROCEDURE) OXYGEN 111
(6.7L DESEL)
16 CJCJCJCJCJCJCJCJ 9
MODULE-02
SENSOR
(8.7L DIESEL) 81b4fcac
9 - 1762 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
2. (K79) 021/1 HEATER RETURN CIRCUIT OPEN

Measure the resistance of the (K79) 02 1/1 heater return circuit
Yes »Go To 3
SENSOR·
OXYGEN 1/1
18 (1.7LDESEL)
16 9
MODULE-02
SENSOR
(B.7L DIESEL) 81b4fcbO
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 .. 1763
3. (K89) 021/1 PUMP CURRENT CIRCUIT OPEN

Measure the resistance of the (K89) 02 1/1 pump current circuit
Ves »Go To 4
5
7 SEN8OR-
OXYGEN 111
(1.1L DIESEL)
16 cccccccc 9
MODULE"()2
SENSOR
(6.7L DIESEL) 81b4fcb4
4. (K902) 02 1/1 RETURN CIRCUIT OPEN

Measure the resistance of the (K902) 02 1/1 return circuit between the
02 sensor harness connector and the Smart 02 sensor module har-
ness connector.
Yes »Go To 5
7 SENSOR·
OXYGEN 1/1
(8.7L DIESEL)
16 9
MODULE-02
SENSOR
(1.7l DIESEL) 81b4fcbB
DR - - - - - - - - - EIIGINE - ElECTRICAL~·DIAGNOSTICS - 6.7L -DIESEL 9 -1765
5. (K103) 02 1/1 PUMP CELL CURRENT TRIM CIRCUIT OPEN - ~', ~.
Measure the resistance of the (K103) 02 1/1 pump cell current·trim cir-
cuit between the 02 sensor harness connector and the Smart 02 sen-
sor module harness connector.
Is the resistance less than 10 Ohms? [OJ
Yes »Go To 6
Perform POWERTRAIN VERIFICATION TEST .-' B.7L 6
.2
SENSOR-
OXYGEN 1/1
(6.7L DIESEL)
16 9
MODULE'()2
SENSOR
(8.7L DIESEL)
81d60ab5
9 .. 1766 ENGJNE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
6. (K41) 02 1/1 SIGNAL CIRCUIT OPEN

Measure the resistance of the (K41) 02 111 signal circuit between the 02
sensor harness connector and the Smart 02 sensor module harness
connector.
Yes »Go To 7
2
SENSOR-
OXYGEN iii
~lmDE~ /
B "'cc"'~ 1
16 9
MODULE'()2
SENSOR
(6.7L DIESEL) 81b4fcc1
7. OXYGEN SENSOR
5
4
SENSOR-
OXYGEN 1/1
(6.7L DIESEL)
(COMPONENT 810£)
81b400ab
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSl'ICS • 6.7L DIESEL 9 • 1767
P0135-02 SENSOR 1/1 HEATER PERFORMANCE
l.iTT AI
I L-. - - - - -IIODULI.
I
c--_ - .., ELECTRONICS I Tonu,
r.B(+) IIYllRnlD
I 1
- - - - - - - - - - - - - - - - -'IOIULI·
111 •• 1
I I FUSED IGNITION I I POIII 1 OlAGNOSTIC DIAGNOSTIC CO.TlOL
I SWITCH OUTPUT I I I PORT LOW PORT HIGH 1
I L (RUK-START) ..J I _ D!!!,~ _ _ ....£ATAUN~ _G~N~ _G~N~ _GROUN~ J
1_ _ -_1"_-____ _ 51' C2 31' CI 47 '( C2 48 '( C2 57 '( CI
1902 Z902 Z902
20'( C' 16 16 16
F960 ~ ~ ~
20
PK4.G
EXCEPT
SHIFT ON SHIFT ON
THE FLY THE FLY
e - - - - - - e Inl e - - - e - - - e IU'
I I I
F960 F960 0132 0133 Z902
20 20 18 18 10
PUG PUG WT WTIOR BK
~
I
r- - - - ...... IODULI.
A41 1
j
cu,
.... tU
I FUSED IGNITION l&ln-Locl F960

SWITCH OUTPUT IR1U. 18
I (RUN·START) (lllL) I PK.otG
L- - - - ~ 10 ~ - - -----.k- - - -----. Ct ••
'( 7'( 8'(
F960 0132 0133
20 20 20
PKA.G WT WTIOR
9A 3A 11A
FUSED IGNITION DIAGNOSTIC DIAGNOSTIC I . . ILI·
SWITCH OUTPUT PORT lOW PORT HIGH OIUI.OR
(RUK-START) DATA LINK DATA LINK
,.. nll•• IL)
02111 02111 02111 021n 0211'.1 0211'.1

02111 HEATER HEATER PUMP CELL 021/2 HEATER HEATER PUMP CELL
PUMP 021/1 CONTROL CONTROL CURRENT 02111 CURRENT 02112 CONTROL CONTROL CURRENT 02112
lOT 7T 14T 16T IT 15T 6T 5T 12T BT 2T 13T 4T

Z902 K89 K902 K79 K99 Kl0l K41 K734 K904 KaO K299 1<733 Kf41
20 20 20 20 20 20 20 20 20 20 20 20 20
BK DBn..B
t. .
BRA.G BIWG BR.tB BR.tG BMB BRA:lG DBnlG BRITN BRIWT BR DBNt
J J j .I j .I
12
Z902
20
BK
02112 02112 02112 .021Q 02112 02112 .II.OR.

CURRENT RETURN HEATER HEATER PUMP CEll SIGNAL OIYIII t/2
I
e It"
PUMP CONTROL
RETURN
CONTROL
SUPPLY
CURRENT
TRIM
(l.lL DIIIIL)
3 J'
02111 021/1 02111 02111 02 lit 02 111 II.IOR·
PUMP RETURN HEA TER HEA TER PUMP CELL SIGNAL OIYIII tit
CURRENT CONTROL CONTROL CURRENT (1.1L 1IlIILI
RETURN SUPPLY TRIM
Z902
10
BK
I
.... ttt

9 • 1768 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
• When Monitored:
• Set Condition:
Possible Causes

(K79) 02 1/1 HEATER RETURN CIRCUIT OPEN
02 SENSOR MODULE
Diagnostic Test
1 . (K99) 02 1/1 HEATER SUPPLY CIRCUIT OPEN

2
Yes »Go To 2
SENSOR-
(Refer to 9 - ENGINE - STANDARD PROCEDURE) OXYGEN 111
~)
8 ClClCJCJClClCl~( 1
16 DDCJDDDDCl 9
MODULE-02
SENSOR
(6.7L DIESEL) 81 b4fcac
2. (K79) 02 1/1 HEATER RETURN CIRCUIT OPEN

Measure the resistance of the (K79) 02 1/1 heater return circuit
Ves »Go To 3
No » Replace Aftertreatment Wiring Harness.
SENSOR·
OXYGEN 1/1
16 (8.7L DIESEL)
16 9
MODULE-02
SENSOR
(6.7L DIESEL) 81 b4fcbO
3. (K89) 021/1 PUMP CURRENT CIRCUIT OPEN

Yes »Go To 4
7 SENSOR·
OXYGEN 111
(8.7L DIESEL)
18 9
MODULE'()2
SENSOR
(B.7L DIESEL) 81b4fcb4
4. (K902) 02 1/1 RETURN CIRCUIT OPEN

ness connector.
Yes »Go To 5
Perform POWERTRAtN VERIFICATION TEST - 6.7L.
7 SENSOR·
OXYGEN 1/1
(8.7L DIUEL)
18 9
MODULE"()2
SENSOR
(8.7L DIESEL)
81b4fcb8
9 . . 1772 ENGINE . . ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
5. (K103) 02 1/1 PUMP CELL CURRENT TRIM CIRCUIT OPEN

Measure the resis~ance of the (K103) 02 1/1 pump cell current trim cir-
Is the resistance less than 10 .Ohms?
Yes »Go To 6
2
SENSOR·
OXYGEN 111
(1.7L OESEL) 13
18 9
MODULE"()2
SENSOR
(6.7L DIESEL) 81b4fcbc

Measure the resistance of the (K41) 02 1/1 signal circuit between the 02
sensor harness connector and the Smart 02 sensor module harness
connector.
Yes »Go To 7
No » Replace Attertreatment Wiring Harness.
2
SENSOR.
16
MODULE-02
SENSOR
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 ·1773
7. OXYGEN SENSOR
s
SENSOR-
OXYGEN 111
(6.7L OlESEL)
(COMPONENT 8I)E)
81b400ab
9 .. 1774 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
P0137-02 SENSOR 1/2 CIRCUIT LOW
IIlTT 11
I L-. - - - - -IIODULE-
c~ _ I
TOTALLY - - - - - - - - - - - - - - - - - 1 MODULE.
I '8(+) - l ElECTRONICS UITEARlYED I I EI'UIE
I I FUSE!) IGNITION I I POW!I I DIAGNOSTIC DIAGNOSTIC COITIOL
I I SWITCH OUTPUT I I I PORTlOW PORT HIGH I
L (RUN-STARl) ..J I _ DATA LINK _ _ ~ATAlIN~ _G~N~ _G~N~ _G~N~ J
I __-_T_-____ _ 51 C2 31 C2 47 '( C2 48 '( C2 57 '( C2
20 'Yea 2902 Z902 Z902
16 16 16
F!l60 8K BK BK
20
PKlLG
EXCEPT
SHIFT ON
THE FLY
- - - - - - . S115 . - - - . - - - . 1184
r I
F960 0132 0133 Z902
20 18 18 10
PUG PKA.G WT WTiOR flK
r- -
I
~
32-1.
-
FUSED lGNITION
SWITCH OUTPUT
-
I
-, IIODULE.
IAlTI.LOCI
IRAIU
", tF960
Cta.
I
JlGt14
18
IL....
(RUN-START)
___ --J
I (AWALl PKttG
10~ --8 v C101
I
7 V
I I
F960 D132 D133
20 20 20
PKAG WT WTlOR
9A 3A 11A
MODULE·
PORT LOW
02SEIIOI
SWITCH OUTPUT PORT HIGH
(l.lL DIESEL,
(RUN-START) DATA LINK DATA LINK
02 111 02 111 02 111 02112 0211'2 02112

021/1 HEATER HEA TER PUMP CELL 02 112 HEATER HEATER PUMP CELL
PUMP 02 111 CONTROL CONTROL CURRENT 021/1 CURRENT 02112 CONTROL CONTROL CURRENT 02112
GROUND CURRENT RETURN RETURN SUPPLY TRIM SIGNAL PUMP RETURN RETURN SUPPLY TRIM SIGN.&.L
1°T 1T 14 T IT 15 T 6 T 5 T 12T 8\ 2T D\ 4T
Z902 K89 K9C2 K99 KI03 K41 K734 K904 KBO K299 K7J3 K141
20 20 20 20 20 20 20 20 20 20 20 20
8K 8RrtG 8RiDG BRitG BR!lB D81LB BRIf)G DBIDG BRITN BRmT BR DSIYL
"t
Z902
20
8K
C, ..
J
02112 02112
j02112 02112
J .I
02112 021/2 IEUOI·
OIIGEI Itt
CURRENT RETURN HEATER HEATER PUMP CEll SIGNAL
I
. . . 14
PUMP CONTROL
RETURN
CONTROL
SUPPLY
CURRENT
TRIM
IUL DIEtEL)
02111 02111 02111 02111 02111 02111 SElSOR-

PUMP RETURN HEA TER HEATER PUMP CEll SIGNAL OIYCEI 1/1
CURRENT CONTROL CONTROL CURRENT (1.1L DIESEL,
RETURN SUPPLY TRIM
Z902
10
BK
I
... 1114
.n·.... 1

DR - - - - - - - - - - ENGINE· ElECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 ·1775
Theory of Operation
system. This diagnostic monitors the status message broadcast by the Smart 02 sensor module for the downstream
• When Monitored:
• Set Condition:
Possible Causes

(KBO) 02 1/2 HEATER RETURN CIRCUIT OPEN
(K734) 021/2 PUMP CURRENT CIRCUIT OPEN
(K904) 02112 RETURN CIRCUIT OPEN
02 SENSOR MODULE
Diagnostic Test
1. (K299) 02 112 HEATER SUPPLY CIRCUIT OPEN
2
Yes »Go To '2
8I!NSOR.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. OXVGEN112
(Refer to 9 - ENGINE - STANDARD PROCEDURE) (e.7LDIEiIEL)
16 ecce ecce 9
MODULE'()2
SENSOR
2. (KSO) 02112 HEATER RETURN CIRCUIT OPEN

Measure the resistance of the (KBO) 02 1/2 heater return circuit
Ves »Go To 3
OXYGEN1f2
(6.'7L DIESEL)
2
16 00000000 9
MODULE-02
SENSOR
(6.7L DIESEL) 81b4fccd
3. 02 1/2 PUMP CURRENT CIRCUIT OPEN

Yes »Go To 4
Perform POWERTRAIN VERIFICATION TEST . 6.7L.
(Refer 10 9 - ENGINE - STANDARD PROCEDURE)
OXYGEN1f2
(8.7L DIESEL)
8~~5,
16 DDCJClDClClD 9
MODULE-02
SENSOR
(6.7L DIESEL) 81b4fcd1
4. (K904) 02 112 RETURN CIRCUIT OPEN

ness connector.
Ves »Go To 5
2 6
16 00000000 9
MODULE-Q2
SENSOR

Measure the resistance of the (K733) 02 112 pump cell current trim cir-
Ves »Go To 6
8I!NSOR·
OXYGEN 112
ce.7L DIESEL)
16 9
MODULE.-Q2
SENSOR

Measure the resistance of the (K 141) 02 1/2signal circuit between the
ness connector.
Yes »Go To 7
2
SI!NSOR·
16 9
MODULE"()2
SENSOR
(6.7L DIESEL) 81b4fcdd

heater supply and (KBO) 02 heater return circuits.
Is the resistance 3.2 +1- 0.8 ohms at ambient temperature?
4
SENSOR.
OXVGENtl1
(6.7L DIESEL)
(COMPONENT SIDE)
81b400ab
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 1779
P0141-02 SENSOR 1/2 HEATER PERFORMANCE
IBATT AI I
- - - - -1.ODULe.
r B~ 'OTALLY - - - - - - - - - - - - - - - - -'IODULI.
(+) 'l ELECTRONICS I
IMrI!GRATI!D I I
EIIUII!
I FUSED ~~NITION I I
POWI!R I DIAGNOSTIC DIAGNOSTIC CO.'IOL
I I I PORT lOW PORT HIGH I
SWITCH OUTPUT I _ D~ ~ _ _ .,}2ATA LlN~ _G~N~ _G~N~ _GROUN~ J
L (RUN-ST~~ .J
I 51 C2 31 CI 47,(Ct 48'(C2 Sl'(CI
Z902 Z902 Z902
20'( ca
16 16 16
F96:0 BK BK OK
20
PKJlG
1
EXCEPT
SHIFT ON SHIFT ON
THE FLY THE FL Y
~ ----;---.
.------.1171 . - - - . - - - . stat
I , I
F960 F960 D132 0133 Z902
20 20 18 lB 10
PKfLG PKotG WI WTlOR BK
~
32 -t
1
A41 l' etaD
I
.a.G1t4
r- - - - ....,.ODULE. I
I FUSED IGNITION IIITI.LOCI F960
SWITCH OUTPUT IRA lIS 18
I (RUN-START) flWILI I PKI1G
'- - -_...... 10 k- 1 v
"""'\r-
- -B~ Ctll
I I I
F960 D132 0133
20 20 20
PKttG WT WTlOR
9).. 3).. 11).
IOIULE·
OIIEI,Ol
(RUN-STA.Rl) DATA LINK DATAUNK
(I.n 11!Sl!l)
02111 02111 02111 02112 02112 02112

02111 HEATER HEATER PUMP CELL 02112 HEATER HEATER PUMP CELL
PUMP 02111 CONTROL CONTROL CURRENT 02111 CURRENT 02112 CONTROL CONTROL CURRENT 02112
lOT 1T 14T 16 T IT 15 T 61 51 121 8T 2T 13 T 4T

1902 K89 K902 K79 K99 Kl03 K41 K734 K904 K80 K299 K133 K141
20 2C 20 20 20 20 20 20 20 20 20 20 20
BK BRlLG 8RJOG BRtB 8R.tG 8RllB DBlLB BRI1lG DBIDG BRITN BRM'T BR OBNl
"t.
1902
20
BK
11
j j
02112 02112
J02112
j
021/2
J .1
02112 021n IUIOR·
OUAI!I1/2
CURRENT RETURN HEATER HEATER PUMP CElL SIGNAL
PUMP CONTROL CONTROL CURRENT II.n DII!II!LI
I
• Sj14 RETURN SUPPl V TRIM
I 1'- 2I 3I 6)
02111 02111 02111 02111 021/1 02111' SEMSOR·
PUMP RETURN HEATER HEATER PUMP CELL SIGNAL OUG!I fit
CURRENT CONTROL CONTROL CURRENT II.7L DIEIELI
RETURN SUPPLY TRIM
1902
10
BK
I
.a. 111.
IU4 ... t

Theory of Operation
02 Module. The ECM wilt illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn
• When Monitored:
• Set Condition:
The ECM will set the fault jf it receives a FMI (Failure Mode Indicator) message from the Smart 02 Module.
Possible Causes
(K299) 02 112 HEATER SUPPLY CIRCUIT OPEN

(KBO) 02 1/2 HEATER RETURN CIRCUIT OPEN
02 SENSOR MODULE
Diagnostic Test
1. (K299) 02 1/2 HEATER SUPPLY CIRCUIT OPEN

NOTE: Check connectors .. Clean/repair as necessary, inspect for
Measure the resistance of the (1<299) 02 1/2 heater supply circuit
2
Yes »Go To 2
8I!N80R·
Perform POWERTRAIN VERIFICATION TEST - B.7L. OXYGEN 112
(Refer to 9 - ENGINE - STANDARD PROCEDURE) (UL DESEL)
16
MODULE..Q2
SENSOR
DR - - - - - - - - - ENGIN'E • ELECTRICAL DI'AGNOSTICS • 6.7L DieSEL '9 • 1781
2. 02112 HEATER RETURN CIRCUIT OPEN

Measure the resistance of the (K8D) 02 1/2 heater return circuit.
Yes »Go To 3
No »Replace Aftertreatment Wiring Harness. 2
Perform POWERTRAIN VERIFICATION' TEST .:.. B.7L

OXYGEN 112
(6.7L DIESEL)
2
16 9
MODULE.Q2
SENSOR
(8.7L DIESEL) 81b4fccd
3. (K734) 02 1/2 PUMP CURRENT CIRCUIT OPEN

Yes »Go To 4
No », Replace Aftertreatment Wiring Harness. 6
Peiform POWERTRAIN VERIFICATION TEST - B.7L

MODULE.Q2
SENSOR
9 - 1782 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
4. (K904) 021/2 RETURN CIRCUIT OPEN

ness connector.
Yes »Go To 5
16
MODULE'()2
SENSOR

Measure the resistance of the (K733) 02 1/2 pump cell current trim cir-
Yes »Go To 6
No » Replace Aftertreatment Wiring Harness.
SINIOR·
OXYGEN 112
(UL DIESEL)
16 9
MODULE'()2
SENSOR
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6~7L DIESEL 9 ·1783

Measure the resistance of the (K141) 02 1/2signal circuit between the
ness connector.
Yes »Go To 7
No »Replace Aftertreatment Wiring Harness. 2

al!NeaR.
MODULE.02
SENSOR
(8.7l DIESEL) 81b4fcdd

Yes » Replace Smart 02 Sensor Module.
5
4
11!N80R.
OXYGEN 111
(S,7L DIESEL,
(COMPONENT SIDE)
81b400ab
P0148-FUEL DELIVERY ERROR
Theory of Operation
The ECM will turn on the MIL lamp immediately after the diagnostic runs and fails. The ECM will turn off the MIL
• When Monitored:
• Set Condition:
A deviation between the fuel pressure set point and the actual fuel pressure.
Possible Causes
OTHERS DTC'S PRESENT

FUEL LEAKS
LIFT PUMP FLOW
HIGH PRESSURE FUEL PUMP
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
FUEL CONTROL ACTUATOR
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS
CASCADE OVERFLOW VALVE
AIR IN FUEL SYSTEM
Diagnostic Test
1. OTHERS DTC'S PRESENT

Are any other DTC's present?
Yes »Repair other DTC's first.
DURE)
No »Go To 2
2. FUEL LEAKS
Ensure that the fuel level is above 15% using the scan tool.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components.
Do you have any fuel leaks or damaged components?
Yes »Repair the fuel leak.
DURE)
No »Go To 3
3. SETPOINT VS FUEL PRESSURE

With the scan tool watch fuel pressure VS. setpoint with the engine at idle or cranking?
Is the pressure within 500 psi +/- of set point?
If psi is within 500 psi

Document DTC and freeze frame data and attempt to duplicate complaint.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ENGINE - STANDARD PROCE-
DURE)
If the psi is higher than setpoint
Go To 9
If the psi is lower than setpoint
Go To 4
4. LIFT PUMP FLOW

Perform the *IN TANK FUEL LIFT PUMP FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the Lift pump pass the test?
Yes »Go To 5
No »Replace the Lift Pump.
DURE)
5. HIGH PRESSURE FUEL PUMP

Perform the no trouble code test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST. (Refer to 9 - ENGINE -
Did the fuel pump pass the high pressure fuel pump performance test?
Yes »Go To 6
No »Replace the High pressure fuel pump.
DURE)
6. LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS

Perform the *INJECTOR RETURN FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Are any Injectors leaking or high pressure connectors leaking?
Ves »Replace or repair the leaking fuel injectors or high pressure connectors.
DURE)
No »Go To 7

Perform the no trouble code test *FUEL PUMP RETURN FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING)
NOTE: This test can be performed at the same time as the Injector Return Flow test that is listed in step 8
by measure the flow that is normally wasted.
Is the drain flow measured less than 1000 ml/minute at idle?
Yes »Go To 8
No »Replace Fuel Injection Pump.
DURE)

Perform the no trouble code test *PRESSURE LIMITING VALVE ON THE FUEL RAIL FOR INTERNAL LEAKS.
Did the pressure limiting valve pass the test procedure?
Yes »Go To 9
No »Replace the Pressure Limiting Valve.
DURE)
9. FUEL CONTROL ACTUATOR

Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.
NOTE: The fuel control actuator will only click when cycled off.
Do you hear a click from the actuator when you cycle the actuator off with the scan tool?
Yes »Go To 10
No »Replace the fuel control actuator.
DURE)
1o. CHECK VALVE DAMAGED OR BLOCKED

Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?
Yes »Repair the cause of the damaged or blocked check valve or replace the valve.
DURE)
No »Go To 11
11. FUEL PRESSURE SENSOR

Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM.
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
No »Replace the fuel pressure sensor.
PROCEDURE)
P0169-WATER IN FUEL DETECTED FOR TOO LONG
. - - - - - - - - - • 1045
I
K914
18
BRlWT
11 III lOR·
WATER
II FUEL
G123 K914
18 a
VTA.G BRNH
r- -
3I1CI "lei
-WATER - - - - - - - SENSOR - -, .ODULE·
I IN FUEL I EIIIIE GROUND
I SENSOR I COITROL
SIGNAL
II _______________ JI
.-. ,...,
~I 10 1'~'OOo~ 00000 I
20 00000 00000 II
)0 00000 00000 21
~o
SO
00000
00000
0 00000
00000
31
~I
IE.,OR·
60 00000
.A ~
00000
.,. 51
WATER ~ ~
II fUll
II.lLl
.ODULE·
DailE
CONTROL C1
,1.lL,
''''ltlU

9 ·1788 ENGINE· ELECTRICAL DIA~OSTICS • 6.7L DIESEL - - - - - - - - - D R
Theory of Operation
The water-in-fuel sensor is attached to the bottom of the fuel filter. The ECM provides a 5-volt reference signal to
the water-in-fuel sensor. When the water collected in the fuel filter covers the sensor probes, the water in fuel sen-
sor then pulls the 5-volt reference voltage to ground indicating high water accumulation in the fuel filter. The ECM
illuminates the MIL lamp immediately after the diagnostic runs and fails. During this time water in fuel may cause
white smoke, loss of power or hard starting. The MIL lamp will tum off after the diagnostic runs and passes in 4
consecutive drive cycles.
• When Monitored:
• Set Condition:
Water in fuel light was on for a calibrated amount of time.
Possible Causes
OTHER DTC'S PRESENT

WATER IN FUEL
Always perform the Pre-Diagnostic Troubleshooting procedure' before proceeding. (Refer to 9 - ENGINE ..
Diagnostic Test
1. OTHER DTC'S PRESENT
Is P2269 displayed?
Yes »Repair P22B9 DTC first.
DURE)
No »Drain water in fuel.
P0191-FUEL RAIL PRESSURE SENSOR CIRCUIT PERFORMANCE
Theory of Operation
This DTC is mapped to two different tests, a key on test and an idle diagnostic. The key..on error monitors fuel
pressure voltage at key on after an 8 hour cold soak. The fuel rail pressure reading must be below a calibratable
amount in order for the diagnostic to pass. The Idle Diagnostic runs whenever the engine is in an idle condition. The
ECM varies fuel pressure and monitors the final fueling and engine speed to determine if the reading from the
pressure sensor is accurate. The engine must be at operating temperature and must not be in an active Aftertreat-
ment regeneration mode in order to run this diagnostic. The engine will fight the MIL lamp after the diagnostic runs
and fails in two consecutive drive cycles. The ECM will turn off the MIL lamp after the diagnostic runs and passes
in 4 consecutive drive cycles. .,
• When Monitored:
At key on, engine off and at idle conditions .
• Set Condition:
At key on, engine off the fuel pressure sensor is reading above a calibrated threshold. At idle the change in
final fueling value is above a calibrated threshold while the diagnostic is running.
Possible Causes
OTHER FUEL SYSTEM DTCS

FUEL RAIL PRESSURE SENSOR
INJECTOR LEAKAGE
Diagnostic Test
1. OTHER DTCS
Are there any other fuel system related DTCs present?
Yes' »Repair all other fuel system related DTC's first.
No »Go To 2
2. FUEL RAIL PRESSURE SENSOR

With the scan tool, monitor the actual fuel pressure reading while the ignition is on and engine is not running.
Is the actual fuel pressure reading greater than 870 psi?
Yes »Go To 3
No »Go To 4

Visually inspect the fuel system components for signs of tampering, pay particular attention to the fuel pressure
sensor on the fuel rail and the fuel pressure sensor wiring harness.
Were any signs of tampering discovered.?
Yes »Replace the Fuel rail pressure sensor.
DURE)
No »Go To 4
4. INJECTOR LEAKAGE
Perform the no trouble test *INJECTOR RETURN FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
Does the injector drainage meet the test specification?
Yes »Replace the Fuel rail pressure sensor.
DURE)
No »Repair cause of high injector leakage.
DURE)
P0192-FUEL PRESSURE SENSOR LOW
1111 lOR·
FUEl.
RAIL
FUEL PREIIURE
RAIL
SENSOR 5 VOLT SENSOR
GROUND SUPPLY SIGNAL
jV
3'
K916 F855 K181

18 18 18
BRIOR PKlYl BRIYL
•
I 1044
• Ina
I
K9f6 f855
18 18
BRIOR PKIYL
i -
.J
-SENSOR
el 311 e.
5VOlr - -
"e.
FuEl-IIODULlo
I GROUND SUPPl Y RAil I :::~R~L
I SENSOR
I ~- I
I
10 1
20 11
lO 21
40 31
SO 41
60 51
l
)
.,"
)
SEll 'OR·
fUEL RAIL
.l PRESSURE IODULE·
;)
)
(DIEIEL) !Iall!
) COIITROL C1
J (••7L,
')
....5
........
Theory of Operation
The Electronic Control Module (ECM) provides a 5-volt supply to the fuel rail pressure sensor using a common
sensor supply circuit. The ECM also provides a ground on the sensor return circuit. The fuel rail pressure sensor
provides a Signal to the ECM on the fuel rail pressure sensor signal circuit. This sensor signal voltage changes
based on the pressure in the fuel rail. The ECM will detect a low signal voltage at low rail pressures. The ECM will
detect a high signal voltage during high rail pressure conditions. The ECM will light the MIL lamp immediately after
the diagnostic runs and fails. During this time the customer may experience a power and or speed derate. The ECM
will turn off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
Possible Causes
OTHER DTC'S
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (F855) RETURN CIRCUIT
(K181) SIGNAL CIRCUIT SHORTED TO (F855) RETURN CIRCUIT
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test
1. OTHER DTC'S
With the scan tool, read OTCs.
Check for multiple DTC that may share the same 5-volt supply circuit and Sensor Ground circuit. Repair as nec-
essary.
Do you have multiple DTC's?
Yes »Repair the shared circuits.
DURE)
No »Go To 2
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 ·1793
2. 5-VOLT SUPPLY AND (K916) RETURN CIRCUIT

Disconnect the Fuel Pressure sensor harness connector.
-&lID
Ignition on, engine not running. :'o~
Measure the voltage between the (F855) 5-volt supply and (K916)
return circuits of the Fuel pressure sensor harness connector.
No
Yes »Go To 3
»Go To 4
R, SENSOR·
FUEL RAIL
PRESSURE
(DIESEL)
813e6b6c

Reconnect the disconnected Fuel Pressure Sensor harness connector.
While monitoring scan tool, disconnect the Fuel Pressure sensor harness connector.
Yes »Replace the Fuel Pressure Sensor.
DURE)
No »Go To 4

(K916) return circuit in the sensor harness connector.
Yes »Go To 5
No »Repair the shorted circuits.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. SENSOR-
FUELRAlL
(Refer to 9 - ENGINE STANDARD PROCEDURE)
PRESSURE
(DIESEL)
813e6bda
9 -1794 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
5. (K181) SIGNAL CIRCUIT SHORTED TO (K916) RETURN CIRCUIT

return circuit in the sensor connector.
Yes »Go To 6
No »Repair the shorted circuits. 2
seNSOR·
FUELRAJI.
PRESSURE
(DUlL)
813e6ba7

Measure the resistance between the signal (K181) circuit in the sensor
harness connector with the (K181) signal circuit in the ECM harness
connector.
Is the resistance less than 10 Ohms? 2
Yes »Go To 7
No »Repair the open (K181) signal circuit.
'.'
,
29 SENSOR·
FUlL RAIL
PR£88URE
(DIESEL)
II /0 )000- "'00000'"
o l~ooo 00000 Ii
g~ggg (0) ggggg 21

31
00000 00000 41
: 00000 00000 $1
'-~ A ~ 'l./
MODULE·
INGINE
CONTROLC1
(t.7L)
81888662
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS ~ 6.7L DIESEL 9 -1795

Measure the resistance between the supply (F855) circuit in the sensor
harness connector with the (F855) 5-volt supply circuit in the ECM har-
ness connector.
Yes »Go To 8
No »Repair the open (F855) 5-volt supply circuit.

Is the resistance greater than 100k Ohms? 2
Yes »Go To 9
3
SENSOR-
FUEL RAIL
PRESSURE
(DI1!9I!L)
813e6bc6
9. (F855) 5-VOlT SUPPLY CIRCUIT SHORTED TO GROUND

Yes »Go To 10
3
No »Repair (F855) 5-volt Supply circuit shorted to ground.
SENSOR-
FUEL RAIL
PRESSURE
(DI1!8I!L)
813e6bda
10. ECM
Reconnect the disconnected Fuel pressure sensor harness connector and ECM harness connectors.
While monitoring scan tool, disconnect the Fuel Pressure sensor connector.
DURE)
DURE)
DR - - - - - - - - - EN'GIN'E ~ ELECTRICAL D.'AGNOSTICS ...6.7l DIESEL 9 .. 1797
P0193-FUEL PRESSURE SENSOR HIGH
r------------, SUIOR.
'UIEL
RlJL
Fun " PREIIU,RE
RAIL
SENSOR 5VOLT SENSOR
GROUND $UPPLY SIGNAL,
1V 3'
K916 F85"5 K181

18 18 18·
BR/oR PKlYL BRIVL
•
I .044
e,_ Ina·
I
K916 F05S
18 10
BR/OR PKIVL
r- -
.JCt l,lct
-sENSOR 5vm - - FuEL -
"Ct ,MODULE.
I GROUND SUPPLY RAIL E•• ,IE
I SENSOR _ I COITROL
I SIGNAL' I
1______ - - - - - -I
10 oooo~ f(;ooo~ 1
20 00000 00000 11
'[~~~l'
30
40 ggggg 0 ggggg 21
31
50 00000 00000 41
SO 00000 00000 51
~
IEIIOR·
FUEL RilL
PI!SIURE 10DULE-
(DIESEL) EI.,IE
COITROL Ct
C··7L,
.t ......

9 -1798 ENGINE .. ELECTRICAL DIAGNOSIICS .. 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The Electronic Control Module (ECM) provides a 5-volt supply to the fuel rail pressure sensor using a common
sensor supply circuit. The ECM also provides a ground on the sensor return circuit. The fuel rail pressure sensor
provides a signal to the ECM on the fuel rail pressure sensor signal circuit. This sensor signal voltage changes
based on the pressure in the fuel rail. The ECM will detect a low signal voltage at low rail pressures. The ECM will
detect a high signal voltage during high rail pressure conditions. The ECM will light the MIL lamp immediately after
the diagnostic runs and fails. During this time the customer may experience a power and or speed derate. The ECM
will turn off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
The circuit voltage to the ECM is above a caUbrated threshold for a certain period of time.
Possible Causes
OTHER DTCIS
(K181) SIGNAL CIRCUIT SHORTED TO VOLTAGE
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K181) SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY CIRCUIT
ECM
Diagnostic Test
1. OTHER OTC'S
Ignition anI engine not running.
Check for multiple DTCs that may share the same 5-volt supply circuit and Sensor Ground circuit. Repair as nec-
essary.
Do you have multiple DTC's?
Yes »Repair the shared circuits.
Perform POWERTRAIN VERIFICATION TEST· 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
DR - - - - - - - - - ENGINE - ELECTRICAL 'DIAGNOSTICS - 6.7L DIESEL 9 - 1799
2. (F855) 5-VOLT SUPPLY AND (K916) RETURN CIRCUIT

D
Measure the voltage between the (F855) 5-volt supply and (K916)
return circuits of the Fuel pressure sensor harness connector.
Yes »Go To 3
No »Go To 5
SENSOR·
FUEL RAIL
PRESSURE
(DIESEL)
813e6b6c

Measure the resistance between the signal (K181) circuit in the sensor
harness connector with the (K181) signal circuit in the ECM harness
~ID
connector.
[] 2
~:~
Yes »Go To 4
29 'm'
= = =
SENSOR-
FUI!LRAL
PRESSURE
(DIESEL)
10
20 11
30 21
oW 31
50 41
50 ~1
MODULE·
m'GIINI!
CONTROt.C1
(8.7L)
81a8e662
9 -1800 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR

While monitoring scan tool, connect a jumper wire between the (K181)
signal circuit and the (K916) return circuit of the Fuel Pressure sensor
connector.
Does the DTC P0192 set? 2
Yes »Replace the Fuel Pressure Sensor.
No »Go To 5
SENSOR-
FUEL RAIL.
PRESSURE
(DIESEL)
813ebe59
5. (K181) SIGNAL CIRCUIT SHORTED TO VOLTAGE

2
Measure the voltage between the (K181) signal circuit of the sensor
Yes »Go To 6 3
No »Repair the (K181) signal circuit shorted to voltage.

Perform POWERTRAIN VERIFICATION TEST - 6.7L. SENSOR·
FUEL RAIL
(Refer to 9 - ENGINE - STANDARD PROCEDURE) PRESSURE
(OIESEL)
813ebe5d
6. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE

Measure the voltage between the (F855) 5-volt supply circuit of the sen-
sor harness connector and battery negative.
Yes »Go To 7
No »Repair the (F855) 5-volt supply circuit shorted to voltage.
SENSOR.
FUEL RAIL
PRESSURE
(DIESEL)
813ebe62
7. (K181) SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY CIRCUIT

Measure the resistance between the (K181) signal circuit and (F855)
5-volt supply circuit in the sensor connector.
2
Yes »Go To 8
•
(Refer to 9 - E.NGINE - STANDARD PROCEDURE)
SENSOR·
FUEL RAIL
PRESSURE
(DIESEL)
B13ebe66

Measure the resistance between the (K916) return circuit in the sensor
harness connector with the (K916) return circuit in the ECM harness
connector.
Yes »Go To 9
SENSOR·
FUEL RAIL
48 PRESSURE
(DIESEL)
10
20 It
30 21
4() 31
50 41
flO 51
MODULE-
ENGINII!:
CONTROl.C1
(8.7L) 81afSOa3
9. ECM
Reconnect the disconnected ECM harness connectors.
While monitoring scan tool, connect a jumper wire between the (K181)
signal circuit of the sensor connector and the (K916) return circuit of the
sensor connector.
NOSIS AND TESTING) 3

Perform POWERTRAIN VERIFICATION TEST - 6.7L. SENSOR·
FUEL RAIL
(Refer to 9 - ENGINE - STANDARD PROCEDURE) PRESSURE
(DIESEL)
813ebe6e
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 • 1803
P0201-FUEL INJECTOR 1 CIRCUIT/OPEN
- - - - - - - - - - - - - - - - - - - - --- - - - - - - - - - - - - IODULE·
I I ENGINE
I INJECTOR INJECTOR INJECTOR I CONTROL
HIGH HIGH HIGH
I SIDE INJECTOR SIDE INJECTOR SIDE INJECTOR I
L~~~ __ ~~~·~ ___ ~~~ __ ~~~·~ _ _ _ ~~~ _ _ ~~~·~I
"I"'K611
16
"I"'
Kll
16
"I"'
K612
16
"I"'
K12
16
'T'
K613
16
"I"'
K13
16
ORIBR BRNl YLIBR BR'{)B GYIBR TN
E L----1----1----1----1----J cm
] '] '] '] A]. ']

K611 K11 K612 K12 K613 K13
14 14 14 14 14 14
BK BK BK BK BK BK
J
~'.'ECT.R.
FUEL 1
J
~'.'ECT.R.
FUEL 2
J
~'''ECT.R.
FUEl3
'i 'i
, ~DDDDDD~A ~oooo"
~1 ~1 ~1 10
20
rooood'
00000 00000
I
II
3G ggggg 0 ggggg 21
~2 ~2 ~2
40 31
CU6 sa 00000 00000 41
60 00000 00000 51
(DIESEL) A ~ ./
II.lECTOR· INJECTOR· IUEeTOR· LJ LJ
FUEL 3 FUEL 2 FUEL 1

(DIESEL) (DIESEL) CDIEIEl)
MODULE·
ENGINE
CONTROL C1
C··lL)
Ctt6
CDIEIEl)

Theory of Operation
The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the noz-
zle tip into the combustion chamber. The MIL lamp will light immediately after the diagnostic runs and fails. During
this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs
and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
When the injector current falls below a calibrated threshold.
Possible Causes
PASS TROUGH CONNECTORS OPEN

FUEL INJECTOR
INJECTOR HARNESS OPEN
HIGH SIDE DRIVER HARNESS OPEN
HIGH SIDE DRIVER CIRCUIT OPEN
LOW SIDE DRIVER CIRCUIT OPEN
HIGH SIDE DRIVER SHORTED TO LOW SIDE DRIVER
HIGH SIDE DRIVERS SHORTED LOW
LOW SIDE DRIVER CIRCUIT SHORTED OTHER LOW SIDE DRIVER CIRCUIT
LOW SIDE DRIVERS SHORTED LOW
HIGH SIDE DRIVER SHORTED TO VOLTAGE
LOW SIDE DRIVER SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED IN INJECTOR HARNESS
INJECTOR
INJECTOR HARNESS
LOW SIDE DRIVER HARNESS OPEN
ECM
Diagnostic Test
1. OTHER DTC'S
Do you have any combination of DTC's P0201, P0202, or P0203?
Perform POWERTRAIN VERIFICATION TES'T (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. LOW SIDE DRIVER CIRCUIT SHORTED IN INJECTOR HARNESS

Measure the resistance of each of the Bank 1 low side driver circuit to
all other Bank 1 low side driver circuit at the ECM harness connector.
Yes »Go To 3
No » Replace the injector harness.
Perform POWERTRAIN VERIFICATION TEST (DIESEL).
(Refer to 9 - -ENGINE - STANDARD PROCEDURE) 11
21
31
41
MODULE·
ENGINE
CONTROLC1
81cc1fd4
3. HIGH SIDE DRIVER CIRCUIT OPEN

Disconnect the Injector 1-3 harness connector.
Measure the resistance of the injector high side driver circuit between
the Bank 1 high side driver circuit in the ECM harness connector and
the high side driver circuit in the injector harness connectors for cylin-
ders 1-3. 10

11
Yes »Go To 4
21
No »Repair the open high side driver circuit from ECM harness 31
connector to the Injector harness connector. 41
MODULE-
ENGINE
a1cbcfcO
4. LOW SIDE DRIVER CIRCUIT OPEN

Measure the resistance of the 1, 2, and 3 injector low side driver circuits
between the ECM harness connector and the injector harness connec-
tors.
Yes »Go To 5
No » Repair the open low side driver circuit. 10
Perform POWERTRAIN VERIFICATION TEST (DIESEL). 30-1~~
(Refer to 9 - ENGINE - STANDARD PROCEDURE) 20 00000 11
I .,II 0000
40-3 30
..gggg000 21
~
o l~ 31
50 L,.~ 0000 41
F=::::::=::=====G
--,-..----~----
60 51
50-2 MODULE-
ENGINE
CONTROL C1
rn
,~~~.
/ _7;J
E-1 C-2
B-3
81cbd025
DR - - - - - - - - - , E N G I N E • ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 -1807
5. HIGH SIDE DRIVER SHORTED TO LOW SIDE DRIVER

Measure the resistance between the Bank 1 high side driver circuit at
the ECM harness connector and the low side driver circuit for injectors
1-3 at the ECM harness connector.
Is the resistance more than 100k Ohms? []F
Yes »Go To 6
No »Repair the High side circuit shorted to the low side circuit.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) F A
C111
(DIESEL'
10
20 11
30 21
40 31
50 41
51
MODULE·
ENGINE
CONTROLC1 81cbd07e
9 - 1808 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
6. HIGH SIDE DRIVERS SHORTED LOW

Measure the resistance of the injector harness connector high side
driver circuits to battery negative for injectors 1-3.
Is the resistance more than 100k Ohms?
Yes »Go To 7
No »Repair the High side driver shorted tow in the harness.
CHI
(DIESEL)
BATTERY-
NEGATIVE
(DII::IEL LEIIT 8ATTERY)
81cbd086
7. LOW SIDE DRIVERS SHORTED LOW

Measure the resistance of the injector harness connector Low side
Yes »Go To 8
No »Repair the Low side driver shorted low in the harness.
F A
C1111
(DIESEL)
BATTERY-
NEGATIIIE
(DII!SEL LEFT BATTERy)
81cbd08a
8. HIGH SIDE DRIVER SHORTED TO VOLTAGE

Measure the voltage between the high side driver circuit in the engine
harness and battery negative.
No
Yes »Go To 9
»Repair the high side driver shorted to voltage.
QF 0 B(~
Perform POWERTRAIN VERIFICATION TEST (DIESEL). ~!J!rL
(Refer to 9 ENGINE - STANDARD PROCEDURE)
&
CHI
(DIESEL)
BATTERY·
"GATIVI
(DIESEL L!!fT IlA.nERV)
81cbd091
9. LOW SIDE DRIVER SHORTED TO VOLTAGE

Measure the voltage between the low side driver circuit
in the engine harness and battery negative for cylinders
1-3.
Yes »Go To 10
No »Repair the low side driver shorted to volt-
age.
Perform POWERTRAIN VERIFICATION
TEST (DIESEL). (Refer to 9 - ENGINE -
STANDARD PROCEDURE)
81cbcO
1o. LOW SIDE DRIVER CIRCUIT SHORTED OTHER LOW SIDE DRIVER CIRCUIT
all other Bank 1 low side driver circuits at the ECM harness connector.
Yes »Go To 11
No »Repair Low side driver circuit shorted to other Low side
driver circuit.
21
31
41
51
MODULE·
ENGINE
CONTROL C1 81cc163e
11. INJECTOR CIRCUITS SHORTED INSIDE ENGINE

Disconnect the injector through head harness connector.
Measure the resistance of each injector from the through head connec-
tor.
NOTE: Be sure to zero the ohm meter prior to checking the injec-
tor circuit.
Is the resistance greater than 0 ohms and less than 1 ohm?
Yes »Go To 12
No »Go To 15
C118
(DIESEq
81cbd099
12. INJECTOR HARNESS

Disconnect the pigtail nuts from injectors 1-3.
Measure resistance of each circuit in the injector harness from pigtail
side to injector harness connector.
Is resistance above 1 ohm?
Yes »Replace the injector harness.
No »Go To 13
INJECTOR·
FUEL.NO.2
(DIESEL) 81cbd0a4
13. INJECTOR
Measure the resistance between the solenoid posts of each injector.
tor circuit.
Is the resistance less than 1 ohm and greater than 0 ohms?
Ves »Replace the fuel injector or injectors.
d~
No »Go To 14
F-1 FUEL.NQ. 1
(DIESEL)
C-2
INJECTOR·
FUEL·NO.2
(DIESEL) 81cbd0a4
14. INJECTOR
Measure the resistance between a solenoid post and battery negative.
NOTE: Be sure to zero the ohm meter prior to checking the injector circuit.
Yes »Go To 15
No »Replace the fuel injector or injectors.
DURE)
15. ECM
Reconnect the all injector pig taUs harness connector.
Reconnect the Injector harness connector.
Start the engine.
Did the DTC return?
Ves »Replace and program the ECM in accordance with the Service Information.
DURE)
No »Go To 16
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6,~7L DIESEL 9 -1813
16. OTHER DTC'S

Are all 6 of the injector DTC's (P0201 - P0206) present?
Yes »Go To 17
No »Go To 18
17. PASS TROUGH CONNECTORS OPEN

Inspect wiring harness for signs of multiple open circuits between the ECM and the injector pass through connec~
tors. Inspect the wiring harness between the pass through connectors to the injectors.
Are there open circuits in the wiring harness?
Yes - »Repair or replace the open connectors or wiring.
DURE)
No »Go To 18
18. -FUEL INJECTOR

Disconnect the pigtail nuts from the suspect injector. Using an Ohmmeter, measure the resistance between the sole-
noid posts of the injector.
NOTE: Be sure to zero the ohm meter prior to checking the Injector circuit.
Yes »Go To 19
No »Replace the fuel injector.
DURE)
9 • 1814 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - - DR
19. INJECTOR HARNESS OPEN

Connect the pigtail nuts for the suspect injector.
Disconnect the injector harness connector for the suspect injector.
NOTE: Check connectors .. Clean/repair as necessary. E
Measure the resistance of the injector harness circuit between the high
side driver circuit and the low side driver circuit for the suspect injector
at the injector harness connector.
'((@ DDDD~'
tor circuit.
53
Yes »Go To 20
No » Replace or repair the injector harness.
10
(Refer to 9 - ENGINE - STANDARD PROCEDURE) 20 11
30 21
40 31
5(1 41
60 51
MODULE·
ENGiNE
CONTROLC1
(UL)
81af6764
20. HIGH SIDE DRIVER HARNESS OPEN

Measure the resistance of the high side driver circuit between the ECM E
connector and the injector harness connector.
Yes » Go To 21
No » Replace or repair the open engine harness.
10
20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(8.7L)
81af6764
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 .. 1815
21. LOW SIDE DRIVER HARNESS OPEN

Measure the resistance of the low side driver circuit between the ECM
[]F
No »Replace or repair the open engine harness.
10
20 11
30 21
.clI 31
50 41
eo &1
MODULE-
ENGINE
COHTROLC1
(t.7L)
B1a8e68e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MODULE·
I I EIIGIIiE
r r .
HIGH HIGH HIGH
'T' 'T'
l~~~ __ 2~LOO,~ _ _ _ ~~~ _ _ ~~oo'~ _ _ _ ~~~ _ _ ~~~'~1
51 52 c, 50' C,
K611 Kl1 K612 K12 K613 K13

16 16 16 16 16 16
ORl8 R BRlYl YllBR BRll B GY18R TN
E l----1----1----1----1----
] '] '] '] ']
J
8]
c".
K611 Kt 1 K612 K12 K613 K1l

14 14 14 14 14 14
BK BK BK BK BK BK
J
~'NJECT •••
FUEL 1
J
~'.JECT ••.
FUEL 2
J
~'.JECT ••.
FUEL 3
'I 'I 'I

, @DDDDDD~A ~ OO~OO~
~1 'D
20 i 00000 00000 '
)0 ,00000 ~ OOOO~'
~
~2 Clts 40
50 00000
00000 Y ,00000
00000 I
(DIESEL) 60 ~ .~O_~~~
INJECTOR· IN.lECTOR· IIII.IECTOR· L.. . r
' ...
FUEL 3 FUEL 2 FUEL t

(DIESELI (DIESEL) (DIESEL)
~l
MODULE·
EIIGINE
COItTRDL CI
(G.lL)
CUG
(DIESEL)
.10 . . . . 2

DR - - - - - - - - - ENGINE .. ElECTRtCAl DIAGNOSIICS .. 6.7l DIESEL 9 .. 1817
Theory of Operation
this t~me the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs
• When Monitored:
• Set Condition:
Possible Cau.ses

FUEL INJECTOR
INJECTOR
INJECTOR HARNESS
ECM
Diagnostic Test
1. OTHER DTC'S
With the scan tool, read DTes.
Penorm POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
9 .. 1818 ENGINE .. ELECTRICAL DIAGNOSrlCS .. 6.7L DIESEL - - - - - - - - - DR

Yes »Go To 3
No » Replace the injector harness.
21
31
41
MODULE-
ENGINE
CONTROLC1
81cc1fd4

the Bank 1 high side driver circuit in the ECM harness connector and [Dd -&JID
ders 1-3. 10 ~'o~
20 11
Yes »Go To 4
30 21
MODULE·
ENGINE
CONTROLC1
n
FSt~~D~~'
F 7=',,, ='\
D (DIESEL) B
81cbcfcO

between the ECM harness connector and the· injector harness connec-
tors.
Yes » Go To 5
No » Repair the open low side driver circuit. 10
Perform POWERTRAIN VERIFICATION TEST (DIESEL). ~1~
40~~
11
21
~_33~g_3__~~51~
31
41
50·2 MODULE..
ENGINE
CONTROLC1
81cbd025
9 -1820 ENGINE - ELECTRICAL DIAGNOSTICS . - 6.7L DIESEL - - - - - - - - - DR

Measure the resistance between the Bank 1 high side driver crrcuit-at
the ECM hamess connector and the low side driver circuit for ifljectors
1-3 at the ECM hamess connector. -&1ID
Is the resistance more than tOOk Ohms? o B ,,~
1 0
o
Yes »Go To 6
No »Repair the High side circuit shorted to the low side circuit. ~~.
Perform POWERTRAIN VERIFICATION TEST (DIESEL) .
. -(Refer to 9 - E~GINE - STANDARD PROCEDURE)
C118
(DIESEL)
10
20 11
30 21
40 31
50 41
51
MODULE·
ENGINE
CONTROLC1 81cbd07e

Is the resistance more than lOOk Ohms?
Yes »Go To 7 [QJF D B r~
No »Repair the High side driver shorted low in the harness.
(Refer to· 9 - ENGINE - STANDARD PROCEDURE)
C111S
(DIESEL)
81cbdOSS

Measure the resistance of the injector harness connector low side
Is the resistance more than lOOk Ohms?
Yes »Go To 8
C11t1
(DIESEL)
81cbdOSa
9· 1822 ENGINE· ELECTRICAL DIAGNOSTICS ." 6.7l D I E S E l - - - - - - - - - DR

Yes »Go To 9
No »Repair the high side driver shorted to voltage.
F A
C111
(DIESEL)
BATTERY-
NEGATIVE
(DIEseL LEFT SATTERY)
81cbd091

1-3.
Yes »Go To 10
age.
STANDARD PROCEDURE)
81cbc03
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 -1823
10. LOW SIDE DRIVER CIRCUIT SHORTED OTHER LOW SIDE DRIVER CIRCUIT
Yes »Go To 11
driver circuit. 10

(Refer to 9 • ENGINE - STANDARD PROCEDURE) 30_1~o00000 11
30 I~ 00000
40-3 II gggg 21
7-l
r'i:..o0000 31
50 Y. 0000
"F======::::ct=
---r.--------;-'T---
41
60 51
50-2 MODULE-
ENGINE
CONTROL C1 81cc163e

tor.
[]
tor circuit.
Yes »Go To 12
No »Go To 15
A-3
C-2
F-1 E-1 0-2 8-3
=~~L=
C118
(DIESEL)
81cbd099
5
9 -1824 ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR

No »Go To 13
INJECTOR·
FUEL-NO.2
(DUEL) 81cbd0s4
D R - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 .. 1825
13. INJECTOR
NOTE: Be sure to zero the ohm meter prior to checking the inJec-
tor circuit.
Yes »Replace the fuel injector or injectors.
No »Go To 14
INJI!.CTOR-
FUEL-NO.2
(DUEL) 81cbd0a4
14. INJECTOR
Yes »Go To 15
DURE)
15. ECM
Reconnect the all injector pig tails harness connector.
Start the engine.
Did the DTC return?
Yes »Replace and program the ECM in accordance with the Service Information.
DURE)
No »Go To 16
Diagnostic Test
16. OTHER DTC'S

Are all 6 of the injector DTC's (P0201 • P0206) present?
Yes »Go To 17
No »Go To 18

Inspect wiring harness for signs of multiple open circuits between the ECM and the injector pass through connec-
Yes »Repair or replace the open connectors or wiring.
Periorm POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 18
18. FUEL INJECTOR

Disconnect the pigtail nuts from the suspect injector. Measure the resistance between the solenoid posts of the
injector.
Yes »Go To 19
DURE)

NOTE: Check connectors - Clean/repair as necessary_
NOTE: Be sure to zero the ohm meter prior to checking the injec- C 0
tor circuit.
Yes »Go To 20
No »Replace or repair the injector harness.
CHI
(DieseL)
81a8e6ea

Measure the resistance of the high side driver circuit between the ECM c
Yes »Go To 21
A
Perform POWERTRAIN VERIFICATION TEST - G.7L.
10
2()
30
40
!IO
80
MODULE·
ENGINE
CONTROLC1
(1.7L)
81afSdea

Is the resistance less than 10 Ohms? D

Perform POWERTRAIN VERIFICATION TEST - G.7L.
10
20 11
30 21
40 31
50 41
60 &1
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a8e713
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MODULE-
I IUMH
I INJECT{)R INJECTOR INJECTOR I COITROL
HIGH HIGH HIGH
L ~E~O~ _ _ ~N~O~.~ _ _ _ D~E~02.. _ _ ..E.?N.!!!.OL~,:'" _ _ _ ~E~02.. _ _ ..E.?N2!0~':"" J
5lr 51r 51r 4sr 5'r ~r

K611 K11 K612 K12 1<613 K13
16 16 15 16 16 16
ORIBR BRNl YLnm BRoa GYIBR TN
1----1----1--
'I 'I DI 1----Jc11l
K611
1~
K1J
14
K612
14
K12
14
Ai
K613
14
8
1
Kl3
14
BK BK BK BK BK ilK
J
~I•• ECTO••
FUEL 1
J
~I"'ECTO"
FUEL I
~ ••
JICTO"
FUEL a
~1 ~1 1
II
21
~2 ~2
11
CUI 41
51
(DIESELJ
I• .IICTOR· II.lECTOR· II.lECTOR·
FlEL3 FUEL I 'UEL t
(DIESELI (DIESEL, (DIIIEL)
MODULE·
III GIllIE
CONTROL Of
II.lL)
C111
IDIESEL)
.,...uJ

DR - - - - - - - - - ENGlNE ~"ElECTRICAL·DIAGNOSTICS - 6.7L DIESEL 9 ·1829
Theory of Operation
The ECM actuates' the solenoid causing the needle valve to rise and fuel flows through the spray holes in the noz-
zle- tip into the combustion chamber. The MIL lamp will light immediately after the diagnostiC runs and fails. During
this',fime the customer may experi~nce engine _surge or stum~le. The MIL lamp will
turn off once the diagnostic runs
and passes in 4 consecutive' drive cycles.' " "
. • When Monitored:
• Set Condition:
When the injector current faUs below a calibrated threshold.
PASS ,"¥ROUGH CO~CTORS OPEN

FUEL :II'4JECTOR
HIGH SIDE DRIVER HARNESS OPEN'
HIGH SIDE DRIVER"SHORTED TO LOW SIDE DRIVER
HIGH SIDE ORJVERS'SHORTED LOW
LOW'SIDE DRIVER SHORtED TO VOLTAGE
INJECTOR
INJECTOR HARNESS
ECM
Always 'pedorm the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9'.. ENGINE -
DIAGNOS1S ~ND TESTING) .'
, ;',
Diagnostic Test
1. OTHER DTe'S
With the scan toolt read OTCs.
Do you have any combination of Ole's P0201, P0202, or P0203?
Yes »Repair other DTCts first.
DURE)
No »Go-To 2
9 ·1830 ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR

Yes »Go To 3
No »Replace the injector harness.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) . 11
21
31
41
MODULE ..
ENGINE
CONTROL C1
81cc1fd4

Disconnect the Injector 1·3 harness connector.
ders 1-3. 10

11
Yes »Go To 4
21
MODULE·
ENGINE
CONTROL C1
81cbcfcO
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 -1831

tors.
Yes »Go To 5
No »Repair the open low side driver circuit.
21
31
41
S1
MODULE·
ENGINE
CONTROL C1
~
'(@~~~'
/ _7.~ B-3
E-1 C-2 81cbd025
9 ·1832 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L · - - - - - - - - - DR

Is the resistance more than 100k Ohms? D B
Yes »Go To 6
(Refer to 9 - ENGINE - STANDARD PROCEDURE) F A
C116
(DIESEL)
10
20 11
30 21
40 31
50 41
51
59 MODULE·
ENGINE
CONTROLC1 81cbd07e
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DlESEL 9 -1833

Measure the resistance of the injector harness connector. high side
D B
Yes »Go To 7
F A
C111
(DIESEL)
BATTERY.
NI!GAlIVE
(DIeseL LEFT BATT!Ry)
81cbd086

driver circuits to battery negative for injectors 1~3.
Yes »Go To 8
C116
(DIESEL)
BATTERY-
NEGATIVE
(Dll!8I!l. LEFT BATTERy)
81cbd08a

Yes »Go To 9 ~l D B r~
C111
(DIESEL)
BATTERY-
NEGATIVE
(DII!8I!L LEFT aATTI!Ry)
81cbd091

1-3.
Yes »Go To 10
age.
STANDARD PROCEDURE)
81cbcO
DR - - - - - - - - - ENGINE ." ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 • 1835
aU other Bank 1 low side driver circuits at the ECM harness connector.
Yes »Go To 11
driver circuit.
21
31
41
51
MODULE·
ENGINE
CONTROL C1 81cc163e

tor.
NOTE: Be sure to zero the ohm meter prior to checking the inJec-
tor circuit.
Yes »Go To 12
No »Go To 15
C111
(DIESEL)
81cbd099
9 -1836 ENGINE .. ELECTRICAL DIAGNOSTICS -- 6.7L DIESEL - - - - - - - - - DR

Disconnect the pigtail nuts from injectors 1·3.
~ID
[OJ <~--,
No »Go To 13
INJECTOR·
FUI!.L·)IIO.2
(DIESEL) 81cbd0a4
13. INJECTOR
tor circuit.
Yes »Replace the fuel injector or injectors.
No »Go To 14
INJECTOR.
FUEL-NO.2
(DESELI 81cbd0a4
14. INJECTOR
Yes »Go To 15
DURE)
15. ECM
Reconnect the all injector pig tails harness connector.
Start the engine.
Did the DTC return?
DURE)
No »Go To 16
9 ·1838 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - DR
16. OTHER DTC'S

Yes »Go To 17
No »Go To 18

Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGiNE - STANDARD PROCE-
DURE)
No »Go To 18
18. FUEL INJECTOR

injector.
Yes »Go To 19
DURE)

NOTE: Be sure to zero the ohm meter prior to checking the injec- C B
tor circuit.
Yes »Go To 20
No » Replace or repair the injector harness.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. F
C118
(DIESEL)
81a8e6e6

Measure the resistance of the high side driver circuit between the ECM
connector and the injector harness connector. A

Yes »Go To 21
51
10
20 11
30 21
40 31
50 41
110 51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81aft)dee

10
20 11
30 21
.w 31
so .oil
60 5.
MOOULE·
ENGINE
CONTROLC1
(6.71.)
81a8e7Of
9 ·1840 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
and passes in 4 consecutive drive cycles.
• When Monitored:
• Set Condition:
When the injector current faits below a calibrated threshold.
Possible Causes

FUEL INJECTOR
INJECTOR
INJECTOR HARNESS
ECM
Diag nostic Test
1 . OTHER DTC'S
With the scan tool, read oTCs.
DURE)
No »Go To 2

Reconnect the disconnected injector harness connector.
aU other Bank 2 low side driver circuit at the ECM .harness connector.
FOB
Yes »Go To 3
F~l~l~~.
C117
(DIEBEL)
10
20 11
30 21
40 31
50 41
51
ENGINE
CONTROLC1 81cc5567

ders 4-6.
Yes »Go To 4 20 11
No »Repair the open high side driver circuit from ECM harness 30 21
connector to the Injector harness connector. 40 31
Perform POWERTRAIN VERIFICATION TEST (DIESEL). 50 41

60 51
MODULE-
ENGINE A-6
F A
C117
(DIESEL) 81ce5571

tors.
Yes »Go To 5
20 11
30 21
40 31
41
51
MODULE-
ENGINE
CONTROLC1
81cc5575

[OJ
FOB
Yes »Go To 6
F~l~l~l~A
C117
(DIESEL)
BATTERY·
POSITNE
(DIESEL LEFT BATTERY)
81cc5579
9 ·1844 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L D I E S E L - - - - - - - - - DR

[]E C A(~
Yes »Go To 7
F~l~~l))).
C111
(DIESEL)
BATTERY·
POSITIVE
(DIESEL lEFT BATTERY)
81cc5581

Yes »Go To 8
No » Repair the Low side driver shorted low in the harness.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). 10
20 11
30 21
40 31
50 41
51
MODULE·
57
ENGINE
CONTROLC1
81cc5585
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 ·1845

Turn Ignition on, engine off.
harness and battery negative~
Ves »Go To 9
, {Refer to 9 - ENGINE - STANDARD PROCEDURE)
20 11
30 21
40 31
so 41
60 51
MODULE-
ENGINE
CONTROLC1
81cc558c

Measure the voltage between the low side driver circuit in the engine
harness and battery negative for cylinders 4-6.
Ves »Go To 10
"
No »Repair the low side driver shorted to voltage.

Perform POWERTRAIN V~RIFICATION TEST (DIESEL).
20 11
30 21
40 31
so 41
60 51
MODULE·
ENGINE
CONTROL C1
81cc5590
9 .. 1846 ENGINE .. ELECTRICAL DIAGNOSTICS" 6.7L DIESEL - - - - - - - - - DR
Yes »Go To 11
driver circuit.
20 11
30 21
40 31
50 41
60 51
MODULE ..
ENGINE
CONTROLC1
81ccS563

tor.
tor circuit.
[]
Is the resistance greater than zero and less than 1 ohm?
Yes »Go To 12
No »Go To 15
C117
(DIESE!L)
81cc559a

NOTE: Check connectors - Clean/repair as neces-
sary.
NOTE: Be sure to zero the ohm meter prior to
checking the injector circuit.
Measure resistance of each circuit in the injector har-
ness from pigtail side to injector harness connector.
STANDARD PROCEDURE)
No »Go To 13
81cbc03
13. INJECTOR
-@JID
Yes »Go To 14
~:~'.~
(Refer to 9 - ENGINE - STANDARD PROCEDURE) E INJECTOR-
INJI!CTOR.
I'UEL-NO.5
(DIESEL)
81ccS5ge
9 ·1848 ENGINE - ELECTRICAL DIAGNOS1"ICS .. 6.7L DIESEL - - - - - - - - - DR
14. INJECTOR
Yes »Go To 15
No »Replace the fuel injector' or injectors.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 . ENGINE - STANDARD PROCE-
DURE)
15. ECM
Reconnect all the injector pig tail harness connectors to the Injectors.
Start the engine.
Did the DTC return?
DURE)
No »Go To 16
16. OTHER DTC'S

Are all 6 of the injector DTC's (P0201 • P0206) present?
Yes »Go To 17
No »Go To 18

Ves »Repair or replace the open connectors or wiring.
DURE)
No »Go To 18
18. FUEL INJECTOR

injector.
Ves »Go To 19
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS ~ 6.7l DIESEL 9 .. 1849

E F
tor circuit.
Is the resistance less than 1 ohm and great~r than 0 ohms?
Yes »Go To 20
C117
(DIESEL)
81a8e6e2

Yes »Go To 21
10
20 11
30 21
.ca 31
50 41
eo 51
MODULE-
ENGINE
CONTROLC1
(6.7L)
81af6df2
9 -1850 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR

Is the resistance less than 10 Ohms? -&JID
F
Yes »Test Complete. ::~
~
'(@DDDDDW' 54
e11?
(DlPaI
10
2C 11
30 21
40 31
so .oil
60 SI
MODULE-
ENGINE
CONTROLC1
(6.7L)
81a8e70b
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. &.7L DIESEL 9 .. 1851
Theory of Operation
The ECM actuates the solenoid causing the needle valve to rise and fuel flows thro.ugh the spray holes in the noz-
• When Monitored:
• Set Condition:
Possible Causes

FUEL INJECTOR
HIGH SIDE DRIVER SHORTf=D TO LOW SIDE DRIVER '
LOW SIDE DRIVERS 'SHORTED LOW'
INJECTOR
INJECTOR HARNESS
ECM
Diagnostic Test
1. OTHER DTC'S
DURE)
No »Go To 2
9 -1852 ENGJNE, .. ~·ElECTRICALD1AG'NOSTICS· - 6.7L DIESEL - - - - - - - - - DR
2. LOW SIDE DRIVER CIRCUIT SHORTED IN INJECTOR HARNESS"

[OJ
. FOB
Yes »Go To 3·· .
F~l~l~li).
C117
(DE8EL)
10
20 11
30 21
40 31
50 41
51
ENGINE
CONTROLC1 81cc5567

ders 4-6.
Yes »Go To 4 20 11
connector to the Injector harness connector. 40 31
60 51
MODULE·
ENGINE A-6
C117
(DIESEL) 81 cc5571

tors.
Yes »Go To 5
20 11
30 21
40 31
41
51
MODULE-
ENGINE
CONTROLC1
81cc5575
5. HIGH SIDE DRIVER SHORTED TO lOW SIDE DRIVER

Yes »Go To 6
{Refer to 9 - ENGINE - STANDARD PROCEDURE}
F A
C117
(DIESEL)
BATTERY.
POSITIVE
81cc5579
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 -1855

Yes »Go To 7
[]
E C A
F~l~l~~A
C117
(DIESEL)
BATTERY-
POSITIVE
(DIESEL LEFT BAnERY)
81cc5581

Yes »Go To 8
20 11
30 21
40 31
50 41
51
57
MODULE·
ENGINE
CONTROLC1
81cc5585
9"·1856 ENGINE -; ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR

Is the voltage less than 1 yolt?
[:;:J
Yes »Go To 9
(Refer· to 9 - ENGINE - STANDARD PROCEDURE)
20 11
30 21
40 31
50 41
60 51
MODULE-
ENGINE
CONTROLC1
81cc558c

harness and battery negative for cylinders 4·6.
Yes »Go To 10
No »Repair the low side driver shorted to voltage.
20
30 21
40 31
so 41
60 51
MODULE·
ENGINE
CONTROLC1
81cc5590
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DtESEL 9 ·1857
Yes »Go To 11
No »Repair Lo~ sid~· driver circuit shorted to other Low side
driver circuit., -
Perform POWERTRAIN VERIF1CATION TEST (DIESEL).
20 11
30 21
.,. 40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
810c5563

tor.
NOTE: Be- sure to zero the ohm meter prior to checking the injec-
tor circuit.
Yes »Go To 12
No »Go To 15
C117
(DESEL)
81cc559a

sary.
STANDARD PROCEDURE)
No »Go To 13
81cbc03
13. INJECTOR
Yes »Go To 14
INJECTOR·
FUEL-NO.5
(DtESEL)
81cc55ge
14. INJECTOR
NOTE: Be sure to zero the ohm meter prior to checking. the injector circuit.
Ves »Go To 15
DURE)
15. ECM
Reconnect all the injector pig tail harness connectors to the Injectors.
Start the engine.
Did the DTC return?
DURE)
No »Go To 16
16. OTHER DTC'S

Ves »Go To 17
No »Go To 18

Ves »Repair or replace the open connectors or wiring.
DURE)
No »Go To 18
18. FUEL INJECTOR

injector.
Yes »Go To 19
DURE)
9· 1860 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - DR

c 0
tor circuit.
Yes »Go To 20
C117
(DIESEL)
81a8e6dd

Measure the resistance of the high side driver circuit between the ECM c
Yes »Go To 21
Perform POWERTRAIN VERIFICATION TEST - 6.7L. A
10
20 11
30 21
4() 31
50 41
eo 51
MODULE·
ENGINE
CONTROLCi
,8.7L)
81af6df6
DR - - - - - - - - - ENGINE - ELECTRICAL 'DIAGNOSTICS - 6;7L DIESEL t · 1861

Is the resistance less than 10 Ohms? o
Ves »Test Complete.
Periorm POWERTRAIN VERIFICATION TEST - 6.7L. 55
(Refer to 9 ENGINE ~ STANDARD PROCEDURE)
M
10
20 11
30 21
40 31
IiO 41
eo $1
MODULE·
ENGINE
CONTROLC1
(1.7L)
8188e707
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IODULE·
I I EIGIIIIE
HIGH HIGH HIGH
I SIDE INJECTOR SIDE INJECTOR INJECTOR SIDE I
L ..!!IV~N~ _ _ -.90~~O~ _ _ _ ~IV~N~ _ _ -.90!!!.R~O.!. _ _ _ .E!IV~N~ _ _ -.90.!:!!.R~O.!. J
60 Ie, 54 Ve, "Ie, 55 'e, "Ie, "Ie,
K614 K14 K638 K38 K658 K58
16 16 16 16 16 16
WTlBR BRfTN lBIBR GY LGlBR BRNT
l----1----1----1----1----1 em
] '] '] '] '] ']

E
K61~ K14 K638 K38 me K58

14 14 14 14 14 14
BK BK BK BK BK BK
J
[BlUEtT••. FUEL 4
J
[BII.•eT••. FUEL 5
J
[BlUEtT••. FUEL I
'I 'I 'I

" "
oooo~
10
20
30
00000
00000
';,0000'1
00000
00000
1
II
21
ctn
40
50
00000
00000
0 00000
00000
31
41
,I
~
60 00000
(DIEIEL) A
I... ICTOR· I... ECTOR· IIII .. ECTOR· '-.J '-,
FUEL I FUELS FUEL 4
IDIEIEL) (DIEIIL) IDIEHL)
IIODULE·
ENIINE
CONTROL C1
(I.n)
CttJ
(DIESIL)
.t ....l

Theory of Operation
• When Monitored:
• Set Condition:
Possible Causes

FUEL INJECTOR
INJECTOR
INJECTOR HARNESS
ECM
Diagnostic Test
1. OTHER DTC'S
DURE)
No »Go To 2

Measure the resistance of each of the .Bank 2 lo~ side driver circuit t.o
all other Bank 2 low side driver circuit at the ECM harness conneclor..
Yes »Go To 3
C117
(DIESEL)
10
20 11
30 21
40 31
50 41
51
ENGINE
CONTROLC1 81cc5567
DR - - - - - - - - - ENGINE .. -ELECTRICAL DIAGNOSTICS .. 6.7L DIESEE. 9 .. 1865

ders 4-6.
Yes »Go To 4 20 11
connector to- the Injector harness connector. 40 31

60 51
MODULE-
E-4 ENGINE A-6
C1t7
(DESEL) 81cc5571

tors.
Yes »Go To 5
(Refer to 9 - ENGINE .. STANDARD PROCEDURE)
20 11
30 21
40 31
41
51
MODULE ..
ENGINE
CONTROLC1
81cc5575
9· 1866 ENGINE· ELEC'rRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR

[]
F D B
Yes »Go To 6
F~l~l~l~A
C117
(DIESEL)
BATTERY·
posrrlVE
81cc5579

Is the resistance more than 100k Ohms? [] ~ID
Ves »Go To 7 ,~
E c A o~
(il~i~l)))
F A
C117
(DIESEL)
BATTERY·
POSITIVE:
81cc5581

Yes »Go To 8
20 11
30 21
40 31
50 41
51
MODULE-
57
ENGINE
CONTROLC1
81cc5585

Yes »Go To 9
20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
81cc558c

harness and battery negative for cylinders 4-6.
Is the voltage less than 1 volt? ~ID
Yes » Go To 10 :'o~
No » Repair the low side driver shorted to voltage.
20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
81cc5590
1o. LOW SIDE DRIVER CIRCUIT SHORTED OTHER LOW SIDE DRIVER CIRCUIT
Yes »Go To 11
driver circuit.
20 11
30 21
40 31
50 41
60 51
MODULE...
ENGINE
CONTROLC1
81cc5563

tor.
tor circuit.
Yes »Go To 12
No »Go To 15
A-6
C117
(DIESEL)
81ccS59a
9 -1870 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR

sary.
STANDARD PROCEDURE)
No »Go To 13
81cbc03
13. INJECTOR
Yes
No
»Go To 14
»Replace the fuel injector or injectors.
[dJ , ~2 .~,
"f~
(Refer to 9 - ENGINE - STANDARD PROCEDURE) ~ 2"'-. E INJECTOR-
/.... B FUEL-NO. <4
A INJECTOR- F
FUEL-NO.6 (DIESEL)
C C117~
V: INJeCTOR·
FUEL-NO.5
(DIESEL)
81cc55ge
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 .. 1871
14. INJECTOR
NOTE: Be sure to zero the ohm meter prior to checking the Injector circuit.
Yes »Go To 15
DURE)
15. ECM
Reconnect aU the injector pig tail harness connectors to the Injectors.
Start the engine.
Did the DTC return?
DURE)
No »Go To 16
16. OTHER DTC'S

Yes »Go To 17
No »Go To 18

Perform POWERTRAIN VERIFICATION TEST - B.7L (Refer to 9 .. ENGINE - STANDARD PROCE-
DURE)
No »Go To 18
18. FUEL INJECTOR

injector.
Yes »Go To 19
Perform POWERTRAtN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
9 ~ 1872 ENGINE - ELECTRICAL DIAGNOSTICS'; 6.7L DIESEL - - - - - - - - - DR

Disconnect the injector harness connector for the susP.GCt injector.
NOTE: Be sure to zero the ohm meter prior to checking the injec- A B
tor circuit.
Yes »Go To 20
[~I
C111
(DIESEL)
81a8e6d9

NOTE: Check connectors • Clean/repair as necessary.
Yes »Go To 21
Perform POWERTRAIN VERIFICATION TEST 6.7L.
10
20 11
30 2t
40 31
!O .1
8Q 51
MODULE·
ENGINE
CONTROLC1
(I.7L)
81af6dfa
21 . LOW SIDE DRIVER HARNESS OPEN

Perform POWERTRAIN VERIFICATION TEST • 6.7L
Perform POWERTRAIN VERIFICATION TEST - 6.7L A
(Refer to 9 - ENGINE • STANDARD PROCEDURE)

45
10
20
'1
30 21
<CO 31
so 41
110 S1
MODULE-
ENGINE
COHTROLC1
('.7L)
81a88703
9 - 1874 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7l D I E S E l - - - - - - - - - DR
P0217-COOLANT TEMPERATURE TOO HIGH
• - - - - - - - - - • SOU
I
K914
18
[E
SEISOR'
ENGIIE
COOLANT
TEIPERATURE
8
1
K2 K914
18 18
~roR ~ml
r - -
,Jet
- - - - - - - - -
,,1 et
- - - - , 10DULE.
EeT SENSOR ENGIIIIE
I SIGNAL GROUND I CONTROL
I I
I I
I _______________ J
10 00000 1
20 00000 11
30 00000 ,1
4D 00000 31
50 00000 41
60 00000 5',
SElSOR· IODULE·
EIIIGIIE ENGIIIIE
COOUNT CONTROL C1
TEIPERAtURE rl.lLl
(DIESEL)
".Iel"

Theory of Operation
The coolant temperature sensor is a variable resistor sensor and is used to measure the temperature of the coolant
voltage caused by changes in the resistance of the sensor to determine the coolant temperature. The engine cool-
engine coolant temperature sensor is located near the thermostat housing. This fault becomes active when the ECM
detects a coolant temperature higher than a calibratable limit for a calibratable amount of time. The ECM illuminates
the MIL lamp after the diagnostic runs and fails once. During this time the customer may experience an engine
power derate. The ECM will turn off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive
cycles .
• When Monitored:
While the engine is running ..
• Set Condition:
The engine coolant temperature is above a calibrated value for a calibrated amount of time.
Possible Causes
ECT SENSOR
OTHER DTC'S
MECHANICAL FAILURE
Diagnostic Test
1 . OTHER DTC'S
Are other Cooling system DTC's present?
Ves »Trouble shoot the other DTC's first.
DURE)
No »Go To 2
2 . ECT SENSOR
Allow the engine to reach normal operating temperature.
Use a temperature probe and measure the engine temperature near the ECT Sensor.
With the scan tool, read the Engine Temperature.
Compare the temperature probe reading with the scan tool reading.
Are the readings within 10° of each other?
Yes »Repair the cause of mechanical failure.
DURE)
No »Replace the coolant temp sensor.
DURE)
P0219-ENGINE OVERSPEED
Theory of Operation
ply to the position sensor and return circuit. As the teeth on the crankshaft speed ring or the dimples in the back of
the camshaft gear move past the position sensor, a signal is generated on the position sensor circuit. The ECM
interprets this signal and converts it to an engine speed. A missing tooth on the crankshaft gear is sued to deter-
mine the position of the engine by the ECM. A MIL lamp will be lit immediately after this diagnostic runs and fails.
While the engine speed is above the overspeed threshold, we shutdown the fueling to the engine. When the engine
speed drops below the overspeed threshold, fueling returns as normal. The MIL lamp will turn off once the diag-
nostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
The ECM detects engine speed is above a calibrated threshold.
Possible Causes
OTHER DTC'S
MECHANICAL OVERSPEED OF ENGINE
Diagnostic Test
1 . OTHER DTC'S
With the scan tool, read and record the freeze frame data.
Is there other Crankshaft position sensor DTC's set?
Yes »Refer to symptom list for problems related to the other Crankshaft position sensor DTC's.
No »Go To 2
2 . MECHANICAL OVERSPEED OF ENGINE

Visually inspect the engine for signs of mechanical overspeed. Such as, bent push rod, broken rocker arms, bent
valves, etc.
Did you notice any overspeed damage?
Yes »Repair or replace any damaged components.
DURE)
No »Test Complete.
P0251-INJECTION PUMP FUEL VALVE FEEDBACK
r - - - - - - - i MODULE.
I I
EIIGIIE
FUEL FUEl I COITROL
I CONTROL CONTROL
I ACTUATOR ACTUA TOR I
L ~T~ _ _ ...,ERIVER _ ..J
10 "'C1 30' C1
K366 K365
18 18
BR~B DaffiR
2/ 1 /'-
~
ACTUATOR'
~ """ FUEL'
M COITROL
n n
~
[aE~
'%
10
20
OOOOO~ 00000 11
00000 00000
30 00000 00000 21
40 000(;)0
00000
0 00000
00000
It
50 41
60 00000 00000 51
.A ~
~ ./'/
L-J L..J
ACTUATOR·
MODULE· FUEL
EIGIIE COITROL
COITROL C1 (DIESELI
11.7L)
.....711

9 ·1878 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The circuit is a PWM driver in the
ECM that controls the FCA. The actuator is grounded in the ECM. The ECM varies the current to this valve to
provide the correct fuel flow to the high pressure pump based on operating conditions. The FCA is a normally open
valve. High circuit resistance may cause fuel. pressure to be higher than commanded at light loads. The ECM illu-
minates the MIL lamp immediately after the diagnostic runs and fails. During this time the customer may experience
low power. The ECM turns off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
When the ignition is on .
• Set Condition:
The ECM detects a discrepancy between the PWM supplied to the Electronic Fuel Control Actuator and the
PWM returned from the Electronic Fuel Control Actuator. Although this is primary an electrical diagnostic
check, fuel supply issues and high pressure leaks can cause the ECM to force the Fuel Control Actuator into
a region where this fault code becomes active.
Possible Causes
FUEL PUMP
(K365) FUEL CONTROL ACTUATOR DRIVER OPEN
(K366) RETURN CIRCUIT OPEN FROM FCA TO ECM
(K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO EXTERNAL VOLTAGE
(K366) FUEL CONTROL ACTUATOR RETURN CIRCUIT SHORTED TO EXTERNAL VOLTAGE
(K366) FCA RETURN CIRCUIT SHORTED TO (K365) FCA DRIVER CIRCUIT
(K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO GROUND
(K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO ANOTHER CIRCUIT
(K366) FUEL CONTROL ACTUATOR RETURN CIRCUIT SHORTED TO ANOTHER CIRCUIT
LIFT PUMP
HIGH PRESSURE FUEL SYSTEM LEAKS
HIGH INLET RESTRICTION
ECM
1. FUEL PRESSURE
With the scan tool watch fuel pressure vs. setpoint with the engine at idle.
is the pressure within 500 psi +/- of set point?
If psi is within 500 psi
Document DTC and freeze frame data and attempt to duplicate complaint.
DURE)
If the psi is higher than setpoint
Go To 4
If the psi is lower than setpoint
Go To 2
2. LIFT PUMP
Perform the lift pump flow test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the test pass?
Yes »Go To 3
No »Repair as necessary.
DURE)
3. INJECTOR RETURN FLOW

Perform the Injector return flow test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the test pass?
Yes »Go To 4
DURE) Diagnostic Test
4. FUEL PUMP
Disconnect the Fuel Control Actuator (FCA) harness connector.
Connect an incandescent test light across the Fuel Control Actuator
driver circuit and the Fuel Control Actuator return circuit at the fuel con-
trol actuator harness connector.
Observe the test light.
The ECM will perform a self test of the circuit which should momentarily
flash the test light brightly, one time, approximately 20 seconds after
being connected.
2
NOTE: Compare test light brightness to that of a direct connection
to the battery.
AC11JATOR-
Did the light flash brightly? FUEL
CONTROL
Yes »Replace the Fuel Pump. (DIESEL) 8175&40e
No »Go To 5
5. (K365) FUEL CONTROL ACTUATOR DRIVER OPEN

Measure the resistance of the FCA driver circuit between the electronic
fuel control actuator harness connector and the ECM harness connec-
tor.
Yes »Go To 6 30
No » Repair the (K365) Fuel Control Actuator Driver circuit

OPEN.
10
20 l'
30 21
40 31
so 41
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a89762

Measure the resistance of the (K366) return circuit between the FCA
harness connector and the ECM harness connector.
-&lID
Yes »Go To 7 :l~M
No »Repair or replace the engine wiring harness.
'.'
10
ACTUATOR-
ruB.
COIfTlIOL
10
20
30
"21
40 31
so 41
60 51
MODULE-
ENGINE
CONTROLC1
(6.7L)
81a8e766
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 . 1881
7. (K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO EXTERNAL VOLTAGE
Measure the voltage between the (K365) FCA driver circuit in the FCA
Is the voltage greater than 1 volts?
Yes »Repair the (K365) FCA driver circuit shorted to external volt-
age.
No » Go To 8
ACTUATOR-
FUEL
CONTROL
(DIESEL) 8175e432
8. (K366) FUEL CONTROL ACTUATOR RETURN CIRCUIT SHORTED TO EXTERNAL VOLTAGE

Measure the voltage between the (K366) FCA return circuit in the FCA
Yes »Repair the (K366) FCA return circuit shorted to external 2
voltage.
No »Go To 9
2
ACTUATOR-
FUEL
Cot.ITROL
(DIESEL) 8175e436
9. (K366) FCA RETURN CIRCUIT SHORTED TO (K365) FCA DRIVER CIRCUIT

Measure the Resistance between the return circuit in the FCA harness
connector and Driver circuit.
Yes »Repair the (K366) FCA Return circuit shorted to (K365) FCA
Driver circuit.
Perform POWERTRAIN VERIFfCATION TEST - 6.7L.
No »Go To 10
2
ACTUATOR·
FUEL
COHTROL
(DIESEL) 8175e43d
9 • 1882 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
1o. (K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO GROUND

Measure the resistance between the (K365) FCA driver circuit in the
FCA harness connector and battery negative.
Yes »Repair the (K365) FCA driver circuit shorted to ground.
No » Go To 11
ACTUATOR-
FUEL
CONTROL
(DIESEL) 81758442
11 . (K365) FUEL CONTROL ACTUATOR DRIVER CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure the resistance between the (K365) FCA driver circuit in the
ECM harness connector and all other circuits in the ECM connectors.
No »Go To 12
Yes »Repair the (K365) FCA driver circuit shorted to another cir-
cuit.
10
20 11
30 :21
40 31
50 .1
80 51
MODULE-
ENGINE
CONTROLC1
(B.1L)
81a8e76a
12. (K366) FUEL CONTROL ACTUATOR RETURN CIRCUIT SHORTED TO ANOTHER CIRCUIT
Measure the resistance between the (K366) FCA Return circuit in the
ECM harness connector and all other circuits in the ECM connectors. I

No »Go To 13
Yes »Repair the (K366) FCA Retum circuit shorted to another cir-
cuit.
(Refer to 9 - ENGINE ~ STANDARD PROCEDURE)
10
20 11
30 21
40 31
9Q ,.1
80 !1
MODULE·
ENGINE
CONTROLC1
(8.7L)
8188e768
13. ECM
Disconnect the Electronic Fuel Control Actuator connector.
Connect an incandescent test light across the Fuel Control Actuator
driver pin and the Fuel Control Actuator return wire at the fuel control
actuator connector.
Observe the test light.
The ECM will perform a serf test of the circuit which should momentarily
flash the test light brightly. one time, approximately 20 seconds after
2
being connected.
NOTE: Compare test light brightness to that of a direct connection
to the battery.
ACTUATOR·
Did the light flash brightly? FUEL
CONTROL
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symp- (DIESEL) 8175e4S1
NOSIS AND TESTING)
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE • STANDARD PROCE·
DURE)
P0300-MULTIPLE CYLINDER MISFIRE
Theory of Operation
The Misfire Monitor gathers and filters engine crank speed data for 10 seconds once the monitor conditions are met.
If the crank speed deviation for a cylinder is less than a calibrated value, a misfire fault is set for that cylinder. If
more than one cylinder is failed, a multiple cylinder misfire fault is set. The ECM illuminates the MIL lamp after the
diagnostic runs and fails twice. During this time the customer may experience a cylinder miss or engine stumble.
The ECM will turn off the MIL lamp once the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
While the engine is idling .
• Set Condition:
Misfire detected on multiple cylinders.
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINES
VALVE TRAIN
OBSTRUCTED FUEL INJECTOR SUPPLY LINES
DAMAGED OR OBSTRUCTED HIGH PRESSURE CONNECTORS
EXTERNAL DAMAGED FUEL INJECTORS
INTERNAL DAMAGED FUEL INJECTOR
NO COMPRESSION
EXCESSIVE ENGINE LEAK DOWN
Diagnostic Test
1. LOW FUEL
Using the scan tool, verify that the fuel level is above 150/0.
Is the fuel level above 15%?
Ves »Go To 2
No »Add fuel go to step 2.
DURE)
2. OTHER DTC'S
Read the Freeze frame data.
Is the DTC equal to the freeze frame DTC?
Yes »Go To 3
No »Repair any other DTC's first.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 • 1885
3. DAMAGED FUEL LINES

Visually inspect the injector supply lines for damage.
Do you have any kinked or bent fuel lines?
Ves »Repair or replace damaged fuel lines.
DURE)
No »Go To 4
4. VALVE TRAIN
Visually inspect the valve train and check the valve lash on the suspect cylinders.
Is the valve train functional and the lash within the specifications listed in the service manual?
Ves »Go To 5
No »Adjust the lash or fix or repair any damaged component(s).
DURE)
5. OBSTRUCTED FUEL INJECTOR SUPPLY

Remove the fuel injector supply lines for the suspect cylinders.
Inspect both ends of the fuel injector supply lines for damage.
Using shop air pressure, blowout the fuel injector supply lines to verify that they are not obstructed.
Are the fuel lines free of debris or damage?
Yes »Go To 6
No »Replace the damaged or obstructed fuel injector supply lines.
DURE)
6. DAMAGED OR OBSTRUCTED HIGH PRESSURE CONNECTORS

Remove the high pressure connectors for the suspect cylinders.
Inspect both ends of the high pressure connectors for signs of damage.
Using shop air pressure, blowout the high pressure connectors to verify that they are not obstructed.
Are the high pressure connectors free of debris or damage?
Ves »Go To 7
No »Replace the damaged or obstructed high pressure connectors.
DURE)
7. FUEL INJECTORS
Remove the suspect fuel injectors.
Are the fuel injectors damaged?
Ves »Replace the external damaged fuel injectors & high pressure connectors.
DURE)
No »Go To 8
9 ·1886 ENGINE· ELECTRICAL. DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
8. INTERNAL DAMAGED FUEL INJECTOR

Switch the misfiring injectors & high pressure connectors with injectors & high pressure connectors from cylinders
that are firing properly.
Operate the vehicle.
Did the misfire DTC follow the suspect injectors & high pressure connectors?
Yes »Replace the internal damaged fuel injector and high pressure connector.
DURE)
No »Go To 9
9. INTERNAL ENGINE DAMAGE

Perform engine compression test
Did the suspect cylinders pass the compression test?
Yes »Go To 10
No »Repair the internal damage to the engine.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - -ENGINE - STANDARD PROCE-
DURE)

Perform engine leak down test
Did the suspect cylinders pass the leak down test?
DURE)
P0301-CYLINDER 1 MISFIRE
Theory of Operation
The Misfire Monitor gathers and filters engine crank speed data for 10 seconds once the monitor conditions are met.
If the crank speed deviation for a cylinder is less than a calibrated value, a misfire fault ;s set for that cylinder. If
more than one cylinder is failed, a multiple cylinder misfire fault is set. The ECM illuminates the MIL lamp after the
diagnostic runs and fails twice. During this time the customer may experience a cylinder miss or engine stumble.
The ECM will turn off the MIL lamp once the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
While the engine is idling at operating temperature .
• Set Condition:
Misfire detected on this cylinder.
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
OBSTRUCTED FUEL INJECTOR SUPPLY LINE
DAMAGED OR OBSTRUCTED HIGH PRESSURE CONNECTOR
EXTERNAL DAMAGED FUEL INJECTOR
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Using the scan tool, verify that the fuel level is above 15%.
Is the fuel level above 15°k?
Yes »Go To 2
DURE)
2. OTHER OTC'S
Is the DTC equal to the freeze frame OrC?
Yes »Go To 3
Perform POWERTRAJN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
3. DAMAGED FUEL LINE

Visually inspect the injector supply line for damage.
Do you have any kinked or bent fuel lines?
Ves »Repair or replace the damaged fuel line.
DURE)
No »Go To 4
4. VALVE TRAIN
Visually inspect the valve train and check the valve lash on the suspect cylinder.
Ves »Go To 5
DURE) ~

Remove the fuel injector supply rine for the suspect cylinder.
Inspect both ends of the fuel injector supply line for damage.
Using shop air pressure, blowout the fuel injector supply line to verify that they are not obstructed.
Ves »Go To 6
No »Replace the damaged or obstructed fuel injector supply line.
DURE)
6. DAMAGED OR OBSTRUCTED HIGH PRESSURE CONNECTOR

Remove the high pressure connector for the suspect cylinder.
Inspect both ends of the high pressure connector for signs of damage.
Using shop air pressure, blowout the high pressure connector to verify that it is not obstructed.
Yes »Go To 7
No »Replace the damaged or obstructed high pressure connector.
DURE)
7. FUEL INJECTOR
Remove the suspect fuel injector.
Ves »Replace the external damaged fuel injector & high pressure connector.
DURE)
No »Go To 8

Switch the misfiring injector & high pressure connector with an injector & high pressure connector from a cylinder
that is firing properly.
DURE)
No »Go To 9

Yes »Go To 10
DURE)

DURE)
9 -1890 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - - DR
Theory of Operation
the position of the engine by the ECM.
• Set Condition:
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Is the fuel level above 150/0?
Yes »Go To 2
DURE)
2. OTHER DTC'S
Yes »Go To 3
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 ·1891

Do you have any kinked or bent fuel line?
Yes »Repair or replace the damaged fuel line.
DURE)
No »Go To 4
4. VALVE TRAIN
Yes »Go To 5
DURE)

Remove the fuel injector supply line for the suspect cylinder.
Inspect both ends of the fuel injector supply Hne for damage.
Using shop air pressure, blowout the fuel injector supply line to verify that they are not obstructed.
Yes »Go To 6
DURE)

Using shop air pressure, blowout the high pressure connector to verify that it is not obstructed.
Yes »Go To 7
DURE)
7. FUEL INJECTOR
Is the fuel injector damaged?
Yes »Replace the external damaged fuel injector & high pressure connector.
DURE)
No »Go To 8

Did the misfire DTC follow the suspect injector & high pressure connector?
DURE)
No »Go To 9

Yes »Go To 10
DURE)
1O. INTERNAL ENGINE DAMAGE

DURE)
Theory of Operation
The crankshaft position and camshaft position sensors are hall effect type sensors. The ECM provides a 5 volt
supply to the position sensor and a return circuit. As the teeth on the crankshaft speed ring or the lobes on the
camshaft gear passes past the position sensor, a signal is generated on the position sensor signal circuit. The ECM
• When Monitored:
• Set Condition:
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Yes »Go To 2
DURE)
2. OTHER DTC'S
Yes »Go To 3
DURE)

Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
No »Go To 4
4. VALVE TRAIN
Is the valve train functional and the lash within the specifications listed In the service manual?
Ves »Go To 5
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 • ENGINE· STANDARD PROCE·
DURE)

Yes »Go To 6
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)

Using shop air pressure; blowout the high pressure connector to verify that it is not obstructed.
Yes »Go To 7
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9· ENGINE - STANDARD PROCE·
DURE)
7. FUEL INJECTOR
Ves »Replace the external damaged fuel injector & high pressure connector.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE~
DURE)
No »Go To 8

that are firing property.
DURE)
No »Go To 9

Yes »Go To 10
DURE)

DURE)
Theory of Operation
shaft gear passes past the position'sensor, a signal is generated on the position sensor signal circuit. The ECM
• When Monitored:
• Set Condition:
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Is the fuel level above 15% ?
Yes »Go To 2
Perform POWERTRAIN VERIFICATION TEST - 6.lL. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
2. OTHER DTC'S
Yes »Go To 3
Perform POWERTRAIN VERIFICATION TEST - 6,lL. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)

DURE) .
No »Go To 4
4. VALVE TRAIN
Is the valve train functional and the lash within the speCifications listed in the service manual?
Yes »Go To 5
DURE)

Inspect both ends of the fuel injector supply line for damage.
Using shop air pressure, blowout the fuel injector supply lines to_ verify that they are not obstructed.
Yes »Go To 6
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGINE - STANDARD PROCE-
DURE)

Using shop air pressure. blowout the high pressure connectors to verify that it is not obstructed.
Yes »Go To 7
DURE)
7. FUEL INJECTOR
DURE)
No »Go To 8
9·1S9S ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR

Switch the misfiring injectors & high pressure connector with an injector & high pressure connector from a cylinder
DURE)
No »Go To 9

Yes »Go To 10
DURE)

Perform engine leak. down test
DURE)
Theory of Operation
• When Monitored:
• Set Condition:
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Is the fuel level above 150/0? -
Yes »Go To 2
DURE)
2. OTHER DTC'S
Yes »Go To 3
DURE)
9 ·1900 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L D I E S E l - - - - - - - - - - DR

DURE)
No »Go To 4
4. VALVE TRAIN
Yes »Go To 5
DURE)

Remove the fuel injector supply lines for the suspect cylinder.
Yes »Go To 6
No »Replace the damaged or obstructed fuel injector supply lines.
DURE)

Remove the high pressure connectors for the suspect cylinder.
Using shop air pressure, blowout the high pressure connector to verify that they are not obstructed.
Are the high pressure connector free of debris or damage?
Yes »Go To 7
DURE)
7. FUEL INJECTOR
DURE)
No »Go To 8

Did the misfire DTC follow the suspect injector & high pressure connector?
DURE)
No »Go To 9

Yes »Go To 10
DURE)

DURE)
Theory of Operation
• When Monitored:
• Set Condition:
Possible Causes
LOW FUEL
OTHER DTC'S
DAMAGED FUEL LINE
VALVE TRAIN
NO COMPRESSION
Diagnostic Test
1. LOW FUEL
Using the scan tool, verity that the fuel level is above 15%.
Yes »Go To 2
DURE)
2. OTHER DTe'S
Is the DTe equal to the freeze frame OTe?
Yes »Go To 3
DURE)

Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
No »Go To 4
4. VALVE TRAIN
Yes »Go To 5
DURE)

Using shop air pressure, blowout the fuel injector supply line to verify that it is not obstructed.
Yes »Go To 6
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ENGINE - STANDARD PROCE-
DURE)

Inspect both ends of the high pressure connectors for signs of damage.
Using shop air pressure. blowout the high pressure connector to verify that they are not obstructed.
Yes »Go To 7
DURE)
7. FUEL INJECTOR
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGrNE - STANDARD PROCE·
DURE)
No »Go To 8

Did the misfire DTe follow the suspect Injectors & high pressure connectors?
Perform POWERTRAIN VERIFICATiON TEST - 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
No »Go To 9

Old the suspect cylinders pass the compression test?
Yes »Go To 10
DURE)

DURE)
P0335-CRANKSHAFT POSITION SENSOR PERFORMANCE
M.IOI· IUIoR·
caMs...n C......H.FT
PO.'IO. CKP '011T10.
cUP SENSOR BOLT 5 VOLT CKP SENSOR
SIGNAL GROUND SUPPLY SUPPl Y SIGNAL GROUND
'I
1(44
2i
Kgl,
'i
fBS5
'I 'I
K824 K24
2i
K925
,8 18 18 18 18 18
OBIGY BRIOR PKIVL DBJBR 8R4.8 8RIOR
.....
I I
.Iua
I I
K91S FB55
18 18
BRIOR PKlVL
17 01 .. 101 11101 "01 11 01 «01

r~~-~~~-~~------~~-w--~~~ MODULE·
I SIGNAL GROUND SUPPLY SUPPLY SIGNAL SENSOR I EIIIIE
CO.TAOL
I GROUND I
~------------------------
~ ~
10
~ooo~ I'
00000
,
20 00000
00000
00000
00000
II
21 ~'''CK
lO
40
00000
00000
0 00000
00000 31
54l 00000 00000 41
10
.....
~
'-'
..I
51 3ll!!)Jl
.E.IO.. • .I'OR·
MODULE· c•• III An CUI'I... FT
.IIIIE Po.TlOI PDIITIOI
COI'AOLCt (DIE'IL, (DIEIEL,
(l.fLI
•• MM••

Theory of Operation
The ECM provides a 5·volt supply to the engine crankshaft speed/position sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The crankshaft speed/position sensor provides a signal to
the ECM on the crankshaft speed/position sensor signal circuit. This sensor generates a signal to the ECM as the
crankshaft speed indicator ring passes the sensor. The ECM interprets this signal into an engine speed reading and
determines engine position. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. Dur-
ing this time the camshaft speed sensor is used to provide engine speed and position information to the ECM. The
customer may experience an engine misfire as control switches from the primary to the backup speed sensor. The
ECM will turn off the MIL lamp when the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
• Set Condition:
The ECM no longer detects a signal from the Crankshaft Position Sensor.
Possible Causes
OTHER DTC'S
P0337 PRESENT
CKP SENSOR
VISUAL DAMAGE
(K824) 5-VOLT SUPPLY CIRCUIT OPEN
(K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K925) RETURN CIRCUIT
(K24) SIGNAL CIRCUIT SHORTED TO (K824) 5-VOLT SUPPLY CIRCUIT
(K24) SIGNAL CiRCUIT SHORTED TO GROUND
(K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
Always perform the Pre-Diagnostic TrOUbleshooting procedure before proceeding. (Refer to 9 - ENGINE·
Diagnostic Test
1. OTHER DTC'S
Are there other DTC set along with this one?
Yes »Repair other DTC's.
DURE)
No »Go To 2
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 .. 1907
2. VISUAL DAMAGE
Visually inspect the sensor, engine belt, sensor connector,' and the ECM connector.
Is there any damage?
Yes »Repair or replace the sensor. engine belt. harness, or the ECM.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ~ ENGINE - STANDARD PROCE-
DURE)
No »Go To 3
3. CKP SENSOR
Disconnect the CKP sensor harness connector.
Measure the resistance between the (KB24) 5-volt supply circuit and the (K24) signal circuit of the sensor.
Yes »Go To 4
No »Replace the CKP sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ENGINE - STANDARD PROCE·
DURE)

Measure the resistance of the (K24) signal circuit between the ECM
harness connector and the CKP sensor harness connector.
Yes »Go To 5
No »Repair the open (K24) signal circuit. CRANKSHAFT
Perform POWERTRAIN VERIFICATION TEST - 6.7L. POSmoN
(DIESel.)
10
26 11
30 21
40 31
50 41
60 S1
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a8f3c4
9 - 1908 ENGINE - ELECrRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
5. (K824) 5-VOLT SUPPLY CIRCUIT OPEN

Measure the resistance of the (K824) 5-volt supply circuit between the
ECM harness connector and the CKP sensor harness connector.
1
~
Yes »Go To 6 8LACK
No »Repair the open (K824) 5-volt supply circuit. 1.
Perform POWERTRAIN VERIFICATION TEST - B.7L. 3 1
28
SENSOR.
CRANKSHAFT
POSITION
(DIESEL)
20 11
30 21
~o 3t
so ~,
60 51
MODULE·
ENGINE
CONTROlC1
(6.7l)
81a8f3c8
6. RETURN CIRCUIT OPEN

Measure the resistance of the (K925) return circuit between the ECM
Yes »Go To 7
10
20 11
30 21
46 31
50 41
60 51
MODULE-
ENGINE
CONTROLC1
(6.7L)
81a8f3cc
DR - - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 -1909

Measure the resistance between the (K24) signal circuit and the (K92S)
Yes »Go To 8
2
No »Repair the short circuit or replace the engine harness.
1~
Perform POWERTRAIN VERIFICATION TEST ~ 6.7L.
SENSOR-
CRANKSHAFT
POSITION
(DIESEL)
8140bf52
8. (K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K925) RETURN CIRCUIT

Measure the resistance between the (K824) 5-volt supply circuit and the
(K925) return circuit in the sensor connector.
Yes »Go To 9
SENSOR·
CRANKSHAFT
POSITION
(DIESEL)
8140bf59
9. (K24) SIGNAL CIRCUIT SHORTED GROUND

Measure the resistance between the (K24) signal circuit and ground.
Yes »Go To 10
SENSOR-
CRANKSHAFT
POSITION
(DIESEL)
8140bf5d
9 -1910 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
10. (K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Measure the resistance between the (K824) 5-volt supply circuit and
ground.
Yes »Go To 11
CRANK8HAFT
POSI11ON
(DI!SEL)
8140bf62
11 . (K24) SIGNAL CIRCUIT SHORTED TO (K824) 5-VOLT SUPPLY CIRCUIT

Measure the resistance between the (K24) signal circuit and the (K824)
Yes »Go To 12
Perform POWEATRAIN VERIFICATION TEST - B.7L.
SENSOR-
CRANKSHAFt
P08f11ON
(DIESEL)
8140bf66
12. ECM
Connect a jumper wire between the sensor supply circuit and the sen-
sor return circuit in the sensor harness connector.
Did DTC P0337 set?
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) SENSOR-
CRANKsHAFT
No »Replace the ECM. POSITION
Perform POWERTRAIN VERIFICATION TEST - B.7L (DIESEL)
8140bf6d
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 • 1911
P0336-CRANKSHAFT POSITION SENSOR PERFORMANCE
8EIISOR· SENSOR·
CAISHAfT CRlIlSHAFT
POlmOIL CKP POSITIOI
CMP SENSOR 5 VOLT 5VOlT CKP SENSOR
'I II
SIGNAL GROUND SUPPLY SUPPLY SIGNAL GROUND
"
K44
18
K916
18
F855
18
11
K824
18
'I K24
18
"
K925
18
OBKlY BR/oR PKffl DBIBR BRIlB 8RIOR
I
• 1044
I
• sna
I I
K916 F855
18 18
BRIOR PKIYL
r cUP -
31 Cf .. 1 ,.1
SENSoR- -
Cl
5VOlT -
Cf
- - - - -
26 Cf 31
5VolT - CKP - - CKP- -I
Cf •• Cl
10DULE·
I SIGNAL GROUND SUPPl Y SUPPLY SIGNAL SENSOR I EIIIIIIE
COITROL
GROUND
I I
...... _-----------------------
11 BLACK
21
31
41
51
SElSOR· SEII80A·
10DULE·
CAl SHAFT CRAlIIHAFT
ENGIIiE
POSITIOII POSITIOI
CO.TROl C1 (DIEIELI (DIESELI
(l.lL)

Theory of Operation
The ECM provides a 5-vott supply to the engine crankshaft speed/position sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The crankshaft speed/position sensor provides a signal to
the ECM on the crankshaft speed/position sensor signal circuit. This sensor generates a signal to the ECM as the
crankshaft speed indicator ring moves past sensor. The ECM interprets this signal into an engine speed reading and
determines engine position. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. Dur-
ing this time the camshaft speed sensor is used to provide engine speed and position information to the ECM. The
customer may experience an engine misfire as control switches from the primary to the backup speed sensor. The
ECM will turn off the MIL lamp when the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
With the key on .
• Set Condition:
The voltage detected at the Crankshaft position sensor is below a calibrated value.
Possible Causes
CKP SENSOR
(K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K925) RETURN CIRCUIT
(K24) SIGNAL ClRCUIT SHORTED TO (K824) 5-VOLT SUPPLY CIRCUIT
(K824) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
Diagnostic Test
1 . CKP SENSOR
Measure the resistance between the (K824) 5-volt supply circuit and the (K24) signal circuit of the sensor.
Yes »Go To 2
No »Replace the CKP sensor.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS _r 6'.7L DIESEL 9 - 1913

Measure the resistance of the (K24) signal circuit between the ECM
Is the resistance .1$sS than 10 ohms?
Yes »Go To 3
SEHSOR·
No »Repair the open (K24) signal circuit. CRANKSHAFT
Perform POWERTRAIN VERIFICATION TEST - 6.7L POSmoN
(DIESEL)
10
20 11
30 21
40 31
50 41
eo 51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81a8f3c4

Measure the resistance of the (K824) 5-volt supply circuit between the
ECM harness connector and the CKP sensor harness connector.
Yes »Go To 4
No »Repair the open (K824) S-volt supply circuit.
28
SENSOR·
CRANKSHAFT
POSITION
(DIESEL)
10
20 11
30 21
40 l1
50 41
80 ~1
MODULE·
ENQINE
CONTROLC1
«(I.7l.
81a8f3c8
9 ·1914 ENGINE - ELECTRICAL DIAGNOSTICS- 6.7L DIESEL - - - - - - - - - DR

Ves »Go To 5
10
20 11
30 21
40 31
50 41
00 51
MODULE-
ENGINE
CONTROLC1
(6.7L)
81aBf3cc

Yes »Go To 6
[OJ
2
1~
(Refer to 9 - ENGINE ~ STANDARD PROCEDURE)
SENSOR·
CRANK8HAFT
POSITION
(DIEseL)
8140bf52
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 - 1915
6. (K824) 5·VOLT SUPPLY CIRCUIT SHORTED TO (K925) RETURN CIRCUIT

Measure the resistance between the (K824) 5-volt supply circuit and the
(K925) return circuit in the sensor connector.
Yes »Go To 7
2
3
SENSOR-
CAANtCSHAFf
POSITION
41)IESEL)
8140bf59
7. (K24) SIGNAL CIRCUIT SHORTED GROUND

Measure the resistance between the (K24) signal circuit and ground.
Yes »Go To 8
No »Repair the shorted circuit.Perform POWERTRAIN VERIFI-
CATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
SENSOR·
POSITJON
(DIeBEL)
8140bf5d

Measure the resistance between the (K824) 5-volt supply circuit and
ground.
Yes »Go To 9
No »Repair the shorted circuit.Perform POWERTRAIN VERIFI-
CATION TEST - B.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
CRANKSHAFT
POSITION
(Dll!en)
8140bf62
9 -1916 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
9. (K24) SIGNAL CIRCUIT SHORTED TO (K824) 5·VOLT SUPPLY CIRCUIT

Yes »Go To 10
SENSOR-
CRANKSHAFT
POSrrlON
(DIESEL)
8140bf66
10. ECM
Connect a jumper wire between the sensor supply circuit and the sen-
sor return circuit in the sensor harness connector.
Did DTC P0337 set?
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) SENSOR·
CRANKSHAFT
No » Replace the ECM. POSITION
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (DIESEL)
8140bf6d
P0340-CAMSHAFT POSITION SENSOR CIRCUIT - BANK 1 SENSOR 1
SElSOR· SEI.OR·
CAISHAFT CRAIISHAFT
P0811101 CKP P08.1101
CMP SENSOR 5 VOL T 5 VOLT CKP SENSOR
SIGNAL GROUND SUPPl Y SUPPLY SIGNAL GROUND
'I KH
21
K918
'I
F855
'I 'I
K824 K24
21
K925
18 18 18 18 18 18
DSIGY BRIOR PKiYl D8JBR BRIlB BR/OR
I I
• Sn3
• 1044
I I
K916 F855
18 18
BRIOR PKNL
,1
r CMP -
01 ,,101
SENSOR- -
.. 1CI
5VOlT - - - - - -
2.
5VolT -
CI 31 CI
CKP - - CKP--I
"CI
10DULE·
I SIGNAL GROUND SUPPl Y SUPPl Y SIGNAL SENSOR I EIGIIIE
COITROL
I GROUND I
10
2a 11 ~BLACK
30 21
40 31
50
60
41
51 3[gjl
SElSOR· SEIIOR·
10DULE· CAl SHAFT CRANKSHAFT
EIGIIE P081TI01 POSITIOII
COll1ROL C1 CDIEIEl, (DIESELI
CI.U)

Theory of Operation
The ECM provides a 5-volt supply to the engine camshaft speed/position sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The camshaft speed/position sensor provides a signal to
the ECM on the camshaft speed/position sensor signal circuit. The sensor generates a signal to the ECM as the
camshaft speed indicator lobe moves past the sensor. The ECM interprets this signal into an engine speed reading
and determines engine position. This sensor is used as a backup sensor if the primary engine crankshaft speed/
position signal is lost. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. During the
time the customer may experience a hard start/no start condition. The ECM will turn off the MIL lamp after the
• When Monitored:
• Set Condition:
The ECM no longer detects a signal from the Engine Position Sensor.
Possible Causes
INJECTOR DTC'S PRESENT

OTHER DTC'S
CAMSHAFT SENSOR
(K44) SIGNAL CIRCUIT SHORTED TO SUPPLY (F855) CIRCUIT
(K44) SIGNAL CIRCUIT SHORT TO VOLTAGE
ECM
Diagnostic Test
1. INJECTOR DTC'S PRESENT

Do are there injector(s) DTCs present?
Yes »Repair injector DTC's first.
DURE)
No »Go To 2
2. OTHER DTC'S
Is any other DTC's present?
DURE)
No »Go To 3
3. CAMSHAFT SENSOR
Disconnect the cam sensor harness connector.
Measure the resistance between the (F855) 5-volt supply circuit and the (K44) signal circuit of the sensor.
Yes »Go To 4
No »Replace the camshaft sensor.
DURE)

ECM harness connector and the cam sensor harness connector.
Yes » Go To 5 3
No » Repair the open (F855) 5-volt supply circuit.

Perform POWERTRAIN VERIFICATION TEST - B.7L. 36
SENSOR-
(Refer to 9 - ENGINE - STANDARD PROCEDURE) CAMSHAFT
POBmON
(DIESEL)
10
20 11
30 21
40 31
60 .(1
60 61
MODULE-
ENGINE
CONTROLC1
(8.7L)
81a8f7a1
9·-1920 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR

harness connector and the cam sensor harness connector.
2
Yes »Go To 6
Sl!N&OR-
48
10
20 11
30 21
4() 31
50 41
50 51
MODULE..
ENGINE
CONTROLC1
(8.7L) 81a8f7ab
6. SIGNAL CIRCUIT SHORTED TO GROUND

Ves »Go To 7
SENSOR-
CAMsttAFT
PosmON
(DIESEL)
81413b1c
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. &~7L DIESEL 9 ·1921
7. (K44) SIGNAL CIRCUIT SHORTED TO (F855) 5..VOLT SUPPLY CIRCUIT

Measure the resistance between the (K44) signal circuit and the (F855)
5-volt supply circuit in the sensor harness connector.
Yes »Go To 8
No » Repair (K44) signal circuit shorted to the (F855) 5-volt sup-
ply circuit.
Pedorm POWERTRAIN VERIFICATION TEST - 6.7L.
SENSOR·
CAMSHAfT
POSITION
(DIE8&L)
81413b21

Yes »Go To 9
2
No »Repair (K44) signal circuit shorted to the (K916) return cir-
cuit.
SENSOR·
CAMSHAFT
POSITION
(DIESEL.)
81413b25
9. (K44) SIGNAL CIRCUIT SHORT TO VOLTAGE

Measure the voltage between the (K44) signal circuit in the sensor har-
Yes »Go To 10
No »Repair (K44) signal circuit shorted to voltage.
SENSOR-
CAMSHAFT
POSITION
(DIESEL)
81413b29
10. ECM
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symp- 3
NOSIS AND TESTING)
SENSOR.
CAMSHAFT
posmON
(DIESEL)
B1413b6B
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 1923
P0341-CAMSHAFT POSITION SENSOR PERFORMANCE - BANK 1 SENSOR 1
SENSOR· SElSOR·
CllSHAFT CRlIUHlFT
POSITlOIL CKP POIITIDII
CMP SENSOR HOLT 5 VOLT CKP SENSOR
SIGNAL GROUND SUPPLY SUPPl Y SIGNAL GROUND
2'
'I 'I 'I 'I 'I

K44 K916 F855 KB24 K24 K925
11! 18 18 18 18 18
DBIGY Bf/IOR PKNL DBI13R BRilB BRiaR
I I
• 1044 • 8173
I I
K916 F855
lB 18
BRiaR PKlYl
31.t
r CMP -
.. l.t
SENSoR- -
1
.. et
5VOLT - - - - - -
26.t
5VOlT -
31 et ...,
CKP - - CKP- -I IODULE·
I SIGNAL GROU ND SUPPL Y SUPPL Y SIGNAL SE NSOR I Ell Gill E
COITROl
GROUND
I f
'--------------------------
10
00000 BLACK
~
10 00000 11
30 00000 21
00000
40 00000 ~1
50 00000 41
60 51
SElSOR· SElSOR·
10DUlE· CAISHAFT CRlllSHAFT
EIGIIIE POSITIOII POSITIOI
CONTROL ct (DIESEL, CDIESELI
(S.lL)
.t ....,
Theory of Operation
The ECM provides a 5-volt supply to the engine camshaft speed/position sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The camshaft speed/position sensor provides a signal to
the ECM on the camshaft speed/position sensor signal circuit. The sensor generates a signal to the ECM as the
camshaft speed indicator lobe moves past the sensor. The ECM interprets this signal into an engine speed reading
and determines engine position. This sensor is used as a backup sensor if the primary engine crankshaft speed/
position signal is lost. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. During the
time the customer may experience a hard start/no start condition. The ECM will turn off the MIL lamp after the
• When Monitored:
• Set Condition:
The ECM no longer detects a signal from the Engine Position Sensor.
Possible Causes
INJECTOR DTC'S PRESENT

OTHER DTC'S
CAMSHAFT SENSOR
(K44) SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY CIRCUIT
(K44) SIGNAL CIRCUIT SHORT TO VOLTAGE
ECM
Diagnostic Test
1. INJECTOR DTC'S PRESENT

Are there any injector DTC(s) present?
Yes »Repair injector DTC's first.
DURE)
No »Go To 2
2. OTHER DTC'S
Is any other DTC's present?
Ves »Repair other DTC's first.
DURE)
No »Go To 3
3. CAMSHAFT SENSOR
Disconnect the Camshaft sensor harness connector.
Measure the resistance between the (F855) 5-volt supply circuit and the (K44) signal circuit of the sensor.
Ves »Go To 4
No »Replace the camshaft sensor.
DURE)

Measure the resistance of the (K44) signal circuit between the ECM harness connector and the sensor harness
connector.
Ves »Go To 5
DURE)
9 • 1926 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
5. (F855) 5·VOLT SUPPLY CIRCUIT OPEN

ECM harness connector and the sensor harness connector.
Yes »Go To 6
No »Repair the open (F855) 5-volt supply circuit.

36
8I!NSOR-
CAMSHAFT
POImON
(DIESEL)
10
20 11
30 21
40 31
50 4'
eo 61
MODULE-
ENGINE
CONTROLC1
(8.7L)
8188f7a1

harness connector and the sensor harness connector.
2
Yes »Go To 7
No » Repair the open (K916) return circuit.
SENSOR-
48 CAMSHAFT
POSmoN
(DIESEL)
10
20 11
30 21
40 31
5(1 41
60 S1
MODULE·
ENGINE
CONTROLC1
(8.7L) 8188f7ab

Yes »Go To 8
SENSOR-
CAMSHAfT
PosmON
(DIESEL)
81413b1c
8. (K44) SIGNAL CIRCUIT SHORTED TO (F85S) S-VOlT SUPPLY CIRCUIT

Measure the resistance between the (K44) signal circuit and the (F855)
5-volt supply circuit in the sensor harness connector.
Yes »Go To 9
No » Repair (K44) signal circuit shorted to the (F855) 5-volt sup-
ply circuit.
SENSOR-
C.AM8HAFT
POtmON
(DIISIL)
81413b21

Yes »Go To 10
No »Repair (K44) signal circuit shorted to the (K916) return cir-
cuit.
SENSOR·
CAIISHAFT
P06lT1ON
(DIISIIL,
81413b25
9 ... 1928 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
1o. (K44) SIGNAL CIRCUIT SHORT TO VOLTAGE

Ves »Go To 11
No »Repair (K44) signal circuit shorted to voltage.
SENSOR-
CAMSHAFT
POSITION
(DIESEL.)
81413b29
11. ECM
Yes »Test Complete. 3
SENSOR-
CAMSHAFT
POSmoN
(DIESEL.)
81413b68
P0381-WAIT TO START LAMP INOPERATIVE
• When Monitored:
Ignition on .
• Set Condition:
The cluster sends a signal to the ECM that it has detected a failed wait to start lamp.
Possible Causes
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

WAIT-TO-START LIGHT BULB
WIRING/CONNECTOR PROBLEM
ECM
Diagnostic Test
1. WAIT-TO-START LAMP DOES NOT COME ON

While watching the wait-to-start lamp, turn the ignition key on.
Did the wait-to-start lamp light?
Yes »Go To 2
No »Go To 3
2. WAIT-TO-START LAMP STAYS ON ALL THE TIME

While watching the wait-to-start lamp, turn the ignition key on.
Does the wait-to-start lamp stay on all the time?
Yes »Go To 3
No »Wait-to-start Lamp operating normally. Test passed.
Perform POWERTRAIN VERIFICATION TEST VER - 6.7L. (Refer to 9 - ENGINE - STANDARD PRO-
CEDURE)
3. FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

Remove the cluster.
NOTE: Check connectors ... Clean/repair as necessary.
Using a 12-Volt test Light, check the Fused Ignition Switch Run/Start
circuit while the ignition is in the run/start position.
Is the light illuminated and bright?
Yes »Ga To 4 #25
No »Repair the open fused Ignition Switch Output circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 6.7L.
CLUSTERC3
81413b81
4. WAIT-TO-START LIGHT BULB

Remove and inspect the Wait-to-Start Bulb.
Is the Bulb Ok?
Yes »Test complete.
No »Replace the Wait-to-Start Bulb.
Periorm POWERTRAIN VERIFICATION TEST VER 6.7L. (Refer to 9 - ENGINE - STANDARD PRO-
CEDURE)
P0400-EGR SYSTEM FLOW MALFUNCTION
1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -,MODULE-
EI.'IE
I I COMTROL
I 5VOLT EGR EGR EGR SENSOR EGR EGR EGR I
LSU~Y _ _ C~TROlN~ _ --E0~ROlN0.2. _ ~O~O~.~ _ 20~D _ _ S~A!:!O . .2.- _ ~N~N~ _ ~G~N~}-'
l
31 Ot ! Ot 3 Ot ,Ot IIi Ct 25 01 5 Ot Jl Ot
K916
F855
18 18
PKJYl BRIOR
• Ina .8D44
F855 K682 K684 K686 K916 K681 K685 K687

18 18 18 18 18 18 18 18
PKlYl DBMIT DBlYl Gy,uB BRIOR DB/GY DB Da~B
.1 J J .1 .1 J j AI.E.IL'.EGR
II r h ' II
. I
"LYE
., .,
~
PINK
10
2Q
30
1'1:
00000""
00000
00000
VOOOOO'
00000
00000
" 11
21
40
SO
00000
00000
0 00000
00000
3. I ==== 4
41
60 00000 00000 51
5 =>== 8
.A ~ /.J
~
'-' ......
. .SEMILY·
EIR
MODULE·
I!•• IIE 'IILYE
(l.lL)
COlnOL C1
('.U)
1 . . ., .

9 - 1932 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
Theory of Operation This diagnostic monitors EGR position when it is commanded
closed.
• When Monitored:
Engine running, EGR valve commanded closed .
• Set Condition:
Detected EGR position is greater than 6% for more than 2 seconds.
Possible Causes
iOTHER EGR VALVE DTC'S

Diagnostic Test
1. OTHER DTC'S
Are there other DTC's?
Yes »Troubleshoot other DTC's first.
No »Replace EGR valve.
DURE).
P0401-EGR SYSTEM PERFORMANCE
1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -,IODULE.
EIGIIE
I I~~
I
I 5 Val T EGR EGR EGR SENSOR EGR EGR EGR I
"I .. ,..
~UPPLY _ _ c~m~N~ _ ~O~R~0.2. _
l ••
'-:O~OlNO.~ _
I c.
~OUND _ _ SIGNAlNO.~ _
Ie c. "C,
SIGN~0..2 _
'C,
~G~~3..J
35 e.
K916
F8SS
HI
18
BRIOR
PKJVl
• 1173 • 8044
F8S5 K682 K684 K686 K916 K6B3 K685 1(687

18 18 18 18 18 18 18 18
PKNl DBfNT DBNL GYiDB BRIOR DBIGY DB DBLB
j .1 J .1 J .1 J J AISEIIL Y·EGR
'~ II
VALVE
Jj I \11
v "1
11 11
PINK
1/ :V
dj
10
10
/00006 rooooo II
00000 00000
30 00000 00000 21
~o 00000
00000
0 00000
00000
31 1 .::=I C::;:n::::lE::::1 4
50 41
SO 00000 00000 5f
5 ===<= 8
~
~ ..A
'l
LJ l-I
ASSEIILY·
EGR
IODULE·
EIIGINE VALVE
(i.lL)
CONTROL C1
li.n,
..."..
9 ·1934 ENGINE .. ELECTRICAl. DIAGNOSTICS . . 6.7L D I E S E L - - - - - - - - - DR
Theory of Operation
This diagnostic is used to check for low EGR flow conditions. When the EGR valve is open more than 60% , the
diagnostic calculates an error based on the commanded and actual EGR position. If there error is too high for a
calibrated period of time, the diagnostic fails. This algorithm is not used at areas high on the torque curve. The ECM
will light the MIL lamp immediately after the diagnostic runs and fails. The ECM will turn off the MIL lamp once the
diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
Engine running, Coolant temperature above a calibrated threshold. Intake Manifold temperature above a cali-
brated threshold, EGR valve is open a calibratable amount.
• Set Condition:
Commanded versus actual EGR fraction differs by a calibrated threshold.
Possible Causes
OTHER DTCS
EGR LEAK
AIR INLET LEAK
AIR FILTER RESTRICTION
BOOST LEAK
EGR COOLER LEAK
EGR COOLER FOULING
CROSSOVER TUBE RESTRICTION
INTAKE AIR HEATER RESTRICTION
Diagnostic Test
1. OTHER DTCS
Are there any other DTCs present?
No »Go To 2
2. EGR LEAK
Look for visible signs (soot streaks) of an external EGR leak.
Are there any EGR leaks?
Yes »Correct the failure.
Perform POWERTRA1N VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 3
DR - - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 .. 1935
3. AIR INLET LEAK

Check for areas in the inlet air system that would allow air to be brought in after the air filter.
NOTE: During normal engine operation a hole in this area would not result in an inlet air leak.
Is there a hole in the inlet air system?
Yes »Correct the failure.
DURE)
No »Go To 4
4. AIR FILTER RESTRICTION

Examine air filter minder.
Is the air filter restriction within allowable limits?
Yes »Go To 5
No »Replace air filter.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 .. ENGINE - STANDARD PROCE·
DURE)
5. BOOST LEAK
Check system for leaks. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Are there any boost air leaks?
Yes »Correct the failure
DURE)
No »Go To 6
6 . EGR COOLER LEAK

Verify EGR cooler is not leaking.
Check for coolant in EGR plumbing, engine overheat fault codes, and low coolant level.
Are there signs of an EGR Cooler leak?
Ves »Replace EGR Cooler.
Perform POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 7
7. EGR COOLER FOULING

Remove the inlet and outlet EGR tubes from the EGR cooler.
Inspect the cooler for debris and plugging.
Is there excessive soot build up in the EGR cooler?
Yes »Replace EGR Cooler.
DURE)
No »Go To 8
8. EGR CROSSOVER TUBE RESTRICTION

Remove EGR Crossover tube from EGR cooler and EGR valve.
Inspect tube for restriction.
Is the EGR crossover tube restricted?
Yes »If possible clean tube. If not, replace tube.
DURE)
No »Go To 9
9. INTAKE AIR HEATER RESTRICTION

Remove air inlet connection and inspect intake air heaters.
Is the intake air heater restricted?
Yes »Clean area and reassemble.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 . ENGINE - STANDARD PROCE-
DURE)
No »Repair complete, verify complaint is not longer present. If condition still exists return to beginning of test.
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6~7L DIESEL 9 ·1937
P0402-EGR FLOW EXCESSIVE DETECTED
r--------------------------------~I~~
••• 11'
I · I CO.'IOL
I
"I
5VOLT
et
EGR
l2U~V _ _ C~TR~N~ _
2 et 3
EGR
'-:O!!!.R~02.. _
It
EGR
..E.0~O~O.~ _
,et
SENSOR
" I el
EGR
~O~D _ _ S~A!:!O ..!..
25 et
_
EGR
~N~N~ _
5 O'
EGR
~G~~l..J
31 Ot
I
K9t.
fB5S
18
18
BRIOR
PKJYl
• ana ....
F855 K682 K684 K686 K916 K683 K685 K687
18 f8 18 18 18 18 18 18
PKIVL oamT DBJYl GYKlB BRIOR OSlGY DB OBA.8
J .1
11
J 'I
.1 j .1 j J " ....L'....
VAL••
II J II III .
M II
~"
/;
10
20
OOOO~ "00000 11
00000 00000
30 00000 00000 21
40 00000
00000
0 00000
00000
31
5Q 41
60 00000 00000 - 51
.A
~'-
\0.. .~
......
IODULI·
•••.1.
L...I
.1.
'".I.LY·
VlLI•
COITIIOL It tl·JLI
,1.lLl
.t......

9 ·1938 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The purpose of this diagnostic is to check for a condition where EGR flow is higher than commanded. This algo-
rithm runs at idle. The diagnostic closes the EGR valve, and limits the intake air throttle valve. It then looks at fresh
air flow fraction and the difference in pressure between the exhaust manifold pressure sensor and boost pressure
sensor to determine if the EGR valve is leaking. The ECM will illuminate the MIL lamp after the diagnostic runs and
fails in two consecutive drive cycles. The ECM will also illuminate the ETC lamp. The MIL lamp will turn off once the
• When Monitored:
Engine running, Coolant temperature above a calibrated threshold, Intake Manifold temperature above a cali-
brated threshold, EGR valve is closed .
• Set Condition:
When intake throttle is closed, EGR fraction increases more than a calibrated threshold.
Possible Causes
EXHAUST GAS PRESSURE SENSOR

EGR AIRFLOW THROTTLE CONTROL VALVE
EGR VALVE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 . ENGINE·
Diagnostic Test
1 . OTHER DTC'S
Are there any other DTCs present?
No »Go To 2
2. THERMOSTAT OUTLET
Remove the exhaust gas pressure sensor from the thermostat outlet.
Is the outlet free of debris?
Yes »Go To 3
No »Remove debris from outlet.
Go To 3
3. EXHAUST GAS PRESSURE SENSOR TUBE

Remove the steel tube from the exhaust manifold to the exhaust pressure sensor port.
Is the tube free from debris?
Yes »Go To 4
No »Clean the tube and reinstall.
Go To 4
DR - - - - - - - - - ENGINE .' ELECTRICAL DIAG:NOSTICS • 6.7L DIESEL 9 -1939
4. EGR AIRFLOW THROTTLE CONTROL VALVE

Remove the boot from the EGR airflow throttle control valve. Using a mirror, look at the butterfly valve on the inside
of the EGR airflow throttle control valve.
Start the vehicle, let idle for 10 seconds and key off.
NOTE: If functioning properly the EGR airflow throttle control valve will cycle closed immediately after the
engine is shut down.
Did the EGR airflow throttle control valve cycle closed immediately after the engine was shut down?
Yes »Go To 5
No »Replace the EGR airflow throttle control valve.
DURE)
5. P0402 ACTIVE
Is P0402 still active?
Yes »Replace EGR Valve.
DURE)
DURE) .
P0403-EGR CONTROL CIRCUIT/OPEN
r--------------------------------~·~~
EIGIII
I I~~
I
I 5 VOL T EGR EGR EGR SENSOR EGR EGR EGR'
~UPPlY _ _ C~R~N~ _ "':O~OL NO,2. _ ":'ONTRO~,~ _ ~O~D _ _ SIGNA~O,!.. _ ~N~Nc:! _ ~G~ ~3.-J
"iO' 2 ct 2 ct ,Ct '" C. 25 O. 5 O. 25 C.
K916
F855
18
18
PKNL BR/oR
• S173 • S044
F855 K682 K684 K686 K916 K683 K685 K687

18 18 18 18 18 18 18 18
PKNL OBmT OBNL GYIDB BRIOR DBIGY DB DBAS
J,
.1 J J J J J J "SEIBL '.EGR
~ II ~ II
VlLVE
~ , I A
J 1 J I
r1
,..,
P'NK
/'i :\'
6
~
00000 "'00000'
10
00000 00000
3D 00000 00000
40
50
00000
00000
0 00000
00000
11
41
1 === 4
;0 00000 00000 51
5 ==== 8
A ~ ./..1
"-
L..J L..J
ASSEIBLT·
MODULE.
EGR
EJlG.IE WALVE
COIITROL Ct
,lan)
(I.n)

Theory of Operation
The EGR valve is opened by a motor located on top of the EGR valve. A motor shaft extends from the motor and
contacts the dual~poppet valve to open the EGR valve. The EGR valve motor does not actually retract the EGR
valve. The motor current is reduced and the spring pushes the EGR valve closed. The EGR valve motor contains
three position sensors that detect to location of the EGR valve. These sensors report the position of the valve back
to the ECM over the EGR position A. Sf and C wires. This diagnostic monitors the EGR solenoid driver circuits. If
there is a short of open circuit detected for more than a calibrated period of time then the diagnostic will fail. The
ECM lights the MIL lamp immediately after this diagnostic runs and fails. During this time the ECM will stop con-
trolling the EGR valve. The default position for the valve is closed. The ECM will turn off the MIL lamp after the
• When Monitored:
Engine running.
• Set Condition:
Short or open circuit detected for more than calibrated amount of time.
Possible Causes
EGR VALVE 5-VOLT SUPPLY DTC

EGR MOTOR OUTPUT 1, 2 OR 3 IS OPEN
EGR MOTOR OUTPUT 1. 2 OR 3 IS SHORTED TO GROUND
EGR MOTOR OUTPUT 1, 2 OR 3 IS SHORTED HJGH
INTERNAL EGR VALVE CIRCUIT ERROR
ECM
Diagnostic Test
1. OTHER DTCS
Are there any DTCs related to EGR valve voltage supply line?
Yes »Repair other EGR DTC's first.
No »Go To 2
2. OPEN CIRCUIT
Disconnect the EGR valve motor harness connector.
Measure the voltage from the EGR (F855) 5-volt supply circuit to the
EGR (K916) return circuit at the EGR valve connector on the engine
harness. PINK
Yes »Go To 3
No »Repair the open circuit from the EGR valve harness con- 4
nector to the ECM. 8
Perform POWERTRAIN VERIFICATION TEST .. 6.7L
(Refer to 9 .. ENGINE .. STANDARD PROCEDURE)
ASSEMBLY·
EGR
VALVE
(&.7L) 81af7403
3. SIGNAL CIRCUIT OPEN

Disconnect the engine harness from the ECM.
Measure the resistance between the EGR Motor (K682) control 1 circuit
at the EGR valve harness connector and the EGR Motor (K682) control
1 circuit at the ECM harness connector.
Measure the resistance between the EGR Motor (K684) control 2 circuit
Measure the resistance between the EGR Motor (K686) control 3 circuit K682
Yes »Go To 4
to
No »Repair or replace the engine harness for an open circuit. ~ 11
Perform POWERTRAIN VERIFICATION TEST - 6.7L ac 21

~ <0 31
to 41
eo 51
MODULE.
ENGINE
CONTROLC1
[e.7L) 81af7461
4. SIGNAL CIRCUIT SHORT TO ANOTHER CIRCUIT

Measure t~e resistance between the EGR Motor (KB82) control 1 circuit
at the ECM harness connector and all other circuits in the connector.
Measure the resistance between the EGR Motor (KB84) control 2 circuit
Measure the resistance between the EGR Motor (KB8B) control 3 circuit
Yes »Go to 5
No »Repair or replace the engine harness for a short circuit.
10
20
3t)
oW
50
60
MODULE-
ENGINE
CONTROLC1
(6.7L)
81af7470
5. EGR VALVE
Measure the resistance between EGR Motor (KB82) control 1 circuit on the EGR valve and EGR Motor (KB84)
control 2 circuit on the EGR valve.
Measure the resistance between EGR Motor (KB82) control 1 circuit on the EGR valve and EGA Motor (KB8B)
Measure the resistance between EGR Motor (KB84) control 2 circuit on the EGR valve and EGR Motor (KB8B)
Is the resistance between 1.8 and 2.4 Ohms?
Yes »Replace the ECM.
DURE)
No »Replace the EGR valve.
DURE)
9 - 1944 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - - DR
P0404-EGR POSITION SENSOR PERFORMANCE (DIESEL)
I - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -,MODULE.
ENG III E
I ICO.TROl
I
I HOLT EGR EGR EGR SENSOR EGR EGR EGR I
"1·
~UPPl V_ _ CONTR~ N~ _
t
,.t
~ONTR~02 _
, .t
~O~O~O.':'" _
4.t
~OUND _ _ SIGNA~O.2- _
" .t 25.t
~N~N0.2 _
5.t
~GNAL N~3 ~
35.t
K916
F855
18 18
BRIOR
PKIYL
• 1173 • 8044
F855 K682 K684 K6B6 K916 KaRl K685 K687

18 18 18 18 18 18 18 18
PKNL DBfWT DBft'l GVIDB 8RIOR D8/GY DB DBltS
J .1'1
J J J
I' '1
.1
4
J J &SIElaL'·EGR
VALVE
II ~ II II
""I
D C1
PINK
I/.
€j
~
!G
20
I"oooo~ "'00000
II
00000 00000
)0 00000 00000 21
00000
00000
0 00000
00000
31 1 ==== •
50 ~1
==== 8
60
,,, 00000
L...J
A ~
00000
./.J
L...J
51 5
&SSElaLY·
EGR
IODULE·
VALVE
EIGIIE
COITROL C1 (I.ll)
(1.1L)
For a· complete wiring diagram Refer to Section 8W.

DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 • 1945
Theory of Operation
The EGR valve contains three hall effect sensors to detect position. The three position sensors correspond to 6
valid sectors that the valve can be in. If the valve position skips a sector(s)t a fault counter is incriminated, else
decremented. Once the counter equals a calibrated threshold, the rationality fault becomes active. The position sen-
sors are integral to the valve assembly and are not serviced separately. The ECM wilt light the MIL lamp once the
diagnostic runs and fails in two consecutive drive cycles. The ECM will turn off the MIL lamp once the diagnostic
runs and passes in 4 consecutive drive cycles .
• When Monitored:
Key on l engine off & while running .
• Set Condition:
EGR solenoid internal position reading does not fortowexpected values.
Possible Causes
EGR SOLENOID POSITION SENSOR

Diagnostic Test
1. OTHER DTC'S
Ignition on engine off.
With a scan toof, read DTCs.
Do you have any additional EGR related DTC's?
Yes »Repair all other DTC's first
No »Replace EGR valve.
DURE)
P0405-EGR POSITION SENSOR CIRCUIT LOW
r--------------------------------~·~~
EIGIIE
I CONTROL I
, 5 VOL T
36.'
EGR
L:UPPLY _ _ C~TR.£.!:.N~ _
,.,
EGR
"'::ONTR~0.2. _
3 .,
EGR
-':O~OLNO.-=- _
,., I.' ".,
SENSOR EGR
~O~D _ _ SIGNA~O .
"
.!.. _
EGR
~N~<::,: _
!.,
fGR
~GNAlN~3.-J
3S.'
I
F855 K918
18 18
PKlYl BRJOR
• St13 • 1044
F855 K682 K684 K686 K916 K68J K685 K687

18 18 18 18 18 18 18 19
PKIYL DBNH DBIYL GYA)B BR/OR DBIGY D8 D84.B
.1 .1'I
J ""
.1 J .1 J J A..EMIL '·EGR
VALVE
,
III III \ II .
1 I
rr rr
//. ~, P'NK
6
ooooo~
1G IY I
00000 II
"
3D
00000
00000
00000
00000 11
40 00000
00000
0> 00000
00000
31
41
1 ==== 4
50
60 00000 00000 51
5 =c::>c::>= 8
~ \-.
~ '~
LJ LJ
ASSEMILY·
EGR
MODULE·
EIGIIE VALVE
COMTROL C1
(s.u,
II·1LI

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 .. 1947
Theory of Operation
The EGR valve is opened by a motor located on top of the EGR valve. A motor shaft extends from the motor and
contacts the dual-poppet valve to open the EGR valve. The EGR valve motor does not actually retract the EGR
valve. The motor current is reduced and the spring pushed the EGR valve closed. The EGR valve motor contains
three position sensors that detect the location of the EGR valve. These sensors report the position of the valve back
to the ECM over the EGR position A, B, and C wires. The ECM will light the MIL lamp immediately after this diag-
nostic runs and fails. The ECM will tum off the MIL lamp after the diagnostic runs and passes in four consecutive
drive cycles.
• When Monitored:
Ignition on and battery voltage greater than 9 volts .
• Set Condition:
All three EGA valve position sensors are reading either High or Low.
Possible Causes
EGR POSITION SENSOR WIRING SHORTED TO GROUND

EGR POSITION SENSOR WIRING OPEN
EGR POSITION SENSOR WIRING SHORTED TO POWER SUPPLY
EGR VALVE
LOSS OF EGR POSITION SENSOR (F855) 5-VOLT SUPPLY VOLTAGE
LOSS OF EGR POSITION SENSOR (K916) SENSOR GROUND CIRCUIT
ECM
Diagnostic Test
1. OTHER DTC'S
WilD the scan tool I read OTCs.
~ I.,.. • •
Is DTC P0652 present?

Yes »Repair P0652 first.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE .. STANDARD PROCE-
DURE)
No »Go To 2
9 -1948 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
2. OPEN CIRCUIT
Measure the voltage from the EGR (F855) 5-volt supply circuit to the
EGR (K916) return circuit at the EGA valve connector on the engine
harness. PINK
Yes »Go To 3
No »Go To 7 4
ASSEMBLY·
EGR
VALVE
(6.7L) 818f7403
3. DTC P0405 ACTIVE

Reconnect the EGA valve motor harness connector.
With the scan tool read DTCs.
l
Is DTC P0405 Active?

Yes »Go To 4
No »Repair complete. The removal and reinstallation of the connector corrected the failure.
DURE)
DR - - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 1949
4. SIGNAL CIRCUIT OPEN

Measure the resistance between the EGR Motor (K6B3) signal 1 circuit
at the EGR valve harness connector and the EGR Motor (K683) signal
at the EGR valve harness connector and the EGR Motor (K68S) signal
at the EGR valve harness connector and the EGR Motor (K6B7) signal
Yes »Go To 5 10
20 II
No »Repair or replace the engine harness for an open circuit. 30 21

40 31
Perform POWERTRAIN VERIFICATION TEST - 6.7L. 50 41

eo ~1
MODULE.
ENGINE
CONTROLC1
(8.7l) 81at76ac
5. SIGNAL CIRCUIT SHORT TO ANOTHER CIRCUIT

Measure the resistance between the EGR Motor (K6BS) signal 2 circuit
Yes »Go To 6
No » Repair or replace the engine harness for an short circuit.
10
20 II
30 21
40 31
50 41
80 51
MODULE.
ENGINE
CONTROLC1
(8.7L) 81af775d
6. DTC P0405 ACTIVE

Reconnect the EGR valve motor harness connector.
Yes »Replace EGR valve.
DURE)
No »Repair complete. The removal and reinstallation of the connector corrected the failure.
DURE)
7. OPEN CIRCUIT
Measure the resistance between the (F855) 5-volt supply circuit at the
~
PINK
EGR valve harness connector and the (F855) 5-volt supply circuit at the
~
r::::::::I=r::::::::I 4
Measure the resistance between the (K916) sensor ground circuit at the 5 ::':;><:::1<:::1 8
EGR valve harness connector and the (K916) sensor ground circuit at ~
"--c:I--'L.::
the ECM harness connector. F855 ASSEMBLY.
EGR
Yes » Go To 8
No » Repair or replace the open engine harness. 10
20 11
30
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L) 81af7762
CONTROL CIRCUIT SHORT TO ANOTHER CIRCUIT
10
20 11
3() 21
~ 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L) 81af7766
Measure the resistance between the EGR Motor (F855) 5-volt supply circuit at the ECM harness connector and all
other circuits in the connector.
Measure the resistance between the EGR Motor (K916) sensor ground circuit at the ECM harness connector and all
other circuits in the connector.
Yes »Go To 9
No »Repair or replace the shorted engine harness.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE • STANDARD PROCE-
DURE)
9. DTC P0405 ACTIVE

Reconnect the EGR valve motor harness connector.
Yes »Replace ECM.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
DURE)
9 - 1952 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - - DR
P040B-EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR 1 CIRCUIT

PERFORMANCE
r - - - - - - - - - - - iMODULE.
I 1ENGINE
EGR CONTROL
I TEMPERATURE I
I SENSOR SENSOR I
L _SIGNAl _ _ _ _ _ _ ~ROUN~ ...J
41 C1 47 C1
K914
18
BRJWT
K935 • 1045
18
DB
K914
18
8RMT
11 SEUOA·EGR
EGR SENSOR
TEMPERATURE
TEU PERATURE GROUNO
SENSOR
SIGNAL
11 n
/....: ~
lG
00000'" 00000 11
lG 00000 00000
)0
00000 00000 21
40 00000
00000
0 00000
00000
31
41
50
60 00000 00000 ,1
~
.A ~ .// SEIISOR·EGR
~ ~
TEIIPERATURE
,1.7L)
IIODULE·
ENGIIIE
COIITROL C1
(G·JLI
'IIU~tt
For a complete wiring diagram R.fer to Section 8W.
Theory of Operation
The exhaust gas recirculation temperature sensor is a variable resistor sensor and is used to measure the temper-
ature of the EGR gas flow after it exits the EGR cooler. The ECM supplies 5-volts to the exhaust gas recirculation
temperature signal circuit. The ECM monitors the change in voltage caused by changes in the resistance of the
sensor to determine the coolant temperature. The EGR temperature sensor has two rationality tests: Key-on and
Dither. The Key·on test fails if the EGR temperature sensor value is differenfthan the key on temperature estimate
by more than a calibrated threshold. The Dither test fails if the EGR temperature sensor value does not change by
more than a calibrated threshold, over a calibrated period of time. If this fault becomes active the ECM wilt light the
MIL light immediately. During this time the EGR valve will be closed. The ECM turns off the MIL when the diagnostic
• When Monitored:
Ignition on
• Set Condition:
The Key-on test faits if the EGR temperature sensor value is different than the key on temperature estimate by
more than a calibrated threshold. The Dither test fails if the EGR temperature sensor value does not change
by more than a calibrated threshold, over a calibrated period of time.
Possible Causes
EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR

Diagnostic Test
1. P040B ACTIVE
Is P040B active?
Yes »Replace EGR temperature sensor.
DURE)
No »Go To 2
2. EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR

Disconnect the EGR temperature sensor harness connector.
Remove the temperature sensor and reconnect the wiring harness connector to the sensor.
Turn the Ignition on, engine off.
Does the reading from the sensor' increase at least 2.78° C (5° F) on the scan tool?
Yes »Refer to the INTERMITTENT CONDITION· DIESEL Symptom. (Reier to 9 • ENGINE - DIAGNOSIS
AND TESTING)
No »Replace EGR temperature sensor.
PROCEDURE)
P040C-EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR 1 CIRCUIT LOW
r - - - - - - - - - - - -, MODULE.
I IEIGIIE
EGR COITROL
I TEMPERA TURE I
j SENSOR SE~SOR j
L _Sl~l _ _ _ _ _ _ ...!!ROUN~ ...J
41 C1 47 C1
K914
18
BRIWT
K935 • S045
18
DB
K914
18
BRIWT
EGR SENSOR
SEIIISOR·EGR
TEMPERA TURE GROUND TEMPERATURE
SENSOR
SIGNAL
n n
/;: :",\
"'C
10
20
00000 rooooo' 11
00000 00000
JO 00000 00000 21
40 00000 <) 00000 JI
50 00000 00000 41
SO 00000 00000 51
,-,-'- A \0... ...1...1 SEISO"'!GR
'-' '-' TEMPERITURE
(1.7L)
MOIHILE·
EIGINE
CONTROL C1
(1.7L,
It.,O"
Theory of Operation
sensor to determine the coolant temperature. The exhaust gas recirculation temperature value is used by the ECM
for the engine protection system, and engine emissions control. This fault code is set active if the sensor signal
voltage is above or below the normal operating range for the sensor and the ECM has commanded the EGR valve
open. This fault code will not be set active if the ECM has commanded the EGR valve closed. If this fault becomes
active the ECM will light the MIL light immediately. During this time the EGR valve will be closed. The ECM turns off
the MIL when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
When the key is on and battery voltage is above 10.4 volts .
• Set Condition:
The circuit voltage to the ECM is below a calibration threshold for a calibratable period of time.
Possible Causes

(K935) SHORTED SIGNAL CIRCUIT
ECM
Diagnostic Test
1. P040C ACTIVE
Is DTC P040C Active?
Ves »Go To 2
AND TESTING)
2. (K935) EGR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the engine ground and the (K935) EGR temperature sensor signal circuit at the
sensor harness connector.
Yes »Go to 3
No »Repair the harness.
DURE)
9 ·1956 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
3. (K935) EGR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO OTHER CIRCUIT

Measure the resistance between the (K935) EGR temperature sensor
signal circuit and all other circuits at the ECM harness connector.
Yes »Go To 4
41
No »Repair/replace harness.
(Refer to 9 ~ ENGINE - STANDARD PROCEDURE)
10
20 '1
30 21
40 31
50 41
eo 51
MODULE.
ENGINE
CONTROLC1
(6.7L)
81a3dbfd

Disconnect the exhaust gas recirculation temperature sensor harness
connector.
Measure the resistance between the (K935) EGR temperature signal
circuit and the (K914) EGR temperature return circuit of the EGR tem-
perature sensor.
Is the measured resistance between 200 ohms and 2.4M ohms?
Yes » Go to 5
No » Replace the EGR temperature sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. SENSOR-EGR
TEMPERATURE
(Refer to 9 - ENGINE - STANDARD PROCEDURE) (8.7L)
81af9501
5. ECM
Reconnect the exhaust gas recirculation temperature sensor harness connector.
While monitoring with the scan tool, disconnect the EGR temperature sensor harness connector.
Is DTC P040D become active?
AND TESTING)
No »Replace and program the Powertrain Control Module per the Service Information. Refer to 8 - ELEC-
TRICAUELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE for the appropriate
service procedure.
P040D-EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR 1 CIRCUIT HIGH
r - - - - - - - - - - - ..., 10DULE.
I I EIGIIE
EGR CONTROL
I TEMPERATURE I
I SENSOR SENSOR I
L _SI~l _ _ _ _ _ _ ~ROUN~ ...J
41 Ct 47 Cf
K914
16
BRNJT
K935 • S045
18
DB
K914
18
BRIWT
EGR
11
SENSOR IEI'OR·EGR
TEMPERATURE GROUND TEMPERATURE
SENSOR
SIGNAL
I't: " "

10 ='" I
20
00000' 00000 11
00000 00000
H 00000 00000 ~
~ 00000
00000
0 00000
00000
~
50 41
SO 00000 00000 51
A t-..
~ ....... ......
'/ SENSOA-EaR
TEl PERATURE
(l.lL)
IODULE·
EIGIIE
CONTROL C1
(1.7L)
Theory of Operation
sensor to determine the coolant temperature. The exhaust gas recirculation temperature value is used by the ECM
for the engine protection system, and engine emissions control. This fault code is set active if the sensor signal
voltage is above or below the normal operating range for the sensor and the ECM has commanded the EGR valve
open. This fault code will not be set active if the ECM has commanded the EGR valve closed. If this fault becomes
active the ECM will light the MIL light immediately. During this time the EGR valve will be closed. The ECM turns off
the MIL when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
When the key is on and battery voltage is above 10.4 volts .
• Set Condition:
The circuit voltage to the ECM is above a calibration threshold for a calibratable period of time.
Possible Causes

(K935) OPEN SIGNAL CIRCUIT
(K914) OPEN RETURN CIRCUIT
ECM
Diagnostic Test
1. P040D ACTIVE
Is DTC P040D Active?
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION .. DIESEL Symptom. (Refer to 9 .. ENGINE .. DIAGNOSIS
AND TESTING)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 • 1959
2. (K935) OPEN SIGNAL CIRCUIT

NOTE: Check connectors· Clean/repair as necessary. 2
Measure the resistance between the engine harness ECM connector
and the engine harness EGR temperature sensor connector of the
(K935) Signal circuit.
Is the measured resistance less than 10 ohms?
Yes » Go to 3
No » Repair the open (K935) Signal circuit.
8ENSOR~GR
41
Perform POWERTRAIN VERIFICATION TEST - 6.7L. TEMPERATURE
(Refer to 9 - ENGINE - STANDARD PROCEDURE) (e.7LI
10
20 11
30 21
40 31
50 41
eo 51
MODULE·
ENGINE
CONTROLC1
(8.7L) 81a3dbfS
3. (K914) OPEN RETURN CIRCUIT

Measure the resistance between the engine harness ECM connector
and the engine harness EGR temperature sensor connector of the
(K914) Return circuit.
Yes »Go to 4
No »Repair the open (K914) Return circuit.
SEMSOR-EGR
TEMPERAlURE
(ULI
10
20 11
30 21
40 31
50 41
60 51
MODULE-
ENGINE
CONTROLC1
(6.7L) 81a3dbf9
9 -1960 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L D I E S E L - - - - - - - - - DR

Disconnect the exhaust gas recirculation temperature sensor harness
connector.
Measure the resistance between the EGR temperature SIGNAL circuit 2
and the EGR temperature RETURN circuit of the EGR temperature sen-
sor.
Is the measured resistance between 200 ohms and 2.4M ohms?
Yes »Go to 2
No »Replace the EGR temperature sensor.
SENSOR.
EXHAUST
TEMPERATURE
(8.7L)
(COMPONENT SIDE)
81d3cOa7
5. ECM
With the scan tool, erase DTC's.
While monitoring with the scan tool, use a jumper wire and connect the sensor signal circuit to the sensor return
circuit at the sensor connector.
Did the DTC P040C set?
Ves »Test complete.
DURE)
P0420-CATALYST EFFICIENCY BANK 1
Theory of Operation
The aftertreatment diesel oxidation catalyst is designed to react with hydrocarbons in the exhaust stream, this chem-
ical reaction reduces hydrocarbon emission levels and also produces heat. Periodically. the ECM win utilize the heat
generated by this reaction in the aftertreatment diesel oxidation catalyst to actively regenerate and clean the after-
treatment diesel particulate filter. This diagnostic checks that the aftertreatment diesel oxidation catalyst is present
and functioning correctly. The ECM monitors the efficiency of the aftertreatment diesel oxidation catalyst through
interpretation of data received from. the aftertreatment diesel oxidation catalyst jnlet and diesel particulate filter inlet
temperature sensors, the monitor checks for a temperature rise across the aftertreatment diesel oxidation catalyst.
The ECM will set the fault if it detects that the aftertreatment diesel oxidation catalyst is not present in the after-
treatment/exhaust system. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails.
The ECM will turn off the MIL lamp immediately after the diagnostic runs and passes .
• When Monitored:
This diagnostic runs when the engine is running, and performing an active regeneration of the aftertreatment
particulate filter.
• Set Condition:
The ECM will set the fault if it detects that the aftertreatment diesel oxidation catalyst is not present in the
aftertreatmentlexhaust system.
Possible Causes
AFTERTREATMENT DIESEL OXIDATION CATALYST HAS BEEN REMOVED FROM THE VEHICLE
AFTERTREATMENT DIESEL OXIDATION CATALYST IS DAMAGED OR NOT FUNCTIONING PROPERLY
AFTERTREATMENT DIESEL OXIDATION CATALYST INLET AND/OR OUTLET TEMPERATURE SENSORS ARE
DAMAGED/FAILED
IMPROPER FUELING
WIRING HARNESS
Always perform the Pre-Diagnostic- Troubleshooting procedure before proceeding. (Refer to 9 .. ENGINE -
Diagnostic Test
1. OTHER DTC'S
With the scan tool read DTC's.
l
Are any other DTC's Active?

Yes »Repair other DTC's.
DURE)
No »Go To 2
9 ·1962 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
2. EXHAUST LEAK
Perform the no trouble code test *CHECKING THE EXHAUST SYSTEM FOR LEAKS.
Are leaks found?
Yes »Repair or replace as necessary.
DURE)
No »Go To 3
3. AFTERTREATMENT DIESEL OXIDATION CATALYST INLET AND/OR OUTLET TEMPERATURE SENSORS

Remove and inspect the aftertreatment diesel oxidation catalyst and temperature sensors for damage and presence.
Are the components found to be damaged or missing during the inspection of the aftertreatment diesel
oxidation catalyst and temperature sensors?
Yes »Replace or repair damaged component(s).
DURE)
No »Go To 4
4. EXHAUST GAS TEMPERATURE SENSOR #1 AND #2 ARE FUNCTIONAL.

For Manual Transmission Vehicle.
• 1. Run the engine at Idle for at least 10 to 12 minutes with the vehicle in PARK.
• 2. Check that Exhaust temperature sensor #1 and Exhaust temperature sensor #2 are within 1500 F - 200 0 F
of each other.
For Automatic Transmission Vehicle.
• 1. Run the engine at Idle for at least 10 to 12 minutes with the PARKING BRAKE ON.
• 2. Check that Exhaust temperature sensor #1 and Exhaust temperature sensor #2 are within 1500 F - 200 0 F
of each other.
Is Exhaust temperature sensor #1 and Exhaust temperature sensor #2 are within 150 F - 200 F of
0 0
each other?
Yes »Go To 5
No »Replace both exhaust temperature sensors.
DURE)
5. AFTERTREATMENT DIESEL OXIDATION CATALYST IS DAMAGED OR NOT FUNCTIONING PROPERLY

Remove the exhaust plumbing from the turbocharger outlet.
Inspect for signs of oil, coolant or fuel being introduced into the aftertreatment system from the engine or signs of
moisture in the turbocharger exhaust outlet.
Is contamination found in the turbocharger exhaust outlet?
Yes »Identify and repair the source of the contamination within the engine and replace the aftertreatment die-
sel oxidation catalyst after the engine failure has been repaired
DURE)
No »Go To 6
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 ·1963
6. AFTERTREATMENT DIESEL OXIDATION CATALYST

Yes »Replace aftertreatment diesel oxidation catalyst then clear the DTC.
AND TESTING)
9 -1964 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l D I E S E L - - - - - - - - - - DR
P042E-EXHAUST GAS RECIRCULATION CONTROL STUCK OPEN
Theory of Operation
During regeneration of the aftertreatment diesel particulate filter the EGR valve is commanded to be in the closed
position. If the EGR valve is not closed then a temperature rise will occur at the EGR valve orifice. The ECM mon-
itors the orifice temperature of the EGR valve and will set the fault if the temperature is above a calibrated threshold
maximum value. The ECM will illuminate the MIL light immediately after the diagnostic runs and passes in four
• When Monitored:
This diagnostic runs when the vehicle speed is greater than 20 MPH and during a regeneration of the after-
treatment diesel particulate filter.
• Set Condition:
The ECM
Possible Causes
EGR VALVE
Diagnostic Test
1. OTHER DTC'S
Yes »Repair all other DTC's First.
No »Go To 2
2. P042E ACTIVE
Is P042E Active?
Yes »Replace the EGR valve.
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
P0461-FUEL LEVEL SENSOR 1 PERFORMANCE
r - - - - - - - - - - - - - - - - - - 1IODULE.
I I""~
- - - - - - - - -, ELECTRONICS IIiTEGRnED
I I I I POWER
I I I
I FUEl I
I PUMP FUEl I I
I I CONTROL PUMP I
I L _ OUTPU~ ~NTROl_i I
~ __ 1_________ I _____
18 CtO 4 Y Cf
I
K31
Al09
16
1 I 6
II 7
20
BR
I~ Cl30
K31
ORJRO
t
18
8R
I em 2AC2
Al09 IFUEl --, IODULE·

14 PUMP I EIGIIE
ORIRD
I CONTROL CONTROL
4)... 1__ - I
Z927 N4 Z21D
12 18 18
BK DBNH BK
I
• 830a 5 -t
t----t
4 -t CtaS
I
1927 N4 1210
12 20 20
10
BK
Z921
t e135 54
DBIWT
A
'--I
N4
53
BK
Z21Q
AC21.
14 20 20
BK DBIWT BK
7 AC4 7 AC3
r - FUEL- - GROUND 1CLUSTER
I LEVEL I
I SENSOR
• MIT
II AIT
.... t06
1 ~IGNAl _ _ _ _ J
10 1
20 il
30 21
40 31
50 41
60 51
16
MODULE·
IODULE· EIIGIIE
FUEL PUlP COITROL C2 CLUSTER C4
(1·7L1 ........
9 - 1966 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - - DR
Theory of Operation
The fuel level sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, and
arm and a variable resistor track (card). The fuel transfer lift pump is also attached to the fuel pump module. A
constant input voltage source of battery voltage is supplied to the resistor track on the fuel gauge sending unit. This
is fed directly from the ECM. NOTE: For diagnostic purposes, this 12-volt power source can only be verified with the
circuit opened (fuel tank module electrical connector unplugged). With the connectors plugged, output voltages will
vary from about 0.6 volts at FULL, to about 7.0 volts at EMPTY. The resistor track is used to vary the voltage
(resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases
voltage. As fuel level decreases, the float and arm move down which increases voltage. The varied voltage signal
is returned back to the ECM through the sensor return circuit. Both of the electrical circuits between the fuel gauge
sending unit and the ECM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track,
and back to the ECM, the ECM will interpret the resistance (voltage) data and send a message across the multi-
plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading.
When the fuel tank level is measured below 150/0, the following fuel system monitors are shut off: P0191 (Fuel
Pressure Idle Diagnostic portion of it), and DTC's P0300, P0301, P0302, P0303, P0304, P030S, P0306. The ECM
will illuminate the MIL lamp immediately after this diagnostic runs and fails. The ECM will turn off the MIL lamp after
• When Monitored:
• Set Condition:
Fuel level does not change by a calibrated amount over a calibrated amount of time.
Possible Causes
EXTERNAL DAMAGE TO FUEL TANK

FUEL LEVEL SENSOR
INSIDE OF FUEL TANK OBSTRUCTED DAMAGED
Diagnostic Test
1. EXTERNAL DAMAGE TO FUEL TANK

Visually inspect the fuel tank for external damage.
Is the fuel tank damaged from the outside?
Yes »Fix or replace the fuel tank.
DURE)
No »Go To 2
2. FUEL LEVEL SENSOR

Disconnect the wiring harness from the fuel level sensor.
Remove the fuel level sensor from the fuel tank.
Does the fuel level float move freely?
Yes »Go To 3
No »Replace the fuel level sensor.
PROCEDURE)

Measure the resistance between the sensor (N4) signal circuit and (K900) return circuit while moving the sensor
float arm.
Does the resistance level change as you move the sensor arm?
Yes »Go To 4
DURE)
4. INSIDE OF FUEL TANK OBSTRUCTED DAMAGED

Visually inspect the inside of the fuel tank for obstructions.
Is the inside of the fuel tank damaged or obstructing the fuel level sensor?
No »Replace the fuel tank.
Perform POWERTRAIN VERIFICATION TEST - 6.7l). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P0462-FUEL LEVEL SENSOR 1 CIRCUIT LOW
r - - - - - - - - - - - - - - - - - - 1MODILE-
I I TOTALLY
I - - - - - - - - - --, ElECTRONICS INTEGRATED
I I I POWER
I I FUEl I I
I I PUMP FUEL I I
I I CONTROL PUMP I
L~-IT ======= CONTROl~ ____ :
,ar- 4 yet
K31
2D
BR
, 6 ,.l C130
Al09
16
I' 1 t
K31
,t
ORJRO
A109
0111
18
BR
2ACI
IFUEL -, IOOULE·
14 PUMP I ENGINE
ORJRD I CONTROL CONTROL
LA. 1_ _ - I
r - - - , . : - - - - - - - - - - - - - - - - , MODULE.
FUEL
PUI'
IT 2T
Z927 N4 Z210
12 18 18
BK DBNH BK
I
• laOI
I
5 -l
1- ~ ctas
1927 N4 1210
12 20 20
10
1927
t
BK
C135 54
DBNJT
t--
N4
Sl
I'
Z210
8K
l Ct11
14 20 20
BK OBIWT BK
7 AC. 7 A C3
r- FUEL- - GROUND-I CLUSTER
I LEVEL I
I SENSOR
"
, MIT
AIT
"'0101
I ~IGNAL _ _ _ _ J
10 1
,0 11
30 21
40 11
50 41
60 ;1
16
MODULE·
IODULE· EIGIIE
FUEL PUI' CONTROL C2 CLUSTER C4
,1·'lL1 .i ....

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTI,CS t_ 6. 7L' DIESEL 9 • 1969
Theory of Operation
is fed directly from the ECM. NOTE: For diagnostic purposes, this 12-volt power source can' only be verified with
the circuit opened (fuel tank module electrical connector unplUgged). With the connectors plugged, output voltages
will vary from about 0.6 volts at FULL. to about 7.0 volts at EMPTY. The resistor track is used to vary the votJage
sending unit and the ECM are hard-wired (not multi-pJexed). After the voltage signal is sent from the resistor track,
and back to the ECM, the ECM will interpret the resist;amce (voltage) data and send a message across the multi-
When the fuel tank level is measured below 150/0, the following fuel system monitors are shut off: P0191 (Fuel
Pressure Idle Diagnostic portion of it), and DTC's P0300, P0301, P0302, P0303, P0304. P0305, P0306. The ECM
the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
Ignition on and battery voltage above 10.4 volts.
• Set Condition:
The signal voltage from the sensor faUs below a calibrated value for a calibrated amount of time.
Possible Causes
FUEL LEVEL SENSOR

(N4) SIGNAL CIRCUIT OPEN
(N4) SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM
Diagnostic Test
Disconnect the Fuel Level Sensor harness connector.
Measure the resistance of the sensor across the (N4) signal circuit and (K900) return circuit.
Yes »Go To 2
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 * ENGINE - STANDARD
PROCEDURE)
2. (N4) SIGNAL CIRCUIT OPEN

Disconnect the Cluster C4 harness connectors.
Measure the resistance of the (N4) signal circuit between the Cluster
C4 harness connector and the fuel level sensor harness connector.
Yes »Go To 3 3
No »Repair the open (N4) signal circuit.
(Refer to 9 ~ ENGINE· STANDARD PROCEDURE)
7
CLUSTERC4
81a90c6d
3. (N4) SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage between the (N4) signal circuit and battery nega-
tive.
Yes »Repair the (N4) signal circuit shorted to voltage.
No »Go To 4
MODUl!.
FUEL PUMP
81416e84
4. ECM
While monitoring with the scan tool, connect a jumper wire between the
(N4) signal circuit in the sensor harness connector and battery negative.
Did the OTC P0463 set?
~,
N4
MODULE-
FUELPU'"
81416ea4
9 • 1972 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
P0463-FUEL LEVEL SENSOR 1 CIRCUIT HIGH
r - - - - - - - - - - - - - - - - - - IIODULE.
I 1- - - - - - - - - - - - - --, ELECTRONICS I ~NOTTE~~:TED

I I POWER
I
I I
1 FUEL I 1
I PUMP FUEL I 1
I 1 CONTROL PUMP 1
_OUTPU~ ~NTROL_I
I
I L _______ 1
~ __ ] _________I ___ __ I
lS C10 4 Y C1
K3l
20
BR
, 8 ~ C130
Al09 " 7 I'
16 K31
ORiRO
Al09
t cns
18
BR
2 )..C2
IFUEL --, MODULE·
14 PUMP I ENGINE
ORiRD
I CONTROL CONTROL
LA 1 __ - I
Z927 N4 Z210
12 lS 18
BK DBMIT 8K
I
• S308 5 A
t-------t
4 A CU5
I
Z927 N4 Z210
12 20 20
10 t
BK
Z927
C135 54
DBMIT
t- - _5~
N4 mo
8K
C219
14 20 20
BK DBMIT BK
7 )..C4 7 )..C3
r- ruEL- - GROUND-I CLUSTER
1 LEVEL I
1 SENSOR
.a. G106
"
, MIT
AIT
I~I~L _ _ _ _ J
10 1
GRAY 20 II
El
30 21
40 11
~O 41
00 51
IODULE·
MODULE· ENGINE
FUEL PUlP CONTROL C2 CLUSTER C4
(S.lLl
Ihllell

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 ·1973
Theory of Operation
is fed directly from the ECM. NOTE: For diagnostic purposes, this 12-volt power source can only be verified with the
circuit opened (fuel tank module electrical connector unplugged). With the connectors plugged, output voltages will
vary from about 0.6 volts at FULL, to about 7.0 volts at EMPTY. The resistor track is used to vary the voltage
sending unit and the ECM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track,
and back to the ECM, the ECM will interpret the resistance (voltage) data and send a message across the multi-
When the fuel tank level is measured below 15%, the following fuel system monitors are shut off: P0191 (Fuel
Pressure Idle Diagnostic portion of it), and DTC's P0300, P0301, P0302, P0303, P0304, P030S, P0306. The ECM
• When Monitored:
Ignition on and battery voltage above 10.4 volts .
• Set Condition:
The Signal voltage from the sensor goes above a calibrated value for a calibrated amount of time.
Possible Causes
FUEL LEVEL SENSOR

(N4) SIGNAL CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test

Disconnect the Fuel level sensor harness connector.
Measure the resistance of the Fuel level sensor across the (N4) signal circuit and (K900) return circuit.
Ves »Go To 2
No »Replace the Fuel level sensor.
DURE)
2. (N4) SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the (N4) signal circuit in the sensor
Yes »Repair the (N4) signal circuit shorted to ground.
No »Go To 3
MODULE!-
FUE!LPUMP
81418bf4
3. ECM
While monitoring with the scan tool, disconnect the Fuel level sensor harness connector.
Perform POWERTRAIN VERIFICATION TEST - 6.71. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSIICS - 6.7L DIESEL 9 - 1975
P0471-EXHAUST PRESSURE SENSOR 1 PERFORMANCE
. - - - - - - - - - - - - - . I04t
I
F855
18
PKNL
11 SENSOR·
EIHAUST
I
2T
f
. . .lr-. . .-_-_-_-_-_..._-_._.. ""--'
I
PRESSURE 1/1
K9t6
18
BR/OR
I
.SD42
I
F8S5 K9!6
18 18
PKNl BR/OR
I
• 103
I
• 10....
I I
F85S K355 K9!6
18 18 18
PKNl BRiVG 8RIOR
36 ot 5D Ct 48 C1
r "5 VOlT - - - - - -EXHAUST - - SENSOR - , MODULE·
I SUPPLY PRESSURE GROUND EIIIG.IIIE
I I SENSOR COIIITROL
I_ _ _ _ _ _ _ _ _SIGNAL
_ _ _ _ _ _ .Jr
1
11
11
31
Al
51
SENSOR·
MODULE· EIHAUST
EIIIGIIIIE PRESSUAE 1/1
CONTROL et II.lL)
IS.n)

9 -1976 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The exhaust gas pressure sensor is used to measure exhaust gas pressure in the exhaust manifold. The Electronic
Control Module (ECM) provides a 5-volt supply to the exhaust gas pressure sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The exhaust gas pressure sensor provides a signal to the
ECM on the exhaust gas pressure sensor signal circuit. This sensor signal voltage changes based on the pressure
in the exhaust manifold. There are two parts to this fault code, a key on check and a rationality check. At key ON,
the readings for the exhaust gas pressure, intake manifold pressure and ambient air pressure are compared. This
fault code occurs if the exhaust gas pressure reading is different from the other two. This diagnostic is run 5 sec-
onds after key on. During normal engine operation EGR position and Boost Pressure sensor readings are used to
calculate an estimated exhaust pressure. If the difference between the value read from the exhaust pressure sensor
and the estimated is above a calibrated threshold for a calibrated period of time then an error is recorded. The
key-on portion of the rationality will light the MIL immediately after the diagnostic runs and fails. The rationality por-
tion has to fail in two consecutive drive cycles for the MIL to become illuminated. If this fault becomes active the
ECM will light the MIL light immediately. During this time the ECM uses an estimated exhaust gas pressure. The
ECM turns off the MIL when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
5 seconds after key on .
• Set Condition:
The exhaust gas pressure sensor reading at key on differs by a calibratable amount of pressure from the
barometric pressure sensor and boost pressure sensor or the exhaust gas pressure sensor reading varies from
an estimated value during normal engine operation.
Possible Causes
EXHAUST GAS PRESSURE SENSOR

1. EXHAUST GAS PRESSURE SENSOR TUBE

Remove the steel tube from the exhaust manifold to the exhaust pressure sensor port.
Is the tube free from debris?
Yes »Go To 2
No »Clean the tube and reinstall.
DURE)
2. AIR INLET/CHARGE AIR/EXHAUST GAS RECIRCULATION LEAKS

Check vehicle/engine for leaks of inlet air (air filter to turbocharger), Charge Air (Turbocharger to intake manifold), or
EGR gasses (exhaust manifold to intake manifold)
Were there any leaks detected?
Ves »Repair leak condition.
DURE)
No »Go To 3
DR - - - - - - - - - - ENGINE -. ELECTRICAL DIAGNOSTICS - 6.7L -DIESEL '9 ·'1977
3. THERMOSTAT OUTLET
Remove the exhaust gas pressure sensor from the thermostat outlet.
Is the outlet free of debris?
Yes »Go To 4
No »Remove debris from outlet
Go To 4
4. EXHAUST GAS PRESSURE SENSOR

Turn ignition switch on.
Wait 5 seconds after ignition switch is turned ON
With the scan tool, read,DTC's.
Is P0471 stored?
Yes »Go To 5
No »Replace the exhaust gas pressure sensor.
DURE)
5. EXHAUST GAS PRESSURE SENSOR

With the scan tool, erase DTC's.
Start the engine and let it idle for 1 minute.
With the scan tool, monitor the exhaust gas pressure reading.
Does the value fluctuate slightly, indicating the sensor is not stuck?
Yes »Repair complete.
DURE)
No »Replace the exhaust gas pressure sensor.
DURE)
P0472- EXHAUST PRESSURE SENSOR 1 LOW
. - - - - - - - - - - - - - . SU1
I
F855
18
PKNl
11 SENSOR·
I1
,- "- -_-_-_-_-_._-_-_'
1...-01
21
I
. .-. . .I
EIHIUIT
PRESSURE 1/t
K916
18
BR/oR
I
.1042
I
F855 KS16
18 18
PKNL BRJOR
I
• It73
I
• 1044
I I
F855 K355 K916
18 i8 18
PKIYL BRIUG BR/OR
36 Ct 50 Ct 48 Ct
r- 5 VOLT - - - - - -EXHAuST - - SENSOR 'loDULE.
I SUPPLY PRESSURE GROUND I EUIIE
I SENSOR CONTROL
_________SIGNAL
______ .JI
I
rl -"
10 00000 00000 I
20 00000 00000 II
30 00000 00000 21
40 00000 0 00000
00000
31
!~
00000
00000 00000 ~i
~
~ ~
SEUoA·
lIoDULE· EIHlUST
EIUUIE PREIIURE tit
CONTROL Ct (l.lL)
II.lL)
.1.nII..

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 -1979
-rheory of Operation
The exhaust gas pressure sensor is used to measure exhaust gas pressure in the exhaust manifold. This informa-
tion is used by the ECM to control emissions and EGR valve operation. The Electronic Control Module (ECM) pro-
vides a S-volt supply to the exhaust gas pressure sensor on the sensor supply circuit. The ECM also provides a
ground on the sensor return circuit. The exhaust gas pressure sensor provides a signal to the ECM on the exhaust
gas pressure sensor signal circuit. This sensor signal voltage changes based on the pressure in the exhaust man-
ifold If this fault becomes active the ECM will light the MIL light immediately. During this time the ECM uses an
estimated exhaust gas pressure. An engine power derate may be experienced. The ECM turns off the MIL when the
• When Monitored:
Ignition on, engine not running .
• Set Condition:
Possible Causes
OTHER DTC'S
EXHAUST PRESSURE SENSOR
EXHAUST PRESSURE SENSOR (K355) SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND
CIRCUIT
EXHAUST PRESSURE SENSOR (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO THE (K916) SENSOR
GROUND
ECM
Diagnostic Test
1. OTHER DTC'S
Are there any S...volt supply DTCts ?
No »Go To 2
2. P0472 ACTIVE
Is DTC P0472 active?
Yes »Go To 3
AND TESTING)
Disconnect the Exhaust pressure sensor 1/1 harness connector.
Turn the ignition on. 2
Measure the voltage from the Exhaust pressure sensor 1/1 (F855)
5-vott supply circuit to the Exhaust pressure sensor 1/1 (K916) sensor
return circuit at the sensor harness connector.
Yes »Go To 4 3
No »Go To 6
SI!NSOR·
EXHAUST
PRESSURE 1/1
(Ul)
81af951b
4. EXHAUST PRESSURE SENSOR

While monitoring scan tool, use a jumper wire to connect the (F855)
5-volt supply circuit with the (K355) signal circuit at the sensor harness
connector.
Does the scan tool show a P0473 DTC? 3
Yes »Replace the Exhaust pressure sensor

No »Go To 5
SENSOR·
EXHAUST
PRESSURE 111
(B.7l)
81af9540
5. EXHAUST PRESSURE SENSOR (K355) SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND
CIRCUIT
Measure the resistance between the (K355) signal circuit and (K91B) 3 2
sensor ground circuit in the Exhaust pressure sensor harness connec-
tor.
Is the resistance greater than 100 k Ohms?
Ves »Go To B
No »Repair or replace the shorted wiring harness.
Perform POWERTRAIN VERIFICATION TEST - B.7L
(Refer to 9 - ENGINE - STANDARD PROCEDURE) SINSOR.
EXHAUST
PRESSURE 111
..., (1l7L) ...,
/' ""'I ~
10
00000 f"ooooo.....
20 11
00000 00000
30 00000 00000 21
40 00000
00000
0> 00000
00000
31
50 ~1
60 00000 00000 !>1
\..'
..1,
"- '..I.,;
u w
MODULE·
ENGINE
CONTROLC1
(8.7L) 81af9544
6. EXHAUST PRESSURE SENSOR (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO THE (K916) SENSOR
GROUND
(K91B) sensor ground circuit in the Exhaust pressure sensor harness
connector.
2
Ves »Go To 7
No »Perform POWERTRAIN VERIFICATION TEST - 6.7L
3
SINSOR.
EXHAUST
PRESSURE 111
(UL)
81af9548
9 - 1982 ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR

Measure the resistance between the (K355) signal circuit in the Exhaust
Pressure sensor harness connector and the (K355) signal circuit in the
Ves »Go To 8
No »Repair or replace the open wiring harness.
10
20 11
3Q 21
40 31
50 ~1
eo 51
MODULE·
ENGINE
CONlROLC1
(S.7L) 81at954c

Exhaust Pressure sensor harness connector with the (F855) 5-volt sup-
ply circuit in the ECM harness connector.
Ves »Go To 9
10
2JJ l'
3Q 21
40 31
50 ~1
60 51
MODULE.
ENGIN!
CONTROLC1
(6.TL) 81af9550
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 .. 1983

Measure the resistance between the (K355) signal circuit in the Exhaust
pressure sensor connector and battery negative.
Yes »Go To 10
No »Repair or replace the shorted to ground wiring harness.
8I!NIOR.
EXHAUST
PRESSURE 111
(1.7L)
BATTERY-
NEGAnve
(DIESEL LEfT BATT1!RY)
81af9554
10. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Exhaust pressure sensor connector and battery negative.
Ves »Go To 11
8I!HSOR-
EXHAUST
PRESSURE 1/1
(&.7L)
BAlTERV-
NEGAnVE
81af9558
9 ·1984 ENGINE .. ELECTRICAL DIAGNOSTICS" 6.7L DIESEL - - - - - - - - - DR
11. ECM
While monitoring scan tool, use a jumper wire to connect the (F855)
5-volt supply circuit with the (K355) signal circuit at the sensor harness
connector.
Does the scan tool show a P0473 DTC? 3
Yes »Refer to the INTERMITTENT CONDITION - DIESELSymp-

SINSOR-
EXHAUST
PRESSURE 111
(UL)
81af955c
P0473- EXHAUST PRESSURE SENSOR 1 HIGH
. - - - - - - - - - - - - - . I.ott
-I
F8SS
18
PKIYl
,1
.~ 8E110R·
EIHAUIT
'REISURE tit
1
K916
18
BR/oR
I
.e042
I
F855 K916
18 18
PKIYL BRIOR
I
.lnJ
I
• S044
I I
F855 K355 K916
18 18 18
PJ(IYL BRI1)G BRIOR
36 Ct 50 C1 48 C1
r -; VOLT - - - - - -EXHAUST - - SENSOR I MOIULE·
I SUPPL Y PRESSURE GROUND I EIIIIIIE
I SENSOR CONTROL
I_ _ _ _ _ _ _ _ _SIGNAL
_ _ _ _ _ _ ..1I
,..., ,.....
10 loooO~ ~ooo~ I
20 00000 00000 II
30 00000 00000 21
40 00000
00000
0 00000
00000
31
i~ 00000 00000 ~l
...... '-"
lEN lOR·
MODULE· EI"AUST
E... INE PRESSURE tIt
COITROL C1 (1.1L)
.1.lL)
l'IJillII

Theory of Operation
The exhaust gas pressure sensor is used to measure exhaust gas pressure in the exhaust manifold. This informa-
tion is used by the ECM to control emissions and EGR valve operation. The Electronic Control Module (ECM) pro-
vides a 5-volt supply to the exhaust gas pressure sensor on the sensor supply circuit. The ECM also provides a
ground on the sensor return circuit. The exhaust gas pressure sensor provides a signal to the ECM on the exhaust
gas pressure sensor signal circuit. This sensor signal voltage changes based on the pressure in the exhaust man-
ifold If this fault becomes active the ECM will light the MIL light immediately. During this time the ECM uses an
estimated exhaust gas pressure. An engine power derate may be experienced. The ECM turns off the MIL when the
• When Monitored:
Key on
• Set Condition:
The circuit voltage to the ECM is above a calibrated threshold for a certain period of time
Possible Causes
OTHER DTCS
(K355) SIGNAL WIRE SHORTED TO (F855) 5-VOLT SUPPLY
(F855) 5 VOLT SUPPLY SHORTED TO HIGH VOLTAGE
(K355) SIGNAL CIRCUIT TO (F855) 5-VOLT SUPPLY
ECM
Diagnostic Test
1. OTHER DTC'S
Are there any 5-volt supply DTC's ?
No »Go To 2
2. P0473 ACTIVE
Yes »Go To 3
AND TESTING)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 -1987
3. (F855) 5-VOLT SUPPLY

Disconnect the Exhaust pressure sensor 1/1 harness connector.
Measure the voltage between the (F855) 5-volt supply circuit and 2
(K916) return circuit of the exhaust pressure sensor harness connector.
Yes »Go To 4
No »Go To 5
SINSOR.
EXHAUST
PRESlUR&111
(1.7L)
81af951b

While monitoring the scan tool, use a jumper wire to connect the (K916)
return circuit to the (K355) signal circuit at the Exhaust Pressure sensor
harness connector.
Does the scan tool show a P0472-Exhaust Pressure sensor low 3 2
OTe?
Yes »Replace the Exhaust Pressure Sensor.
(Refer to 9 ~ ENGINE ~ STANDARD PROCEDURE)
No » Go To 5
UNBOR.
EXHAUST
PAESSURE111
(1.71)
81af9567
9 - 1988 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL - - - - - - - - - - DR
5. (K355) SIGNAL WIRE SHORTED VOLTAGE

Measure the voltage between the (K355) signal circuit of the Exhaust
Pressure sensor connector and battery negative.
Ves »Go To 6
Periorm POWERTRAIN VERIFICATION TEST - 6.7L. SENSOR·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) EXHAUST
PRESSURE 111
(B.7L)
BATTERY.
NEGAlWE
(DIESEL LEFT BATTERY) 81af956b
6. (F855) 5 VOLT SUPPLY SHORTED TO HIGH VOLTAGE

Measure the voltage between the (F855) 5 volt supply circuit of the sen-
sor connector and battery negative.
Ves »Go To 7
SENSOR.
EXHAUST
PRESSURE 111
(s.7L)
BATTERY·
NEGATIVE
(DII!SI!L LI!FT BATTERY)
B1af956f
DR - - - - - - - - - ENGINE . . ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 .. 1989
7. SIGNAL CIRCUIT TO (F855) 5...VOLT SUPPLY

Measure the resistance between the (K355) signal circuit and the
(F855) 5-volt supply circuit of the Exhaust Pressure sensor harness
connector.
Ves »Go To 8
Perform POWERTRAIN VERIFICATION TEST 6.7L.
SI!.NSOR.
EXHAUST
PRESSURE 1M
(UL)
81af9573

Measure the resistance between the (K916) return circuit in the Exhaust
Pressure sensor harness connector with the (K916) return circuit in the
Yes »Go To 9
SENSOR.
EXHAUST
10
20
311
"
21
40 3'
50 41
eo ~1
MODULE·
ENGINE
CONTROLC1
(UL) 81af9577
9 ·1990 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
9. ECM
While monitoring scan tool use a jumper wire to connect the (K916)
l
return circuit with the (K355) signal circuit at the Exhaust Pressure sen- 3 2
sor harness connector.
Does the scan tool show a P0472 Exhaust Pressure sensor low
DTC?
Ves »Refer to the INTERMITTENT CONDITION - DIESEL Symp-
Periorm POWERTAAIN VERIFICATION TEST - 6.7L.
SI!NSOR·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) EXH.AUaT
PAEnURE1J1
(UL)
818f9567
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS ·'6.7L DIESEL 9 - 1991
P0480-COOLING FAN 1 CONTROL CIRCUIT/OPEN
r - - - - - - - - - - - - - - - - - .., IODULE·
FAN FAN 1111111'
I SPEED SPEED I COIITROL
I SENSO R SENSOR SENSO R SENSOR 5 VOL T
L GROUND _ _ GROU~ _ _ S~A':- _ _ ~ROUND_ _s~l!...1
V
22"'C' 48' Ct 18 '''Ct 7 Ci 3S Ct
K971 K916 F855

18 18 18
BRJPK BRIOR PKlYl
• sua • S044 • 8173
K971 K916 N27 K1S1 FOSS

18 18 18 18 18
BRIPK BRIOR DB/GV BRiB flKlYl
1, 2 ," 5"
SENSOR SENSOR FAN FAN 5 VOLT
DRIWE.,AII·
GROUND GROUND SPEED SPEED SUPPLY RADIATOR
SENSOR SENSOR
SIGNAL GROUND
~D'GRAY
10 ~ 16000';- 1
20 00000 00000 II
30 ggggg 0 ggggg 21
4G
sa
6a
~
00000
00000
LJ
\;..
00000
00000
LJ
./
31
41
SI
(E}) :
DRIVE·FAN·
IODULE· RADIATOR
EIIGIIIE (DIESEL)
COIITROL Cf
(a.'lL)

Theory of Operation
The cooling fan is a hydro-electric controlled device that is engine mounted. The ECM monitors various sensors to
control fan speed. The cooling fan provides temperature control for engine coolant engine charged air AlC Freon
l l
and automatic transmission fluid. Fan speed increases as cooling requirements increase. Since the fan is mounted
to the engine, fan speed is related to engine speed (RPM). The PCM sends a Pulse Width Modulated (PWM) signal
to the cooling fan hub. Asthe PWM signal increases the fan hub which allows more fluid to drive the fan. When the
fan is fully engaged it is capable of speeds about 10% greater than engine speed. The fan will rotate anytime the
engine is running, even when the ECU is not send a PWM signal.
• When Monitored:
• Set Condition:
When the control coB is electrically shorted or open.
Possible Causes
FAN CLUTCH
WIRE HARNESS DAMAGED
OPEN FAN CLUTCH DRIVER CIRCUIT
FAN CLUTCH DRIVER CIRCUIT SHORTED TO RETURN CIRCUIT
FAN CLUTCH DRIVER CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
Diagnostic Test
1. FAN CLUTCH
Disconnect the fan clutch harness connector.
Measure the resistance between the Fan Clutch Driver circuit and the
fan speed sensor return circuit on the fan clutch assembly.
Yes »Replace the fan clutch.
No » Go To 2 3
DRIVE~FAN
RADIATOR
(DIESEL)
81af95a3
DR - - - - - - - - - ENGINE - ELECTRICAL -DIAGNOSTICS· 6.7L DIESEL 9 - 1993
2. FAN CLUTCH
Disconnect the Fan Clutch harness connectors;
fan clutch battery supply circuit on the fan clutch assembly.
[] 6
Is the resistance less than 6 ohms or greater than 10 ohms?
Yes »Replace the fan clutch.
Perform POWERTRAIN VERIFICATION TEST -- B.7L.
No » Go To 3 3
DRIVE-FAN-
RADIATOR
(DIESEL)
81af95a7
3 . FAN CLUTCH DRIVER CIRCUIT OPEN

Measure the resistance of the fan clutch Fan Clutch Driver circuit between the EcM harness connector and the Fan
Clutch harness connector.
Is the' resistance less than 10 ohms?
Ves »Go To 4
No »Repair the :open fan clutch river circuit.
DURE) .
4. FAN CLUTCH DRIVER CIRCUIT SHORTED TO RETURN CIRCUIT

fan speed sensor return circuit at the sensor harness connector.
Is the resistance greater than 100K ohms?
Yes »Go To 5
No »Repair the Fan Clutch Driver circuit shorted to Return cir-
cuit.
3
DRiVE-FAN-
RADIATOR
(DIESEL)
81af95a3
9 - 1994 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL - - - - - - - - - DR
5. DRIVER CIRCUIT SHORTED TO BATTERY NEGATIVE

Measure the resistance between the fan clutch Fan Clutch Driver circuit
and the battery negative.
Yes »Go To 6
No »Repair the Fan Clutch Driver circuit shorted to battery neg-
ative.
~ DKGRAV
DRrvE·FAN·
BAmRY- RADIATOR
AUXILIARY· (DIESEL)
NEClATl\IE
(DIEIlEl.I 81af95b3
6. ECM
Measure the resistance of the Fan Clutch Driver circuit between the fan
clutch connector and battery negative.
Is the resistance greater than lOOk Ohms?
NOSIS AND TESTING) 3
No » replace the ECM. e 4
Perform POWERTRAIN VERIFICATION TEST - 6.7L. DRIVE-FAN·

(Refer to 9 - ENGINE - STANDARD PROCEDURE) RADIATOR
~y1
BATTERY·
HEGA1IVE
(01ESe.. LEFT BATTERY) 81af95b7
P0483-COOLING FAN SPEED
I - - - - - - - - - - - - - - - - - .., MODtlLE·
FAN FAN I Ela.IE
I SPEED SPEED I
CONTROL
I SENSOR SENSOR SENSOR SENSOR 5 VOL T
L GROUND _ _ G~U~ _ _ S~Al_ _ _ ..£ROUNO_ _s~l~1
22 '" C1 48 C1 18' Ct 7 v Ct 36 '" C1
K971 K916 F855

18 18 18
8RJ1lK BRJOR PKNl
• 1043
•••• • 1178
K971 K916 N27 K161 FB55

18 18 18 18 18
BRIPK BRJOR DBIGY BRA.B PKlYl
I ,,' 3 ... 6" SA

SENSOR SENSOR FAN FAN 5VOlT
DRIIE..II·
GROUND GROUND SPEED SPEED SUPPl Y UDIITOR
SENSOR SENSOR
SIGNAl GROUND
m
i""""\ 1""""1
DKGRAY
10 7Q~0~ 00000 1
20 00000 00000 11
30 00000 00000 21
40 00000 0 00000 31 r~
50 00000 00000 41
60 oooo~
~
00000
.J
51
~
u -.::::r
DRIVE·"N·
MODULE· RADIATOI
Ela.IE (DIESEL)
COITROL C1
(I.'IL)
It'-'.

9 -1996 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - - DR
Theory of Operation
The cooling fan is a hydro-electric controlled device that is engine mounted. The ECM monitors various sensors to
control fan speed. The cooling fan provides temperature control for engine coolant, engine charged air, AlC Freon
and automatic transmission fluid. Fan speed increases as cooling requirements increase. Since the fan is mounted
to the engine. fan speed is related to engine speed (RPM). The ECM sends a Pulse Width Modulated (PWM) signal
to the cooling fan hub. As the PWM signal increases the fan hub which allows more fluid to drive the fan. When the
fan is fully engaged it is capable of speeds about 10% greater than engine speed. The fan will rotate anytime the
engine is running, even when the ECU is not send a PWM signal.
• When Monitored:
• Set Condition:
The actual fan speed is less than 50 RPM or more than 6000 RPM.
Possible Causes
OTHER DTC'S
(N27) SIGNAL CIRCUIT SHORT TO (K85S) 5-VOLT SUPPLY CIRCUIT
(N27) SIGNAL CIRCUIT OPEN FROM ECM TO FAN CLUTCH ASSEMBLY
(K85S) S-VOLT SUPPLY CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO FAN CLUTCH HARNESS
CONNECTOR
(N27) SIGNAL CIRCUIT SHORTED TO (K161) RETURN IN THE HARNESS
(N27) SIGNAL CIRCUIT SHORTED TO VOLTAGE
(N27) SIGNAL CIRCUIT IN ECM SHORTED TO GROUND INSIDE ECM
(N27) SIGNAL CIRCUIT SHORTED TO VOLTAGE IN THE ECM
(K855) 5-VOLT SUPPLY CIRCUIT IN ECM
Diagnostic Test
1 . OTHER DTC'S PRESENT

Is DTC P0480 present?
DURE)
No »Go To 2
2. FAN CLUTCH SHORTED

Disconnect the wiring harness from the fan clutch assembly.
Measure the resistance between the (N27) signal circuit in the fan clutch assembly and the (K161) return circuit in
the fan clutch assembly.
Yes »Replace the fan clutch assembly.
DURE)
No »Go To 3
3. FAN CLUTCH ASSEMBLY SHORTED TO GROUND

Measure the resistance between the (N27) signal circuit in the fan clutch assembly and battery negative.
Yes »Replace the fan clutch assembly.
Perform POWERTRAIN VERIFICATION TEST 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 4
4. (N27) SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT

Disconnect the Fan clutch connector.
Measure the resistance between the (N27) signal circuit in the fan
clutch assembly and the battery 5-volt supply circuit in the fan clutch
5
assembly.
Yes »Replace the Fan clutch assembly.
3
No » Go To 5
DRIVE-FAN-
RADIATOR
(DIESEL)
81b48789
5. (N27) SIGNAL CIRCUIT OPEN FROM ECM TO FAN CLUTCH ASSEMBLY

Measure the resistance of the (N27) Signal circuit between the ECM 3
harness connector and the fan clutch assembly harness connector.

Yes »Go To 6
No »Repair the open circuit from the ECM harness connector to 3 18
the Fan clutch harness connector.
6 4
(Refer to 9 - ENGINE - STANDARD PROCEDURE) DRlVE-FAN-
10
20 11
30 71
40 31
50 41
00 Sl
MODULE-
ENGINE
CONTROLC1
(6.7L)
B1b48790
9 -1998 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L D I E S E l - - - - - - - - - DR
6. (K855) 5-VOLT SUPPLY CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO FAN CLUTCH HARNESS
Measure the resistance of the (K8SS) 5-volt supply circuit between the
ECM harness connector and the fan clutch assembly harness connec-
tor. 3

Yes »Go To 7 DKGRAY
No »Repair the open (K85S) 5-volt circuit from ECM harness

connector to Fan clutch connector.
18
Perform POWERTRAIN VERIFICATION TEST - 6.7l).
MODUI..E-
ENGINE
CONTROLC1
(6.1L)
81b48790
7. (N27) SIGNAL CIRCUIT SHORTED TO RETURN IN THE HARNESS

clutch assembly harness connector and the return circuit in the fan
clutch assembly harness connector.
Yes »Repair the shorted (K161) circuit.
No »Go To 8
3
DRIVE-FAN-
RADIATOR
(DIESEL)
81b48798
8. (N27) SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage between the signal circuit in the fan clutch assem-
bly harness connector and battery negative.
§ID
Yes »Repair the (N27) signal circuit shorted to voltage. ~3~@]
~
DKGRAY
No »Go To 9 3 00
C::lI:) 0
4
DRIVE-FAN·
RADIATOR
(DIESEL)
IlATTliRY·
AUXlUAJIY-
NI!GAT1V!
(DIESEL)
81b487a2
9. (N27) SIGNAL CIRCUIT IN ECM SHORTED TO GROUND INSIDE ECM

clutch assembly harness connector and battery negative_
No »Go To 10
DRIVE-FAN·
RADIATOR
(DIESEL)
IlATTVlY-
AUXIL.IAAY-
NI!GAT1V!
(DII!!SEl..)
81b487a2
9 - 2000 ENGINE· ELECTRICAL -DJAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
10. (N27) SIGNAL CIRCUIT SHORTED TO VOLTAGE IN THE ECM

Reconnect the fan harness connector.
Tum the ignition on.
While back probing the fan connector measure the voltage between the
fan speed (N27) signal circuit in the fan clutch assembly harness con-
nector and battery negative while manually rotating the !an blade.
Did voltage go from less than 0.7 volts to 4.S to 5.5 volts?
Yes »Repair the Fan Speed Signal circuit in the engine harness. 3
(Refe"r to 9 - ENGINE - STANDARD PROCEDURE) 3
DRIVE-FAN·
No » Go To 11
RADIATOR
(DIESEL)
81b487ae
11. (K8SS) 5-VOLT SUPPLY CIRCUIT IN ECM

Measure the voltage between the (K8SS) 5-volt supply circuit in the fan
clutch assembly harness connector and battery negative.
Ves »Refer to the INTERMITTENT CONDITION - DIESEL Diag-
nostic Procedure). (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) 3
No » Replace the ECM. 6 4

DRIVE-FAN-
RADIATOR
(DIESEL)
IlAT1WKY·
AUXLIAIIY.
NEQATlVI!
(DIEII!L,
81b487b2
DR - - - - - - - - - ENGINE .' ELECTRICAl-DIAGNOSTICS • 6.7L DIESEL 9 • 2001
P0487-EGR AIRFLOW THROTTLE CONTROL CIRCUIT A OPEN
----RELAy·
I 1•• ARl
I 1'0.11
I SMART I'
POWER
I RELAY I
l_ ~D_ J
.'Y
F348
16 r- - - - - - - - - - - - - MODULI·
PKIOR I I EIIIIIIE
I
42 1
F!8
Cf. I
-
TTVA
M~0'!.tl __
TTVA
~0!it)_ _ ~O~ _ _ J
SENSOR I
ICOIITIOL
16 21 Ct 13 C1 22 TCt
PK/OR
10 t C111
K91t
18
BRIPK
f34&
16
PKIOR I
.1043
I
KI5S K314 K971
1ft 18 18
BRlYl BR BRIPK
11 21 .1 TIIOTTLE
SMART TTVA TTVA SENSOR
POWER MOTOR(-) MOTOR(+) GROUND 10lY
RELAY
FEED
1D ,
2D 11
3D 21
40 31
i~ ~l
.0IULE· II LAY·
THROTTLE E..... "IRT
10lY CO.TROL C1 PO.IR
CI.nIIRIL) II.ILI (1.'lL IIESEL) It . . . .

Theory of Operation
The EGR Airllow Throttle is a smart device that is commanded by the ECM through a PWM signal. This is a com-
pletely modulated device. When feedback does not match commanded for more than 2 seconds this algorithm fails.
The ECM will light the MIL lamp immediately after this diagnostic runs and fails. During this time the EGR Airllow
Throttle is disabled and goes to the fully open position (if possible). Active Aftertreatment regenerations make take
longer jf this condition exists. The ECM will turn off the MIL lamp after the diagnostic runs and passes in 4 con-
secutive drive cycles .
• When Monitored:
Ignition on
• Set Condition:
Status line feedback voltage is outside of a calibratable range
Possible Causes
OPEN OR SHORTED AIRFLOW CONTROL VALVE (K1S8) TTVA MOTOR (-) CIRCUIT
AIR THROTILE
ECM
Diagnostic Test
1. DTC P0487 ACTIVE

Yes »Go To 2
No »Refer to the INTERMITIENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
2. OPEN AIRFLOW CONTROL VALVE TTVA MOTOR (-) CIRCUIT

Disconnect the EGR Airflow control valve harness connector.
[]
Measure the resistance of the (K158) TTVA motor (-) ci rcuit from the
EGR Airflow control valve harness connector to the ECM harness con-
nector.
Yes » Go To 3 4
No » Repair/replace open circuit in the engine harness.

10
20 11
30 21
-40 31
50 41
60 S1
MODULE.
ENGINE
CONTROLCt
(1.7L)
81a19602
3. SHORTED AIRFLOW CONTROL VALVE (K158) TTVA MOTOR (-) CIRCUIT

Measure the resistance between the EGR Airflow Control Valve (K158)
TTVA motor (-) circuit at the ECM harness connector and ground
Yes »Go To 4
No »Repair/replace short circuit to ground in the engine harness.
27 BAnERY-
10
2G 11
30 21
4G 31
so '1
60 51
MODULI!!-
ENGINE
CONTROLC1
(6.7L)
81af9606
4. AIRFLOW CONTROL VALVE (K158) ITVA MOTOR (-) CIRCUIT SHORTED TO ANOTHER CIRCUIT
TTVA motor (-) circuit in the ECM harness connector and all other cir-
cuits.
Yes »Go To 5
Peliorm POWERTRAIN VERIFICATION TEST - B.7L.
MODULE·
ENGINE
CONTROLC1
(8.7L)
81af960a
5. THROTTLE BODY
Measure resistance from (F348) smart power relay feed circuit to (K314) TTVA motor (+) circuit.
Is resistance 750 ohms (+/- 15~o)

DURE)
No »Replace the EGR Airflow control valve.
Peliorm POWERTRAIN VERIFICATION TEST - 6.lL. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P0488-EGR AIRFLOW THROTTLE CONTROL CIRCUIT PERFORMANCE
----RELAy.
I I.IIRT
I I POWER
I SMART I
POWER
I RELAY I
l_ FEED_ J
4y
F348
16 r- - - - - - - - - - - - - MODULE·
PK/{)R I , ENGINE
,CONTROL
42 1
F!8
et30 I TTVA TTVA SENSOR
_M~RJl __ ~0!i+) __ ~o~ _ _ J
I
16 27 C1 13 C1 22 TC1
PK/OR
10 tI
C112
K911
18
BRIPK
F348
16
PKiOR I
• 1043
I
K1S8 K314 K971
IS 19 18
BRNL BR BRIPK
21 .1 THROTTLE
SMART TTVA TTVA SENSOR
POWER MOTOR (0) MOTOR (+) GROUND BODY
RELAY
FEED
10 1
20 11
30 21
40 3l
~~
~.
51
IODULE· AELlY·
THROTTLE ENGIIIE S.IAT
BODY CONTROL C1 POWEA
(S.U DIESEL) (S.7L) 16.n DIESEL) .1 .....

Theory of Operation
The EGR Airflow control valve is a smart device that is commanded by the ECM through a PWM signal. There are
two portions to this diagnostic. a key-on portion and a performance portion. The key-on portion checks the status
feedback line from the throttle. At key-on. the ECM toggles the output line and verifies that the status line matches
the command. The performance portion checks the status line for a feedback that matches the ECM output com-
mand. The diagnostic fails if the status line stays low for more than 2 seconds. The ECM will illuminate the MIL
lamp after the diagnostic runs and fails in two consecutive drive cycles. During this time the ECM will not control the
EGR Airflow control valve. If able, the EGR Airflow control valve will go to the default open position. This may cause
active Exhaust Aftertreatment regenerations to last longer. The ECM will turn off the MIL lamp after the diagnostic
• When Monitored:
Ignition on
• Set Condition:
Status line feedback voltage is outside of a calibratable range
Possible Causes
(F348) SMART POWER RELAY FEED SHORTED TO GROUND

(K158) TTVA MOTOR (-) CIRCUIT IS OPEN
(K971) SENSOR GROUND OPEN
(K1S8) TTVA MOTOR (-) CIRCUIT IS SHORTED TO GROUND
(K1S8) TTVA MOTOR (-) IS SHORTED TO VOLTAGE
EGR AIRFLOW CONTROL VALVE
ECM
Diagnostic Test
1. OTC P0488 ACTIVE

Is OTC P0488 active?
Yes »Go To 2
AND TESTING)
2. (F348) SMART POWER RELAY FEED

Disconnect the EGR Airflow Control Valve harness connector.
Measure the voltage on the (F348) smart power relay feed to ground.
Is voltage within one volt of battery?
Yes »Go To 5
No »Go To 3
..
2() 11
30 21
<!G 31
56 41
60 51
MODULE·
ENGINE
CONTROLC1
(UL) 81af9602
3. (F348) SMART POWER RELAY FEED SHORTED TO GROUND

With the scan toolt read DTC's.
Are there any Mass Airflow or Turbocharger OTCs?
Yes »Repair the (F348) smart power relay feed circuit.
DURE)
No »Go To 4
9 :" 2008 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
4. (K971) SENSOR GROUND OPEN

Measure the resistance of the (K971) sensor ground circuit from the
[OJ 4
EGR Airflow Control Valve harness connector to the ECM harness con-
nector.
Yes »Repair open harness from 10 position crossover connector
to EGR Airflqw Control Valve. 4
THROTTLE
No »Repair or replace ,the open harness. Perform POWER- BODY
(6.1L DIESEL)
TRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE
- STANDARD PROCEDURE)
10
20 11
30 2;1
.j() 31
50 41
so 51
MODULE·
ENGINE
CONTRaLe,
(I.7L) 81af9620
5. DlC P0487 ACTIVE

Disconnect EGR Airflow Control Valve harness connector.
Does DlC P0487 become active?
Yes »Go To 8
No »Go To 6
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 ·'2009
6. OPEN AIRFLOW CONTROL VALVE TTVA MOTOR (..) CIRCUIT

Measure the resistance of the (K158) TTVA motor (-) circuit from the 1
EGR Airflow Control Valve harness connector to the ECM harness con-
nector.
Yes »Go To 7
No »Repair/replace open circuit in the ~ngine harn~ss. ..
20 11
90 21
31
'511"' 41
IJ() 51
MODULE·
ENGINE
CONTROLC1
(4..7L)
81a:f9602
7. SHORTED AIRFLOW CONTROL VALVE (K1S8) TTVA MOTOR (-) CIRCUIT

TTVA motor (-) circuit at the ECM harness connector and ground
Ves »Go To 8
No »Repair/replace short circuit to ground in the engine harness.
27 BATTERY·
10
20 j1
90 21
'"'
511
31
41
IJ()
'1
MODULE·
ENGINE
CONTROLC1
(1.7L) 81af9606
8. DTC P0488 ACTIVE

Reconnect the EGR Airflow Control Valve harness connector.
Yes »Go To 9
No »Repair complete. The removal/installation of the harness connectors cleared the condition.
DURE)
9. ECM
Disconnect the EGR Airflow Control Valve hamess connector.
Is P0487 active?
Yes »Replace the EGR Airflow Control Valve.
DURE)
DURE)
DR _ - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 .. 2011
P0489-EGR CONTROL CIRCUIT LOW
-- - -RIUY.
I I ••AIT
I I'OWEI
I SMART I
POWER
I RElAY I
l_ FEED_ J
4'(
F348
16 r - - - - - - - - - - - - - .0IULE·
1
PKJOR I
1
I EIIIIE
ICONTROL
42 t C.IO f TlVA nVA SENSOR I
f348 _M2!.,0'ill _ _ ~O~) _ _ ~O~ _ _ J
PKIOR
18 27 Ot 13 C1 22 Te.
ID
A
i cua
W1
18
F3~8 BRJPK
I
ro
18
PKJOR
KISS K31. KU71

18
BRIYl
f8
BR
18
BRIPK
11 21 .1 THROTTLE
SMART TlVA TlVA SENSOR
POWER MOTOR (-) MOTOR(.) GROUND
10DY
RElAY
fEED
,....., ,....,
m
to Joooo~ 'Oooo~ 1
20 00000 00000 11
30 00000 00000 21
40 00000
00000
0 00000
00000
31
il oooo~ 00000 ~1
~
'-' L..J
.ODULE· RELlY·
THROTTLE EI.IIE S.ART
10lY CONnOL Ot POWER
,'.7LDIHIL) (',1L) (l.lL DIESEL)
.f.""
9 - 2012 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l D I E S E l - - - - - - - - - DR
Theory of Operation
There are two portions to this diagnostic: 1. The diagnostic monitors motor effort as a measure of current. When the
valve is opening to a position, and uses too much motor effort to achieve that position the diagnostic will fail. This
will most likely occur in a situation when the valve is stuck. 2. At every key on, the valve tries to recalibrate it's
position. The valve shaft will move until it comes into contact with the valve. If the distance the valve shaft must
move is different by a calibrated amount than the original learned movement then the diagnostic fails. This will most
likely occur if the valve is stuck in an open position. The valve will perform this autozero function at every key on
and every time the valve is commanded closed throughout the engine operating cycle. The ECM will illuminate the
MIL lamp after the diagnostic runs and fails in two consecutive drive cycles. The ECM will also turn on the ETC
lamp. During this time the ECM will not longer control the EGR valve. The MIL lamp will turn off once the diagnostic
runs and passes in 4 consecutive drive cycles.
• When Monitored:
At key on, while engine running
• Set Condition:
Motor effort exceeds a calibrated level or autozero function fails.
Possible Causes
i EGR VALVE
Diagnostic Test
1. DTC P0489 ACTIVE

Yes »Replace EGR valve.
DURE)
No »Refer to the INTERMITTENT CONDITION - DIESEL (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 • 2013
P0501-VEHICLE SPEED SENSOR 1 PERFORMANCE
r- - - - - - - - - - - - - - - IODULE.
I ITaULLY
I Ir- - - - ElECTRONICS 'INTEDRATED
,PaWER
I I
I I I
I I CAN C CAN C I SElSOR·
I ~us (-) _ _ _ _ BUS I WHEEL
:__ 1____ J______ J

SPEED·AIS·
REAR
'rOM
20
T'
OM
20
1'(
J,
I
822
TWISTED
/PAIR~
2'(
1
B222
I
WT~B WT!G
18 18
TWISTED DGlVl DGIWT
/PJ.IR~
I
• SOU • S012
151 161 Ct35
~
TO TO
OTHER OTHER
AWAl I RWAl AWAl fWAl - AWAl RWAl MODULES MODULES
064
20
WTIL8
I I
D64
18
WT!B
~
065
20
WTIlG
065
18
WTA.G
~~
B22
20
822
18
B222
20
B222
18 065
t t
064
DGlYl DGIVL DGNH DGIWT 1B 18
~ ~~ WT!G WTtB
;~I:~E~ 1 1;~I:~AE~ 1 L:W~:~E:J

~18
E:lE:l3 1 ~J
~~2
I"lAWAL
E:l!"lRWAl
1- -CANG - - - - CAN c- - - - - - - - REAR - - - - REAR - --.
~41
!"lEIS 1
IODULE·
1 IC2
r CANe - -
211 C2
CANC-lIODULE.
BUS (-) BUS (t) WHEEL WHEEl I ANTI· BUS (+) BUS (-) I CONTROL
ENGINE
I SPEED SPEED fLOCK
1 SENSOR (-) SENSOR (t) I IRAKES I' I
I I L ______ J
I
------------------------~
30
10 I
20 II
30 21
40 ~1
SO 41 14
60 II
IODULE·
17 46 AIITI·
EIOINE
IODULE·
CONTROL C2
LOCK IRAIES
IRWAL,
IODULE· 'I.U)
AITI-LOCI
BRAKES
fAWALI
1.ll4nl

• When Monitored:
• Set Condition:
The ECM indicates signals of motion; however, the VSS does not.
Possible Causes
VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO VOLTAGE

VEHICLE SPEED SIGNAL CIRCUIT OPEN BETWEEN CAB AND ECM
VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test
1. VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

Disconnect the ABS/RWAl Module harness connector.
Measure the voltage of the Vehicle Speed signal circuit in the ABS/RWAL or ECM harness connector.
Yes »Repair the short to voltage in the Vehicle Speed Signal circuit between the CAB and ECM.
Perform POWERTRAIN VERIFICATION rEST - B.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN BETWEEN CAB AND ECM
Measure the resistance of the Vehicle Speed signal circuit between the ECM harness connector and the ABS/RWAl
harness connector.
Is the resistance above 5.0 ohms?
Yes »Repair the open in the Vehicle Speed signal circuit between the CAB and ECM.
Perform POWERTRAIN VERIFICATION rEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 3
3. VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the Vehicle Speed signal circuit at the ECM harness connector.
Yes »Repair the short to ground in the Vehicle Speed signal circuit between the CAB and ECM.
Perform POWERTRAIN VERIFICATION rEST - B.7l (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
No »Go To 4
4. ECM
NOTE: Before continuing, check the ECM harness connector terminals for corrosion, damage, or terminal
Ground circuits.
If there are no possible causes remaining, view repair.
Repair
Replace and program the ECM per Service Information.
DURE)
9 ~ 2016 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
P0505-ENGINE SPEED AT IDLE - DATA ERRATIC, INTERMITTENT OR INCORRECT
For a complete wiring diagram Refer to Sec,ion 8W.
Theory of Operation
This algorithm checks if the governor control system is unable to maintain idle speed. If idle speed is off by more
than 50 RPM for a calibrated amount of time (15 seconds), the diagnostic sets a fault.
• When Monitored:
While engine is idling .
• Set Condition:
Idle speed error detected.
Possible Causes
I
IDLE INSTABILITY
DiagnostiC Test
1. OTHER DTC'S
Yes »Repair all other DTC's First.
No »Go To 2
2. P0505 ACTIVE
Is P0505 Active?
Yes »Repair the erratic idle condition.
DR - - - - - - - - - ENGINE .' ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 .. 2017
POS13-INVALID SKIM KEY

• When Monitored:
Key on
• Set Condition:
Invalid Key Code received from SKIM Module
Possible Causes
GENERAL NETWORK ERROR

KEY NOT PROGRAMMED
INCORRECT KEY
INCORRECT VIN IN ECM OR SKIM
LOSS OF COMMUNICATION BETWEEN ECM AND SKIM
Diagnostic Test
1. 'ACTt\.tE DTC
With the scan tool, read the ECM DTCs.
Is the DTC active at this time?
Yes »Go To 2
No »Go To 6
2. NO :COMMUNICATIO~ WITH SKIM

With the scan tool, attempt to communicate with the SKIM.
Car... ~the 'scan -toot, communicate· with the SKIM?
Yes »Go To 3
No »Refer to Section 8 - Electrical VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS and perform
the appropriate Diagnostic Pr,Ocedure. _ . .
Perform SKIM VERIFICATION. (Refer to 8 - ELECTRICALNEHICLE THEFT SECURITY - STANDARD
PROCEDURE) j . ,
3. SKIM TROUBLE CODES SET

With the 'scan tool, check for SKIM DTCs.
Are any DTCs present in the SKIM?
Yes »Refer to Section 8 - ElectTical VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS and perform
the appropriate Diagnostic Procedure. .
Perform SKIM VERIFICATION. (Refer to 8 - ELECTRICAUVEHICLE THEFT SECURITY - STANDARD
PROCEDURE)
No »Go To 4
9 .. 2018 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
4. VIN PROGRAMMED INTO ECM

With the scan tool, display the VIN that is programmed in the ECM.
Has a VIN been programmed into the ECM?
Yes »Go To 5
No »Program the correct VIN into the ECM and retest.
Perform SKIM VERIFICATION. (Refer to 8 • ELECTRICALNEHICLE THEFT SECURITY· STANDARD
PROCEDURE)
5. ECM
Replace and program the SKIM per Service Information.
With the scan tool, erase all SKIM and ECM DTCs.
Attempt to start and idle the engine.
With the scan tool, read the ECM DTCs.
Does the scan tool display this code?
Yes »NOTE: Before continuing. check the ECM harness connector terminals for corrosion, damage, or termi-
nal push out. Repair as necessary. Replace and program the Engine Control Module per Service Infor-
mation.
Perform SKIM VERIFICATION. (Refer to 8 - ELECTRICALNEHICLE THEFT SECURITY - STANDARD
PROCEDURE)
No »Test Complete.
6. IGNITION KEY
NOTE: You must obtain the SKIM pin number.
NOTE: This DTC could have been set if the SKIM harness connector was disconnected, or if the SKIM was
replaced recently.
NOTE: All keys that the customer uses for this vehicle must be tested to verify they are operating properly.
Verify the correct VIN is programmed into the ECM and SKIM.
With each customer key turn the ignition on and crank the engine to start.
With the scan tool, read the ECM DTCs. Look for P0513.
Is the DTe P0513 still active?
Yes »Replace the Ignition Key.
Perform SKIM VERIFICATION. (Refer to 8 - ELECTRICAUVEHICLE THEFT SECURITY - STANDARD
PROCEDURE)
No »Test Complete.
NOTE: If this OTC cannot be reset, it could have been an actual theft attempt.
P0514-BATTERY TEMPERATURE SENSOR PERFORMANCE
m
2 .-
IEISOR.
BATTERY
TEMPERATURE
1""
K25 K900
20 20
DBNT DBIDG
'------ C130
K25 K900
18 18
DRNT DBIDG
301 C2 291 C2
r BATT - - - - - - - - - - - - SENsOR -, MODULE·
I TEMP GROUND I ENGINE
SIGNAL CONTROL
I MfT IL ________________ I ~
" AfT
BLACK
n n
~
10 ~ t;;;oooo I
20 00000 00000 II
30 00000 00000 , 11
40
50
00000
00000
0 00000
00000
31
41
SO 00000 00000 51
~
~ ~
-
SENSOR· MODULE·
BAnERY ENCUNE
TEMPERATURE CONTROL C2
(DIESEL, ,1.fLl

9 • 2020 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
There are two parts to this fault code, a key on check and a rationality check. After an 8 hour cold soak, at key ON
the readings for the ambient air temperature, battery temperature and intake air temperature and coolant tempera-
ture are all compared. If the temperatures differ more than a calibrated amount, then the appropriate sensor fault
code would be recorded. The key on monitor is disabled for ambient temperatures below -6.7° C (20 0 F). This mon-
itor looks for all the sensors to be grouped on one temperature or, in the case that the monitor fails, three sensors
grouped at one temperature and one outlier. In the case that all four sensor values are distributed over a range of
temperatures this diagnostic will not run. A block heater is one possible cause of such a distribution. The rationality
check is referred to as a dither. The dither looks at the temperature reading from the sensor over time and ensures
that it changes. This monitor is used to detect a "stuck" sensor. If the sensor reading does not change over a cal-
ibrated time limit, the fault will be recorded. Both the key-on and dither portions of this rationality error require that
the diagnostic fails in two consecutive drive cycles before the MIL lamp is lit. During this time the ECM uses an
default value for the intake air temperature. The ECM turns off the MIL lamp when the diagnostic runs and passes
in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
At key on engine off, the intake air temperature sensor reads differently than the battery temperature and
ambient air temperature sensors. Or while the engine is running the ECM does not read a change in value
from the intake air temperature sensor over time.
Possible Causes
BATTERY TEMP SENSOR

Diagnostic Test
1. BATTERY TEMP SENSOR

Remove the temperature sensor and reconnect the wiring harness connector to the sensor.
Does the reading from the sensor increase at least -15 C (5° F). on the scan tool?
0
No »Replace the battery temperature sensor.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 - 2021
P0516-BATTERY TEMPERATURE SENSOR CIRCUIT LOW
m
2
IEILIOR'
BiTTER'
TEll PERATU RE
1'
K25 K9DO
20 20
DBNT D8JDG
121 IU
I ' 19 ~'- 'I2~ CUD
K25 K900
18 18
DBNT DBIDG
wl~ ~l~
r BATT - - - - - - - - - - - -Sa;SOR 'IIODULE.
I TEMP GROUND I EIIIIIIE
SIGNAL COIITROL
I MIT I ________________ I
L ~
I ' AIT
BLACK
rl r1
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20 00000 00000 jj
30 00000 00000 2j
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SElSOR· IIODULE·
lATTER' ENGINE
TEIIPERATURE COIITROL C2
(DIESEL) IG.U)
., •...
• When Monitored:
• Set Condition:
Possible Causes
BATTERY TEMP SENSOR

ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE·
Diagnostic Test
1. BATTERY TEMP SENSOR

Disconnect the Battery temp sensor harness connector.
Measure the resistance of the Battery temp sensor.
Yes »Go To 2
No »Replace the battery temp sensor.
DURE)

Measure the resistance between the engine ground and the temperature sensor (K25) signal circuit at the sensor
connector.
Yes »Go To 3
No »Repair the Battery temp sensor (K25) signal circuit shorted to ground.
DURE)
3. (K2S) SIGNAL CIRCUIT SHORTED

Measure the resistance between the Battery temp sensor (K25) signal circuit and all other circuits in the ECM har-
ness connector of the engine harness.
Yes »Go To 4
No »Repair the (K25) signal circuit shorted to another circuit.
PROCEDURE)
Reconnect the disconnected Battery temp sensor harness connector.
While monitoring with scan tool, disconnect the temperature sensor harness connector.
Did P0517 set?
DURE)
9 • 2024 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P0517·BATTERY TEMPERATURE SENSOR CIRCUIT HIGH
m
2
IENIO ••
BATTER'
TEMPERATURE
K25 K900
20 20
DBNT DBIDG
121 119
,,19 ,,25 C130
rn ~
18 1B
DBNT DBIDG
wl~ Hl~
r BATT - - - - - - - - - - - - SENSOR -':::I~ie.
I TEMP I CONTROL GROUND
I SIGNAL I
• MIT
"AfT L ________________ .J
10
20 11
JO 21
40 3'
50 I.'
60 5'
SElSOR· MODULE·
BATTERY ENGINE
TEMPERATURE CONTROL CI
(DIESEL) (I.ILI

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6~7l DIESEL 9 .. 2025
• When Monitored:
• Set Condition:
Possible Causes
BATTERY TEMP SENSOR

ECM
Diagnostic Test
1 . BATTERY TEMP SENSOR

Measure the resistance of the Battery temp sensor
Ves »Go To 2
No »Replace the Battery temp sensor.
DURE)
2. OPEN CIRCUIT
Reconnect the disconnected Battery temp sensor harness connector.
Measure the resistance between the temperature sensor (K25) signal and (K900) return circuits at the ECM harness
connector.
Yes »Go To 5
No »Go To 3

Measure the resistance of the sensor (K25) signal circuit between the sensor harness connector and the ECM har-
ness connector.
Yes »Go To 4
No »Repair the open (1<25) signal circuit.
PROCEDURE)

Measure the resistance of the sensor (K900) return circuit between the sensor harness connector and the ECM
harness connector.
Yes »Go To 5
DURE)

Check for a short circuit from (K2S) signal circuit to all other circuits at the ECM harness connector.
Yes »Go To B
No »Repair the shorted (K2S) signal circuit.
DURE)
6. ECM
While monitoring with the scan tool, use a jumper wire and connect the sensor (K25) signal circuit to the sensor
(K900) return circuit at the sensor harness connector.
Did P0516 set?
Ves »Refer to the INTERMITTENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 2027
P051 B-CRANKCASE PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE
r - - - - - - _ODULE·
1 I.I.IIE
I COlnOL
I CRANKCASE I
I SENSOR I
l_~N~ ___ ....I
14 TCt
K926
18
DBIGY
3).
CRANKCASE
IE. lOR·
CIlllleAlE
SENSOR
SIGNAL
SENSOR 5 VOLT
GROUND SUPPLY
21 IT
K916 F855
18 18
SRIOR PKlYl
I
. 1..4 I
• 1.7'
I I
K916 F855
18 18
BRJOR PKlYt
,,1 et "let-I
r sENsOR - -5 VOi: T .ODULE·
.IIIIIIE
I GROUND SUPPLY I CONnOL
I I
IL _ _ _ _ _ _ I ~
10 /00000 '00000 1
20 00000 00000 11
30
40 ggggg 0 ggggg II
50 00000 00000 41
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CRIIICIH _ODULE·
('.n DI!tILt .IIIIIIE
COITR01. Ct
".lL)

9 - 2028 ENGINE - ELEC'rRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The crankcase pressure sensor is used to monitor the pressure inside the crankcase. The ECM supplies the crank-
case pressure sensor a 5-volt reference voltage. When the crankcase pressure is low, the sensor signal voltage is
low. When the crankcase pressure is high. the sensor signal voltage is near the 5-volt reference voltage. The ECM
monitors the crankcase pressure signal circuit voltage to calculate the pressure of the air within the crankcase. The
ECM does not illuminate the MIL or ETC lamp for any of the crankcase pressure faults .
• When Monitored:
• Set Condition:
At key on, engine not running the crankcase pressure sensor reading is higher than a calibrated threshold. or
during engine operation the crankcase pressure reading is not changing with engine operating conditions.
Possible Causes
CRANKCASE PRESSURE SENSOR

RESISTANCE OR SHORT CIRCUIT IN WIRING HARNESS
ECM
INTERMITIENT CONDrTION
CRANKCASE VENTED TO ATMOSPHERE
Diagnostic Test
1. OTHER OTCS
Turn the ignition on
Wait 5 seconds after ignition is turned on.
Is DTC P0510 or P051C active?
No »Go To 2
2. P051 C ACTIVE
Disconnect the crankcase pressure sensor harness connector.
Is OTC P051 C active?
Yes »Go To 3
No »Go To 5
3. P051 D ACTIVE
Connect a jumper wire between the crankcase pressure (F855) 5-volt supply circuit and the (K926) Crankcase Pres-
sure Signal circuit at the crankcase pressure sensor harness connector.
Is DTC P051 D active?
Yes »Replace the Crankcase pressure sensor.
DURE)
No »Go To 4
4. CRANKCASE VENTED TO ATMOSPHERE

Inspect engine for crankcase leaks of oil or crankcase gases.
Check: Valve cover gasket. Crankcase breather tube. Dipstick tube.Block plugs.Oil fill cap.
Are any leaks found?

Yes »Repair leaks.
DURE)
No »Go To 5
5. ECM
Disconnect the (C 1) ECM harness connector.
Dirty or damaged pins?
Yes »Replace/replace the ECM or engine harness.
DURE)
No »Go To 6
6. ECM
Connect a jumper wire between the crankcase pressure (F855) 5-volt supply circuit and the (K926) Crankcase Pres-
sure Signal circuit at the crankcase pressure sensor harness connector.
With the scan tool , read DTCs.
Is DTC P051D active?
Yes »High resistance or a short circuit has been detected in the engine harness. Repair/replace engine har-
ness.
PROCEDURE)
P051C.. CRANKCASE PRESSURE SENSOR CIRCUIT LOW
I - - - - - - IIDDULE.
I I EIGIIIE
I COIITRDL
I CRANKCASE I
I SENSOR I
l_~N~ ___ -,
14 TCi
K926
18
DB/GY
3~
CRANKCASE IENSOR.
SENSOR
CRANICASE
SIGNAL
SENSOR 5 VOLT
GROUND SUf>PLV
21 IT
K91S F855
18 18
BR/OR PKlYl
I
• SOU I
.117a
I
K916 F855
18 18
BR/OR PKIYL
,,1 e1
ISENSOR --sWT-1
"lei IIODULE·
ENOIIiE
I GROUND SUPPL Y I
CONTROL
I I
Il ______ -'I
10 I
2D II
30 21
4D 11
50 41
60 51
IEIIOR·
CRANKCASE MODULE·
II.n DIESEL] EIGINE
CONTROL C1
,I.U)
IUIUI1

DR - . - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9·2031
Theory of Operation
low. When the crankcase pressure is high, the sensor Signal voltage is near the 5-volt reference voltage. The ECM
• When Monitored:
• Set Condition:
At key on, engine not running the crankcase pressure sensor reading is higher than a calibrated threshold.
Possible Causes
OTHER DTCS
(K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND CIRCUIT
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO THE (K916) SENSOR GROUND
(K926) CRANKCASE PRESSURE SIGNAL CIRCUIT OPEN
(K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE·
Diagnostic Test
1. OTHER DTCS
Are there any 5-volt supply OTCs ?
Yes »Repair other DTCs first.
No »Go To 2
2. P051 C ACTIVE
Is DTC P051 C active?

Yes »Go To 3
AND TESTING)
9 - 2032 ENGINE .. ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
II"U·..,.""'.... off.
Disconnect the Crankcase pressure sensor 1/1 harness connector.
Measure the voltage from the (F855) 5~volt supply circuit to the (K916) Sensor Return circuit at the sensor harness
connector.
Yes »Go To 4
No »Go To 6
4. CRANKCASE PRESSURE SENSOR

While monitoring scan tool, use a jumper wire to connect the (F855) 5-volt supply circuit with the (K926) Crankcase
Pressure Signal circuit at the sensor harness connector.
Does the scan tool show a P051 D DTC?
Yes »Replace the Crankcase pressure sensor
DURE)
No »Go To 5
5. (K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND
CIRCUIT
Measure the resistance between the (K926) Crankcase Pressure Signal circuit and (K916) Sensor ground circuit in
the Crankcase pressure sensor harness connector.
Yes »Go To 6
DURE)
6. (F855) 5..VOLT SUPPLY CIRCUIT SHORTED TO THE (K916) SENSOR GROUND

Measure the resistance between the (F855) 5-volt Supply circuit and (K916) Sensor ground circuit in the Crankcase
pressure sensor harness connector.
Yes »Go To 7
No »Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS ~ 6.7l DIESEL 9·2033
7. (K926) CRANKCASE PRESSURE SIGNAL CIRCUIT OPEN

Measure the resistance of the (K926) Crankcase Pressure Signal circuit from the Crankcase Pressure Sensor har-
ness connector and the ECM harness connector.
Yes »Go To 8
DURE)

Measure the resistance between the (F855) 5-volt Supply circuit in the Crankcase Pressure Sensor harness con-
nector with the (F855) 5-volt supply circuit in the ECM harness connector.
Yes »Go To 9
DURE)
9. CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the (K926) Crankcase Pressure Signal circuit in the Crankcase pressure sensor
connector and battery negative.
Yes »Go To 10
DURE)
1o. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Measure the resistance between the (F855) 5-volt Supply circuit in the Crankcase pressure sensor connector and
battery negative.
Yes »Go To 11
DURE)
11. ECM
While monitoring scan tool, use a jumper wire to connect the (F855) 5-volt supply circuit with the (K926) Crankcase
Does the scan tool show a P051 D DTC?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Symptom: (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
Perform POWERTRAIN VERIFICATION TEST- B.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
9 - 2034 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
P051 D-CRANKCASE PRESSURE SENSOR CIRCUIT HIGH
• - - - - - - MODULE·
I I EII1Q'IIE
I CONTROL
II CRANKCASE I
SENSOR I
l_SIGN~ _ _ _ -,
14 TC1
K926
18
DBIGY
3~
SENSOR·
CRANKCASE
CRlIIKCASE
SENSOR
SIGNAL
SENSOR 5VOL T
GROUND SUPPl Y
2T IT
K916 F8S5
16 18
BRIOR PKIYL
I
• 1044 I
• St73
I I
K916 F8S5
18 18
BRIOR PKIYL
"1.. "1..
'SENSOR - -SVOLT-I MODULE·
EIIGIIE
I GROUND SUPPLY I
CONTROL
I I
Il ______ -'I
10 \
10 \1
10 21
~O 31
50 41
6G 51
SEIISOR·
MODULE·
CRANKCASE EIIG 'II E
CI.7L DIESEL}
COIITROL C1
(1.7L,
ItlHMt

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 • 2035
Theory of Operation
low. When the crankcase pressure is high, the sensor signal voltage is near the 5-volt reference voltage. The ECM
ECM does not illuminate the Mil or ETC lamp for any of the crankcase pressure faults.
• When Monitored:
• Set Condition:
The circuit voltage to the ECM is above a calibrated threshold for a certain period of time
Possible Causes
OTHER DTCS
(K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY
(F855) 5-VOLT SUPPLY SHORTED TO HIGH VOLTAGE
(K916) SENSOR GROUND CIRCUIT OPEN
ECM
Diagnostic Test
1. OTHER OTCS
Are there any 5-volt supply OTCs ?
No »Go To 2
2. P051 D ACTIVE
Is DTC P051 0 active?
Yes »Go To 3
AND TESTING)
3. (F855) 5-VOLT SUPPLY

Disconnect the Crankcase pressure sensor harness connector.
Measure the voltage between the (F855) 5-volt supply circuit and (K916) Sensor ground circuit of the Crankcase
Pressure Sensor harness connector.
Yes »Go To 4
No »Go To 5

While monitoring the scan tool, use a jumper wire to connect the (K916) Sensor ground circuit to the (K926) Crank-
case Pressure Sgnal circuit at the Crankcase Pressure Sensor harness connector.
Does the scan tool show a P-051C Crankcase Pressure sensor low DTC?
Yes »Replace the Crankcase Pressure Sensor.
DURE)
No »Go To 5
5. (K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED VOLTAGE

Measure the voltage between the (K926) Crankcase Pressure Signal circuit of the Crankcase Pressure sensor con-
nector and battery negative.
Yes »Go To 6
DURE)
6. (F855) 5-VOLT SUPPLV SHORTED TO HIGH VOLTAGE

Measure the voltage between the (F855) 5-volt supply circuit of the sensor connector and battery negative.
Ves »Go To 7
DURE)
7. (K926) CRANKCASE PRESSURE SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY

Measure the resistance between the (K926) Crankcase Pressure Signal circuit and the (F855) 5-volt supply circuit
of the Crankcase Pressure sensor harness connector.
Yes »Go To 8
DURE)
8. (K916) SENSOR GROUND CIRCUIT OPEN

Measure the resistance between the (K916) Sensor ground circuit in the Crankcase Pressure sensor harness con-
nector with the (K916) Sensor ground circuit in the ECM harness connector.
Yes »Go To 9
DURE)
9. ECM
While monitoring scan tool, use a jumper wire to connect the (K916) Sensor ground circuit with the (K926) Crank-
case Pressure Signal circuit at the Crankcase Pressure sensor harness connector.
Does the scan tool show a P051 C Crankcase Pressure sensor low DTC?
AND TESTING)
DURE)
P0521-ENGINE OIL PRESSURE SENSOR PERFORMANCE
r - - - - - - .OIULI.
I 11111.11
I ICOITIOL
OIL I
I PRESSURE I
L___ ..!Gf!!:._~
"i e
•
G8
18
VTiGY
[LJ .. ITCII ......

PIEIIUIE
~ ~
r BLACK
10
10
30
40
50
'00000
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'00000
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1
11
21
11
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It...-J ILJ
M 00000 00000 SI
II -,~ \..
o;:J w
2 m
l IE:SlE fJ~l
.OIULE·
~ .1.111
"ITCH-OIL CONtROL Ot
PIIIIUI£ II.n,
.t....

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 • 2039
Theory of Operation
The engine oil pressure switch is used by the ECM to monitor the lubricating oil pressure. If the oil pressure drops
below the engine protection limit, the switch will open and cause the fault to log. The oil pressure switch is normally
closed when the engine is not running and open when oil pressure is present. When the fault is set, the ECM
illuminates the MIL light. There will be a torque derate issued by the ECM limiting the power output of the engine.
The ECM will turn off the torque derate when the oil pressure reading is detected to be within the normal operating
range. The ECM will turn off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
Oil pressure is detected with engine RPM = 0 for 30 seconds.
Possible Causes
OIL PRESSURE SWITCH

(G6) SIGNAL CIRCUIT OPEN
INTERMITTENT CONDITrON
ECM
Diagnostic Test
1 . OIL PRESSURE SWITCH

Disconnect the Oil pressure switch harness connector.
Measure the resistance between the oit pressure switch terminal and
ground.
Ves »Go To 2
No »Replace the oil pressure switch.
awrrCH-olL
PRESSURE
81427840
2. (G6) SIGNAL CIRCUIT OPEN

Measure the resistance of the oil pressure switch (G6) signal circuit
between the oil pressure switch harness connector and the ECM har-
ness connector.
Yes »Go To 3
No »Repair the open Oil pressure (G6) signal circuit.
31 40
21 30
11 20
1 2 3 4 5 6 7 8 9 10
MODULE-ENQINE
COHTROLC2
81427847
3. ECM
Measure the voltage between the oil pressure (G6) signal circuit at the
oil pressure switch harness connector and ground.
tom (Diagnostic Procedure). (Refer to 9 - ENGINE - DIAG- (G6)
NOSIS AND TESTING)
SwrrCH.QIL
PRESSURE
8142784b
P0524-ENGINE OIL PRESSURE TOO LOW
r - - - - - - MODULE.
I I ElGIIIIE
I I COIIITROL
OIL I
I PRESSURE I
l ___ 1!.GNAL _ ~
"i
G6
e
•
18
VTIGY
~ SWlTeH·OIL
PAESSUAE
r-"l
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\
r BLACK
10
20
3D
40
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00000
00000
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1'0000;;-
00000
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II
21
31
50 00000 00000 41
~ ~ 1 60 00000
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f1~1
~ ~
2m IE5lIE'J
IIODULE·
~ ElallllE
S.ITCH·OIL CONTROL C1
PRESSURE (l.lLl
..-.
Theory of Operation
The engine oil pressure switch is used by the ECM to monitor the lubricating oil pressure. If the oil pressure drops
below the engine protection limit, the switch will open and cause the fault to log. The oil pressure switch is normally
closed when the engine is not running and open when oil pressure is present. When the fault is set, the ECM
illuminates the MIL light. There will be a torque derate issued by the ECM limiting the power output of the engine.
The ECM will turn off the torque derate when the oil pressure reading is detected to be within the normal operating
range. The ECM will turn off the MIL light after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
The oil pressure detected by the ECM is less than a calibrated value.
Possible Causes
LOW OIL LEVEL

(G6) SIGNAL CIRCUIT SHORT TO GROUND
OIL PRESSURE SWITCH
INTERNAL ENGINE DAMAGE
Diagnostic Test
1. LOW OIL LEVEL

Check the engine oil level.
Is the engine oil in the safe operating range?
Yes »Go To 2
No »Repair any condition that may cause the oil level to be above or below the safe operating range.
Perform POWERTRAIN VERIFICATION TEST VER - S.7L. (Refer to 9 - ENGINE - STANDARD PRO·
CEDURE)
2. SIGNAL CIRCUIT SHORT TO GROUND

Disconnect the oil pressure switch harness connector.
Turn the ignition on for 1 minute.
Did DlC P0521 set?
Yes »Go To 3
No »Repair the (GS) signal circuit shorted to ground.
CEDURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 • 2043
3. OIL PRESSURE SWITCH

Measure the engine oil pressure with a mechanical gauge.
Is the oil pressure within the acceptable operating range?
Ves »Replace the oil pressure switch.
CEDURE)
No »Repair internal engine damage.
CEDURE)
P0532-A/C PRESSURE SENSOR CIRCUIT LOW
IIATT AD
.-- - - ~ - - - - - - - - - - - - - - - - - - - MODULE·
I r- -
I
r=--_ -
B(t) -
- - -
- - - - - - - - ---, ELECTRONICS I IITOTALLY
INTEGRATED
I I I POWER
I I I I
I I AiC I I
AIC
l I PRESSURE PRESSURE A/c I
5 VOL T PRESSURE I I
I L SIGNAL SUPPL Y GROUND I
1___-[-----,------I-~
_ ____ J _ _ _ _ _ _ _ _ _ _ _ _ _I
12TCl 7TCl 13TCl
C18 GalS GglS

20 20 20
LBItiR LBIOR BKILB
5 1 _____ 1 _____ 1 3 10 cnD
C18 G81S C91S

18 18 18 TO TO
LBIBR LB/OR BKltB OTHER OTHER
MODULES MODULES
1 1 1C112
13
1-----1------1
CIS
11
C81S
12
C91S
r
065
r
D64
18 18 18 18 18
LBItiR LB/OR BKItB WTltG WTila
31 21 11 TRU SDU CER.A/C I

11
CANC- -
C2 211 C2
CANe - , MODULE·
A/c A.IC A/c
PRESSURE
PRESSURE PRESSURE PRESSURE I BUS (t) BUS (-) I :::~·REOL
SIGNAL 5VOLT GROUND
SUPPL Y I I
L _____ ~
GRAY
10 I
20 II
0000000 lO 11
_0 JI
14 DDDDDDD 50 41
60 \'
TRAI SDU CER·A/e

PRESSURE IIODULE·
IIODULE· (8.1L/GAS) EIIIGIIE
TOTALLY CONTROL C2
INTEGRlTED (1.1L)
POWER C7
.1 1M'"

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9·2045
Theory of Operation
The AlC pressure sensor is mounted in the Freon circuit of the AlC system. This sensor monitors the pressure in
the system. This pressure information is part of the information the TIPM uses to determine if the AlC clutch should
turned on or off. This information is also important to protect the Freon compressor from damage. A MIL lamp will
not be lit for this fault. The customer may notice poor AlC performance .
• When Monitored:
• Set Condition:
The circuit voltage to the TIPM falls below a calibrated threshold for a certain period of time.
Possible Causes
OTHER DTC'S
AlC PRESSURE SENSOR
(C18) SIGNAL CIRCUIT SHORTED TO (K55) RETURN CIRCUIT
(C818) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K55) RETURN CIRCUIT
(C18) SIGNAL CIRCUIT OPEN FROM TIPM HARNESS CONNECTOR TO AlC HARNESS CONNECTOR
(C818) 5-VOLT SUPPLY CIRCUIT OPEN FROM TIPM HARNESS TO AlC HARNESS CONNECTORS
(C18) SIGNAL CIRCUIT SHORTED TO GROUND
(C818) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test
1. OTHER DTC'S
Are other DTC's present?
DURE)
No »Go To 2
2. HARNESS OPEN
Disconnect the AlC pressure sending unit harness connector.
Measure the voltage between the (C818) 5-volt supply and (C918)
return circuits of the sensor harness connector. D
Yes »Go To 3
No »Go To 4
TRANSDUCER-AiC
PRESSURE
(6.7UGAS) 81b98c94
3. AlC PRESSURE SENSOR

While monitoring scan tool, use a jumper wire to connect the (C818)
5-volt supply circuit to the (C18) signal circuit at the sensor harness
connector.
Did P0533 set?
Yes »Replace the AlC pressure sensor.
No »Go To 4
TRANSDUCER-Ale
PRESSURE
(6.7UGAS) 81b98c9b
4. (C18) SIGNAL CIRCUIT SHORTED TO THE (C918) RETURN CIRCUIT

Measure the resistance between the (C18) signal circuit and (C918)
Ves »Go To 5
No »Repair the (C18) signal circuit shorted to the (C918) return
circuit. DDDDDDD
Periorm POWERTRAIN VERIFICATION TEST - 6.7L. 14 8
MODULE·
TOTALLY
INTEGRATeD
POWERC7
81b98ca4
5. (C818) 5-VOLT SUPPLY CIRCUIT SHORTED TO THE (C918) RETURN CIRCUIT

Measure the resistance between the (Ca18) 5-volt supply circuit and
(C918) return circuit in the sensor harness connector.
Ves »Go To 6
No »Repair the (C818) 5-volt supply circuit shorted to the (C918)
return circuit.
81b98cab
9 • 2048 ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - - DR
6. (C18) SIGNAL CIRCUIT OPEN FROM TIPM HARNESS CONNECTOR TO AlC HARNESS CONNECTOR
Measure the resistance of the (C18) signal circuit between the sensor
harness connector and the C7 TIPM harness connector.
Ves »Go To 7
No »Repair the open (C18) signal circuit.
TRANSDUCER-AiC
PRESSURE
12 (6.7UGAS)
MODUU-
TOTALLY
~T&I
POWERC7 81b98cb6
7. (C818) 5·VOLT SUPPLY CIRCUIT OPEN FROM ECM HARNESS CONNECTOR TO AlC HARNESS CONN
Measure the resistance of the (C818) S-volt supply circuit between the
sensor harness connector and the C7 TIPM harness connector.
Yes »Go To 8
[OJ
No »Repair the open (C818) S-volt supply circuit.
'(Refer to 9 - ENGINE - STANDARD PROCEDURE)
TRANSDUCER·Ale
PRESSURE
7 (6.7UGAS)
81b98cba
8. (C18) SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the (C18) signal circuit in the sensor
harness connector and battery negative. .
Yes »Go To 9
No »Repair the (C18) signal circuit shorted to ground.
Perform ,POWERTRAIN VERIFICATION TEST - 6.7L.
TRANSDUCER-AIC
PRESSURE
(8.7UGAS) 81b98cc5
9. (C818) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Measure the resistance between the (C818) 5-volt supply circuit in the
Ves »Go To 10
No » Repair the (C818) 5-volt supply circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. GRAY
TRANSDUCER-AIC
PRESSURE
(6.7UGAS) 81b98cce
10. ECM
5-volt supply circuit with the (C18) signal circuit at the sensor harness
connector.
Did DTC P0533 set?
TRANSDUCER-Ale
PRESSURE
(8.7UGAS) 81b98cdO
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 • 2051
P0533-A/C PRESSURE SENSOR CIRCUIT HIGH
IBATT AO
r- - - r:-= - - - - - - - - - - - - - - - - - - - .. ODULE·
I _~ ----- -----~-, III.TECIRATED
TOTALLY
I B(+) I ElECTRONICS
I I I POWER
I I I I
I I Ale I I
l AIC PRESSURE AIC I
I PRESSURE 5 VOL T PRESSURE I I
I L ~NAL _ _ _ _ SUPPL~ ~ROUNO_ ~ I
,___ [ _____ .J______ I ______ --
12 TCl 7 TC7 13 TCl
CIS CSIS e918
20 20 20
LBJBR LBIOR BKlB
"
5 1 --~--
3 1 - - -10 1 Ct30
C18 cm C918
18 18 18 TO TO
LBlBR L8/0R BKIlB OTHER OTHER
13~ _ _ _
MODULES MODULES
1 121
CIS
11
I-----j
C818 em
CU2
t
065
t
064
18 18 1& 18 18
lBIBR LBIOR BKn..B WT/lG WTIlB
IIAIC
21
AIC
11
AIC TRlNSIUCER.A/C
11 C2 211 C2
I CAN C- - CAN C I-ODULE.
PRESSURE PRESSURE PRESSURE PRESSURE
I BUS (+) BUS (-) I EIIIIE
COITROL
SIGNAL 5 VOLT GROUND
I
L _____ -1I
SUPPL Y
GRAY
10 I
0000000 [0 II
3G 21
40 31
14 0000000 50 41
60 51
TAAIIIUCER.A/C
PRElIURE .. DDULE·
IGDULE· 11.7L/ClASJ ENGINE
TOTALLY CONTROL C2
.NTEGRATED (l.fL)
POWER 07

Theory of Operation
The AlC pressure sensor is mounted in the Freon circuit of the AlC system. This sensor monitors the pressure in
the system. This pressure information is part of the information the C7 TIPM uses to determine if the AlC clutch
should turned on or off. This information is also important to protect the Freon compressor from damage. A MIL
lamp will not be lit for this fault. The customer may notice poor AlC performance .
• When Monitored:
• Set Condition:
The circuit voltage to the C7 TIPMis above a calibrated threshold for a certain period of time.
Possible Causes
OTHER DTC'S
AlC PRESSURE SENSOR
(C18) SIGNAL CIRCUIT SHORTED TO BATTERY POSITIVE
(C818) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY POSITIVE
#
(C918) RETURN CIRCUIT OPEN FROM C7 TIPM HARNESS CONNECTOR TO AlC HARNESS CONNECTOR
TIPM
Diagnostic Test
1. OTHER DTC'S
Are other DTC's present?
DURE)
No »Go To 2
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 - 2053
2. HARNESS OPEN
Disconnect the AlC pressure sending unit harness connector.
Measure the voltage between the (C818) 5-vott supply circuit and
(C918) return circuit of the sensor harness connector.
Yes »Go To 3
No »Go To 4
TRANSDUCER-AIC
PRESSURE
(6.7UGAS) 81b98cdb
3. Ale PRESSURE SENSOR

return circuit to the (C18) signal circuit at the sensor harness connector.
Did P0532 set?
Yes »Replace the AlC pressure sensor.
No »Go To 4
TRANSDUCER-AIC
PRESSURE
(6.7UGAS) 81b98cdb
9 - 2054 ENGINE - ELECTRICAL-DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
4. (C818) S-VOlT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE

Disconnect the C7 TIPM harness connectors.
Measure the voltage between the (C818) 5-volt supply circuit at the har-
Yes »Go To 5
No »Repair the (C818) 5-volt supply circuit shorted to the battery
negative.
TRANSDUCER-AIC
PRESSURE
(1.7UGAS)
81b98ct2
5. (C18) SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE

Measure the voltage between the (C18) signal circuit at the harness
connector and battery negative.
Yes »Go To 6
No »Repair the (C18) s!gAal circuit shorted to the battery nega-
tive. .
14 DO DODD 8
MODULE-
TOTALLY
INTEGRATED
POWERC7
81b98cfb
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL g. 2055
6. (C918) RETURN CIRCUIT OPEN FROM C7 TIPM HARNESS CONNECTOR TO AlC HARNESS
CONNECTOR
Measure the resistance of the (C918) return circuit between the sensor
harness connector and the C7 TI PM harness connector.
Is the resistance less than 10 Ohms? GRAY -§JID
Yes »Go To 7 ~:~
No »Repair the open (C918) return circuit.
TRANSDUCER-A/C
PRESSURE
(6.7UGAS)
MODULE·
TOTALLY
INTEGRATED
POWERC7
81b98dOe
7. TIPM
Reconnect the C7 TIPM harness connectors.
return circuit with the (C18) signal circuit at the sensor harness connec-
tor.
Did OTC P0532 set?
NOSIS AND TESTING)
No »Replace the TIPM.
(Refer·to 9 - ENGINE - STANDARD PROCEDURE)
TRANSDUCER-Ale
PRESSURE
(8.7UGAS)
81b98cf2
P0541-INTAKE AIR HEATER CONTROL CIRCUIT 1 LOW
+ BATTERY·
AUIILlARY
A19
4
RDlYl
r---------- ,MODULE.
I
• 81 •• I
EIGIIE
I
COInROL
I INTAKE AIR I
I INTAKE AIR HEATER I
HEA fER RELAY
I RElAY CONTROL I
L ....90~R~ _ _ _ ...!ETURN_ _ .J
'UIIILE 55'1 CZ 39'1 C2
Lilli
A19 K174 Km
10 18 18
RDIYL BRIYL BRJ13K
39 - - - - -1 38
C130
K114
18
BRtYl
.---..".---------------,r---, RELlY.
851
IITlIE AIR
HElTER
87'1 86'1
ASB K974
4 18
BK BRIBK
~
LiJ
mNEiTEA.
INT AlIAI.
~
30
87 10 1
20 11
30 21
40 31
86 85 50 41
60 51
81A
RELAY· MODULE·
IIUIE AIR EMGINE
NUTER CONTROL C2
(DIESEL, (S.lL,

Theory of Operation
The intake air heater is integrated into the intake manifold cover. The air heater element is used to heat incoming
air into the intake manifold. This is done to help engine starting and improve driveability with cool or cold outside
temperatures. Electrical supply for the air heater element is controlled by the ECM through the air heater relay. One
heavy duty cable connects the air heater element to the air heater relay. This cable will supply 12 volts to air heater
elements. The ECM will light the MIL lamp as soon as this diagnostic runs and fails. The ECM will turn off the MIL
lamp when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
When the signal from the intake air heater output does not match the signal from the intake air heater feed-
back.
Possible Causes
LOOSE CONNECTION
INTAKE AIR HEATER RELAY
SIGNAL CIRCUIT OPEN FROM RELAY TO ECM
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
Diagnostic Test
1. RELAY CLICKING
With the scan tool, actuate the Intake Air Heater.
Can you hear the Relay clicking?
Yes »Go To 2
No »Go To 3
2. LOOSE CONNECTION
While the relay is clicking, wiggle the wiring harness and connectors.
Does this Interrupt the clicking?
Yes »Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 .. ENGINE .. STANDARD PROCE-
DURE)
No »Go To 3
9 - 2058 ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
3. INTAKE AIR HEATER RELAY

Remove the Intake Air Heater Relay.
Measure the resistance between the signal and return posts of the intake air heater relay.
Is the resistance between 15 and 25 Ohms?
Yes »Go To 4
No »Replace the Intake Air Heater relay.
DURE)
4. SIGNAL CIRCUIT OPEN FROM RELAY TO ECM

Measure the resistance of the intake air heater relay signal circuit between the ECM connector and the intake air
heater relay connector.
Yes »Go To 5
No »Repair the open signal circuit from PDC to ECM harness connector.
DURE)
5. SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE

Measure the voltage between the signal circuit of the intake air heater relay and battery negative.
Yes »Repair the signal circuit shorted to Battery negative.
DURE)
No »Go To 6
6. ECM
Disconnect the intake air heater relay signal wire and use a jumper to connect it to battery negative.
Did DTC P0542 set?
PROCEDURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 • 2059
POS42-INTAKE AIR HEATER CONTROL CIRCUIT 1 HIGH
~-=-
----
IATTE ..•
AUIILlAR'
--- A19
4
-&- RDIYL
r - - - - - - - - - - --, IODULE·
I
• Itt. I
EIGIIE
I CONTROL
I INTAKE AIR I
I INTAKE AIR
HEATER
HEATER
RELAY
I
I RELAY CONTROL I
L ~O~R~ _ _ _ ~ETUR~ _ ..J
I.. fUSIILE 55 YOI 3§ YC!
LINK
A19 Ktu K974
10 18 18
,... RDIYL BRIYL BRlBK
39 Jr-
y - - - - ---J, CtlO 38 "
Ktu
J
1&
:\___________ =
BRIYL
11 I
851
:~·E':'~~IIR
REUY
i t •
87 y 86 Y
A58 K974
4 18
BK BRlBK
[I] ,l
NUTER·
INTAKE AI.
I
~
30 n r"1
87 10 ~ooo;;' ~oooo'" I
20 00000 00000 11
30 00000 00000 21
86 QQ 85
40
50
00000
00000
0 00000
00000
31
41
60 00000 00000 51
~ ~
L..J L..J
B7A
RELAY· IODULE·
IIUKE AIR EIGIIE
HEATER CONTROL CI
IDIEIEL) (1.7L)
IldU. .

Theory of Operation
elements. The ECM will light the MIL lamp as soon as this diagnostic runs and fails. The ECM will turn off the MIL
lamp when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
When the signal from the Intake Air Heater output does not match the signal from the Intake Air Heater feed-
back.
Possible Causes
LOOSE CONNECTION
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
Diagnostic Test
1. RELAY CLICKING
With the scan tool, actuate the Intake Air Heater relay.
Can you hear the Relay clicking?
Yes »Go To 2
No »Go To 3
2. LOOSE CONNECTION
While the relay is clicking, wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Yes »Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST - 6.lL. (Refer to 9 - ENGINE .. STANDARD PROCE-
DURE)
No »Go To 3
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9·2061

Remove the Intake Air Heater Relay.
Measure the resistance between the signal and return posts of the intake air heater relay.
Is the resistance between 15 and 25 Ohms?
Yes »Go To 4
No »Replace the Intake Air Heater relay.
DURE)
4. SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE

Disconnect the ECM harness connector(s).
Measure the resistance between the signal circuit of the intake air heater relay and battery negative.
Is the resistance greater than 100 K ohms?
Ves »Go To 5
No »Repair signal circuit shorted to battery negative.
DURE)
5. SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the signal circuit of the intake air heater relay and all other circuits in the ECM
harness connector.
Yes »Go To 6
No »Repair signal circuit shorted to other circuits.
DURE)
6. ECM
Disconnect the intake air heater relay signal wire.
Did DTC P0542?
PROCEDURE)
9 .. 2062 ENGINE .. ELECIRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
P0545-EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW - BANK 1 SENSOR 1
• - - - - - . - - - - - - - . - - - - - - - . S1 ••
I EXCEPT I EXCEPT I EXCEPT

~~~
I I I I I I
K900 K900 K900 K900 K900 K900 K900
18 20 18 20 18 20 18
DBJt'lG DBJt'lG DBIDG DBIDG DBIDG DBIDG DBIDG
I I I I I I
~~~
,l SE•• OR· ,[E

1
[E EIHAUST
TEl PERATURE ", IEllaR·
IIHAUIT
TEIPERATURE 1/2
[E 2 SENSOR·
EIHAUST
TEMPERATURE 1/1
1 1
EXCEPT 1 Y EXCEPT EXCEPT
~~~
I I I I I I
K1S5 KISS K372 K372 K1S6 K1D6
20 18 20 18 20 18
BRILB BRIL8 BRJt'lG BRJDG BRIDB BRIDB
I I ! I I I
~~~
"l "l
4
1---1-----1----1 5 6 11 J... C108
K900 K185 K372 K18S

18 18 18 18
DBIDG BRA.B BRJDG BR/oR
291c2 201c2 10lc! glC2

r SENSOR - - EXHAuST - - - - ExHAUsT- - - - -EXHAUST - lIODULE.
I GROUND TEMPERATURE TEM PERA TURE 1/3 TEM PERA TURE 112 I ENG.ITIIREOl
SENSOR 1 SENSOR SENSOR CO
I SIGNAL SIGNAL SIGNAL I
L_____________________ J
10 I
10 II
30 21
40 31
sa 41
50 51
laDUlE·
EIIGIIiE
SENSOR· SEUOR· 8EII.OR· CONTROL C2
EIHAUST EXHAUST EIHAUST ,1.1L)
TEMPERATURE 1/1 TEIPERATURE '/2 TEMPERATURE 1/3
,1.7L) ,1.lL) ,1.1L)
'UN~"
Theory of Operation
The aftertreatment temperature sensors are used by the ECM to monitor the engine exhaust temperatures in the
aftertreatment system. The aftertreatment temperature sensors are thermistors and change resistance based on the
temperature being measured. The ECM provides a 5-volt reference voltage to the sensor. The ECM monitors the
change in signal voltage and converts this to a temperature value. When the exhaust gas temperature is cold, the
sensor or thermistor resistance is high. The ECM signal voltage only pulls down a small amount through the sensor
to ground. Therefore, the ECM senses a high signal voltage or low temperature. When the exhaust gas temperature
is hot, the sensor resistance is low. The signal voltage pulls down a large amount. Therefore, the ECM senses a low
signal voltage. or a high temperature. The ECM will set the fault code if it detects that the aftertreatment diesel
particulate filter inlet exhaust gas temperature sensor signal voltage is less than a calibrated voltage for longer than
a calibrated period. The ECM illuminates the MIL lamp immediately when the diagnostic runs and fails. A default
value for the aftertreatment diesel particulate filter inlet temperature reading will be used and active regeneration of
the diesel particulate filter will be disabled. The ECM will turn off the MIL lamp immediately after the diagnostic runs
and passes .
• When Monitored:
Ignition ON
• Set Condition:
The ECM will set the fault if it detects that the diesel oxidation catalyst inlet exhaust gas temperature sensor
signal voltage is greater than a calibrated voltage (VDC) for more than a calibrated time.
Possible Causes
FAILED SENSOR
(K185) EXHAUST TEMPERATURE 1 SIGNAL CIRCUIT OPEN
(K185) EXHAUST TEMPERATURE 1 SIGNAL SHORTED TO THE 5-VOLT SUPPLY CIRCUIT
(K185) EXHAUST TEMPERATURE 1 SIGNAL SHORTED TO BATTERY
ECM
Diagnostic Test
1. TEMPERATURE SENSOR
Disconnect the Exhaust Temperature Sensor 1.
Using an ohmmeter check the resistance of the sensor.
Is the resistance 82k and 300k ohms at ambient temperature?
Yes »Go To 2
2. (K185) EXHAUST TEMPERATURE 1 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND
CIRCUIT
Reconnect the Temperature sensor.
Measure the resistance between the (K185) Exhaust Temperature 1
[]
Signal circuit and (K900) Sensor groun~ circuit at the ECM harness
connector.
NOTE: The sensor's resistance value increases with decreasing
temperature.
Is the resistance between 82k and 3DOk ohms at ambient tem- 10
perature? 20
00000
00000
.,
30 00000 21
00000
Yes »Go To 5 40 00000 31
so 00000 .1
No »Go To 3 410 51
MODULE.
ENGaNE
CONTROLC2
(1.71.)
81802950
3. EXHAUST TEMPERATURE 1 SIGNAL CIRCUIT OPEN

Disconnect the Exhaust Temperature Sensor 1.
Measure the resistance of the (K185) Exhaust Temperature 1 Signal cir·
cuit between the sensor harness connector and the ECM harness con-
nector.
Yes »Go To 4
No »Repair the open sensor Signal circuit.
Perform POWERTRAfN VERIFICATION TEST. (Refer to 9 -
ENGINE - STANDARD PROCEDURE)
10
20 11
3D 21
40 31
so 41
80 11
MODULI!-
ENGINE
CONTRQl.C2
(8.7L)
81a02955
DR - - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 • 2065

Measure the resistance of the (K900) Sensor ground circuit between the
2
Yes »Go To
No »Repair the open Sensor ground circuit.
Perfonn POWERTRAIN VERIFICATION TEST. (Refer to 9 -
29
SEN8QR-
DteaI!L
OXIDATION
CATALYSTS
(DOC)
10
20 11
30 Z\
40 31
50 41
eo 51
MODULE-
ENOINE
CONTROLC2
(UL) 81a0295d
5. (K185) EXHAUST TEMPERATURE 1 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure resistance from (K185) Exhaust Temperature 1 Signal circuit to
all other circuits at the ECM harness connector.
-@lID
Yes »Go to 6
[OJ ~:@]
No »Repair the circuits that are shorted together. 20
~I.s
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 -
,...,
10
~ooo~
1
20 11
0000 00000
30 00000 00000 2'
40
00000
00000
0 00000
00000 3'
50 00000 00000 41
80 ,~ ~~ 81
~ ~
MODUU!.
ENGINE
CONTROLC2
(1.7L)
81a02969
9 .. 2066 ENGINE .. ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
6. ECM
While monitoring the Exhaust Temperature Sensor 1 with scan tool, use
a jumper wire and connect the sensor (K185) Exhaust Temperature 1
Signal circuit to the sensor (K900) Sensor ground wire at the sensor
connector.
Did the DTC for voltage high go inactive and the OTC for volt-
age low become active?
Yes »Refer to the INTERMITTENT CONDITION Symptom. (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING)
2
Periorm POWERTRAIN VERIFICATION TEST (DIESEL).
(Refer to 9 - ENGINE - STANDARD PROCEDURE) seNSOR.pRE·
CATALYTIC
TEMPERATURE
(DIESEL)
81a029af
P0546-EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH - BANK 1 SENSOR

1
e-----e-------e-------e 8101
EXCEPT I EXCEPT I EXCEPT
I
~~~
I I 1 I I I
1<900 K900 K900 1<900 1<900 1<900 1<900
18 20 18 20 18 20 18
DBIDG DBfOG DBn:lG DelOS DBI1.'lG DBfOG DBIDG
I I I I
'---v---" '---v---"
21
rn21 tE1I80R.
EIHAUIT
TEMPERATURE i!1
rn1 SEISOR.
EIHAUST
TEMPERATURE 1/2
rn
2
SElSOR·
EIHAIST 1
TEMPERATURE 1/3
EXCEPT 1Y EXCEPT EXCEPT

~
I I
~~
I I I I
K185 K185 K372 K312 K186 K186
20 18 20 18 20 18
BR4.B 8RIl8 BRms BRIDG BRIDB BRIDB
I I
'---v---"
1 1
4
,---1-----1--- 5 6
K900 K185 K372 K186

18 18 18 18
DB,uG BRR.B 8RI1.'lG BRJOR
291
r SENSOR -
C2
-
20 C2
EXHAuST -
1
- - -
10 C2 1
ExHAUST- - - -
91
-EXHAUST -
C2
lMODULE.
I GROUND TEMPERATURE TEMPERATURE 1/3 TEMPERATURE 112 I EII.IIIE
SENSOR 1 SENSOR SENSOR COIITROL
I ~ I ~ ~~
L-- ___________________ J
10 1
20 11
30 21
40 31
so 41
to 51
10DULE·
EIOIIE
lEI lOR· 8EIIIOR· SElSOR· COIITROL Cl
EIHAUST EIHAUST EIHAUST (l.fL)
TEMPERATURE 1/t TEMPERATURE 1/2 TEMPERATURE 1/3
(I.n, IS.fL) (I.n)
Theory of Operation
The aftertreatment temperature sensors are used by the Electronic Control Module (ECM) to monitor the engine
exhaust temperatures in the aftertreatment system. The aftertreatment temperature sensors are thermistors and
change resistance based on the temperature being measured. The ECM provides a 5 volt reference voltage to the
sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. When the exhaust
gas temperature is cold, the sensor or thermistor resistance is high. The ECM signal voltage only pulls down a small
amount through the sensor to ground. Therefore, the ECM senses a high signal voltage or low temperature. When
the exhaust gas temperature is hot, the sensor resistance is low. The signal voltage pulls down a large amount.
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will set the fault if it detects that
the diesel oxidation catalyst inlet exhaust gas temperature sensor signal voltage is greater than a calibrated voltage
(VDC) for more than a calibrated time. The ECM illuminates the MIL lamp immediately when the diagnostic runs and
fails. A default value for the aftertreatment diesel oxidation catalyst inlet temperature reading will be used and active
regeneration of the diesel particulate filter will be disabled. The ECM will turn off the MIL lamp immediately after the
diagnostic runs and passes .
• When Monitored:
Ignition ON
• Set Condition:
signal voltage is greater than a calibrated voltage (VDC) for more than a calibrated time.
Possible Causes
EXHAUST GAS TEMPERATURE 1 SENSOR

(K185) EXHAUST GAS TEMPERATURE 1 SIGNAL CIRCUIT OPEN
(K185) EXHAUST GAS TEMPERATURE 1 SIGNAL CIRCUIT SHORTED TO THE (F855) 5-VOLT SUPPLY
(K185) EXHAUST GAS TEMPERATURE 1 SIGNAL CIRCUIT SHORTED TO BATTERY
ECM
Diagnostic Test
Disconnect the Exhaust Gas Temperature Sensor 1.
Is the resistance 82k and 300k ohms at ambient temperature?
Yes »Go To 2
PROCEDURE)
2. EXHAUST GAS TEMPERATURE 1 SENSOR CIRCUIT CHECK

Measure the resistance between the (K185) Exhaust Gas Temperature
1 Signal circuit and the (K900) Sensor ground circuit at the ECM har-
ness connector.
temperature.
Is the resistance 82k and 300k ohms at ambient temperature? 10
20
Ves »Go To 5 30
"
21
40 31
No »Go To 3 !SO 41
eo 51
MODUI.E·
ENGINE
CONTROl.C2
(6.71.)
81a02950
3. (K185) EXHAUST GAS TEMPERATURE 1 SIGNAL CIRCUIT OPEN

Disconnect the Exhaust Gas Temperature Sensor 1
Measure the resistance of the (K185) Exhaust Gas Temperature 1 Sig-
nal circuit between the sensor harness connector and the ECM harness
connector.
Yes »Go To 4
No »Repair the open (K185) Exhaust Gas Temperature 1 Signal
circuit.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) teHlIOll-
01. . . .
QlODAiIQM
CAf~'f1JTlJ
20
jDOC)
10
20 11
110 l1
40
50
eo
.,
31
51
MODULE·
ENGINE
CONTROLC2
(8.7L)
81a02955

Measure the resistance of the sensor (K900) Sensor ground circuit
between the sensor harness connector and the ECM harness connec-
tor.
2
Ves »Go To 6
No »Repair the open (K900) Sensor ground circuit.
29
11
21
31
oil
&1
MODULE-
ENGINE
CON1JIIOL C2
CULt 81a0295d
5. (K185) EXHAUST GAS TEMPERATURE 1 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure resistance from (K185) Exhaust Gas Temperature 1 Signal cir-
cuit to aU other circuits at the ECM harness connector.
-&JID
Ves »Go to 6
[] ::~
No »Repair the circuits that are shorted together. 20
t.~
Periorm POWERTRAIN VERIFiCATION TEST - 6.7L.
n
10 ~~
0000 ~oooo'"
1
1lO 0000 II
00000
30 00000 00000 21
40
00000
00000
0 00000
00000 ~1
50 00000 00000 41
eo ~ /
41
-= .....
MODUI.I-
ENGINE
CONTRot.C2
(e.7L)
81a02969
6. ECM
While monitoring the Exhaust Gas Temperature Sensor 1 with scan tool,
use a jumper wire and connect the (K185) Exhaust Gas Temperature 1
Signal circuit to the (K900) Sensor ground circuit at the sensor connec-
tor.
Did the DTC for voltage high go inactive and the DTC for volt-
age low become active?
SENSOR·PRE-
CATALYTIC
TEMPERATURE
(DIESEL)
81a029af

DURE)
9 • 2072 ENGINE .. ELECIRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
P0562-BATTERV VOLTAGE LOW
• When Monitored:
With the key on or the engine running .
• Set Condition:
The battery voltage detected by the ECM is less than a calibrated value.
Possible Causes
P0622 PRESENT
P2503 PRESENT
P2504 PRESENT
BATTERY TERMINAL CONNECTIONS
ACCESSORY WIRING
BATTERY
HIGH RESISTANCE IN WIRE HARNESS
ECM
Diagnostic Test
1. P0622 PRESENT
Is P0622 set?
DURE)
No »Go To 2
2. P2504 PRESENT
Is P2504 set?
Ves »Repair P0504 first.
DURE)
No »Go To 3
3. P2503 PRESENT
Is P2503 set?
Ves »Repair P2503 first.
DURE)
No »Go To 4
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS ... 6.7L DIESEL 9 .. 2073
4. BATTERY TERMINAL CONNECTIONS

Visually inspect the positive and negative connections at the batteries and inspect the battery negative connections
at the engine block.
Are the connections free of corrosion and are they tight?
Yes »Go To 5
No »Repair the poor connections.
DURE)
5. ACCESSORY WIRING
Check for add-on or accessory wiring at positive (+) terminal of the battery
Are there any damaged wires at the battery?
Yes »Repair accessory wiring.
DURE)
No »Go To 6
6. BATTE RY(S)
Perform battery load test using the Midtronics Micro 420 battery system tester.
Did the battery(s) pass the test?
Yes »Go To 7
No »Replace the weak battery or batteries.
DURE)
7. HIGH RESISTANCE IN WIRE HARNESS

Disconnect the battery terminals.
Measure the resistance from the positive and negative battery posts to the appropriate circuits in the ECM harness
connector
Yes »Go To 8
No »Repair the high resistance in the wire harness.
DURE)
9·2074 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
8. ECM
Reconnect the battery terminars.
Measure and record the voltage between battery positive pins of the ECM connector and the battery negative cir-
cuits of the ECM harness connector.
Use the scan tool to measure and record battery voltage.
Are the readings within 3 volts of each other?
Replace and program the Engine Control Module (Refer to 9 - ENGINE - STANDARD PROCEDURE)
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 • 2075
P0563-BATTERV VOLTAGE HIGH
• When Monitored:
With the key on or the engine running .
• Set Condition:
The battery voltage detected by the ECM is greater than a calibrated value.
Possible Causes
P0622 PRESENT
P2503 PRESENT
P2504 PRESENT
BATTERIES IMPROPERLY INSTALLED
ECM
Diagnostic Test
1. P0622 PRESENT
Is P0622 set?
DURE)
No »Go To 2
2. P2503 PRESENT
Is P2503 set?
DURE)
No »Go To 3
3.' P2504 PRESENT

Is P2504 set?
DURE)
No »Go To 4
9 - 2076 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
4. BATTERIES IMPROPERLY INSTALLED

Measure the battery voltage between the positive circuits and ground of the ECM harness connector.
Is the voltage less than 19 volts?
Yes »Go To 5
No »Install the battery system correctly.
DURE)
5. ECM
Reconnect the battery terminals.
Measure and record the voltage between battery positive pins of the ECM connector and the battery negative cir-
cuits of the ECM harness connector.
Replace and program the Engine Control Module (Refer to 9 - ENGINE - STANDARD PROCEDURE)
DURE)
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 2077
POS71-BRAKE SWITCH 1 PERFORMANCE
Theory of Operation
This diagnostic is designed to detect a faulty brake switch. The algorithm starts to run when the operator is driving
above 30 mph (48 kmh) for more than 5 minutes. If after that time vehicle speed drops to below 2 mph (3 kmh) and
the ECM does not detect brake activity the diagnostic will fail. The ECM will turn on the ETC lamp immediately after
the diagnostic runs and fails .
• When Monitored:
Engine speed is above 30 mph (48 kmh) for more than 5 minutes
• Set Condition:
Vehicle speed is detected at 2 mph (3 kmh) without brake activity.
Possible Causes
VEHICLE SPEED SENSOR

BRAKE SWITCH
ECM
Diagnostic Test
1. OTHER DTC'S
Are other DTCs present?
No »Go To 2
2. ECM
Interview customer. This fault can be set if the customer coasts to a vehicle speed below 2 mph (3 kmh) by using
the parking brake or exhaust brake.
Did the customer coast to a near stop without using the service brake?
Yes »Explain diagnostic operation to customer. Repair complete.
DURE)
9 .. 2078 ENGINE .. ELECTRICAL DIAGNOSTICS" 6.7L DIESEL - - - - - - - - - DR
P0572-BRAKE SWITCH 1 STUCK ON
I
r
BATT 10
F ------ ~
-I MODULE·
TOTAUY
1 I IIMTEGR1TED
1
1
® ~~SE
® ~~SE
1 POWER
1
1 lOA 20A I
~ _1_____1.. ___ I
15,(C3 9v e.
F202
20
PKIGY
I
• 8136
V30
20
VTIWT A103 629
18 20
25 1 6 A
t- - - - ----t-
V30
GYn:l.D
69 1 Cit.
- - - - - - - ----t
Al03
DGNIT
829
20 18 20
VTNJT GYIRD DGNH
31 11 61
2, 5'"
V32 L5D
20 18
t. .
VTm ·WTITN
I
.8214 • Il2i
21
LSO
I
. 14)9 I
18 20 B29
Vl2 WTITN BK/oR 20
20
VTIYL + DGNIT
t
3 C2n
131 cnD L5D

18
WTlTN 21 .13D
I
• 8111
I 829
L5D 18
18 DG/WT
WTlTN
.... a201
V32
21
"I.
18 MODULE·
VTIYL BAlKE
PROVISION
r
ale2
BRAKE - - - - - - - - - - - - - - - - - - - - BRAKE """"I MODULE·
1 SWITCH NO.2 SWITCH NO.1 1EUIIE
1 SIGNAL SIGNAL ICOITAOL
1 ______ - - - - - - - - - - - - - ______ 1

DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 - 2079
• When Monitored:
While the ignition is on
• Set Condition:
The brake switch status is = to OFF and the not brake switch status is = to ON for a calibrated amount of time.
Possible Causes
DAMAGED WIRING HARNESS OR CONNECTORS

BRAKE SWITCH CIRCUIT SHORTED TO GROUND (BRAKE SWITCH WILL ALWAYS BE OFF)
BRAKE SWITCH
ECM
1. BRAKE SWITCH CIRCUIT SHORTED TO GROUND

Disconnect the brake switch connection. Inspect the pins and connector for damage. corrosion. etc.
Disconnect the ECM connectors. Inspect the pins and connector for damage, corrosion, etc.
Measure the resistance between the brake switch circuit in the ECM connector and battery negative.
Yes »Repair the Brake switch circuit shorted to ground.
DURE)
No »Go To 2
2. BRAKE SWITCH CIRCUIT SHORTED TO OTHER CIRCUITS IN HARNESS

Measure the resistance between the brake switch wire in the ECM connector and aU other pins in the ECM con-
nector.
Yes »Repair or replace the harness.
DURE)
No »Go-To 3
3. ECM
Reconnect the ECM connectors.
Measure the resistance between the brake switch circuit at the switch connector and battery negative.
DURE)
No »Go To 4
4. BRAKE SWITCH
Reconnect the brake switch connector.
Using the scan tool, clear the DTCs.
Cycle the brake pedal several times.
Using the scan toolt read the DTCs.
Has the brake switch low DTC returned?
Yes »Replace the brake switch.
DURE)
No »Perform INTERM11TENT CONDITION - DIESEL test. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
POS73-BRAKE SWITCH 1 STUCK OFF
r-r
: @
-------
IAtl AO
: ~
1 ~
-I IODILI·
TOTALLY
~I::::ATED
I ~~SE I ~~SE 1 ,
I lOA 20A 1
1_ _ 1_____1____ I
15 yC3 9 ;' CI
F2D2
20
PlClGY
I
• 1131
V30
20
VTNH Al0a 829
18 20
J t--
V30
GYIRO
61
--t-------
Al03
DGMT
&, 1 02 ..
--t
829
20 18 20
VTMT GYIRD DGAVT
31 11 61
I ~ ! ...
'T 21
V32 LSD
211 18
t
VTfYL WTlTN
I
.12t4 • IUt
21 1211
I
LSO zm I
18 28 B29
Vl2 WTlTN 8K1OR 20
20
VTfYl 3 t 021.
D6"'T
13 f C.at
L50
WTlTN
18
I
• • tU
22 j cIa.
I 829
L50 18
18 DGINT
WTlTN
JL GIGt
V32
18
21 MODULI·
VTfYL IRlIE
6102
r- BRAKE - - - - -
PROVIIIOI
- - - - - - - - - - - - - - -
JC2
BRAKE""" MODULE·
r SWITCH NO.2 SWITCH NO.1 E•• IIEI
I SIGNAL I SIGNAL OONnOL
1______ - - - - - - - - - - - - - ______ 1

9 - 2082 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
• When Monitored:
While the ignition is on .
• Set Condition:
The brake switch status is ::;; to ON and the not brake switch status is ::;; to OFF for a calibrated amount of time.
Possible Causes
DAMAGED WIRING HARNESS OR CONNECTORS

BRAKE SWITCH CIRCUIT OPEN (BRAKE SWITCH WILL ALWAYS BE ON)
BRAKE SWITCH CIRCUIT SHORTED TO BATTERY VOLTAGE (BRAKE SWITCH WILL ALWAYS BE ON)
BRAKE SWITCH
ECM
1. BRAKE SWITCH CIRCUIT OPEN

Disconnect the brake switch connection. Inspect the pins and connector for damage, corrosion, etc.
Disconnect the ECM connectors. Inspect the pins and connector for damage, corrosion, etc.
Measure the resistance between the brake switch signal circuits in the ECM connector and the brake switch con-
nector.
Yes »Go To 2
No »Repair the open brake switch circuits.
DURE)
2. BRAKE SWITCH CIRCUIT SHORTED TO VOLTAGE

Measure the voltage between the brake switch circuits in the ECM connector and battery negative.
Yes »Go To 3
No »Repair the short to voltage in the circuit.
DURE)
3. ECM
Install a jumper wire in the brake switch connector between signal circuit and to ground.
Using the scan tool, read the DTCs.
Is the DTC for brake switch low voltage present?
Yes »Go To 4
PROCEDURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6. 7L DIESEL 9 .. 2083
4. BRAKE SWITCH
Reconnect the brake switch connector.
Using the scan tool, clear the DTCs.
Using the scan tool, read the OTCs.
Has the brake switch High DTC returned?
Ves »Replace the brake switch.
DURE)
No »Perform INTERMITTENT CONDITION - DIESEL test. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
9 • 2084 ENGINE • ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - - DR
P0580-SPEED CONTROL SWITCH 1 CIRCUIT LOW
SWITCH·
SPEED
COIIITROL·
RIGHT
1 ACCEL
2 RESUME
30ECEL
r - - - - - - - - - - - - - - - - - - - - - - , SWITCH.
SPEED
COITROL·
LEn
1 CRUISE CONTROL ON
2CRUISE CON TR OL 0 FF
V937
22
DBItlG
Ai
V937 V37 Vl8 VJ7 V38
22 22 22 22 22
OBIDG VT VTIOR VT VTIOR
!.....--~, ,~
1,---
I ~
! ---------,-II
CO
___ __________ _I
1-3----'-.. . .
::EDE~~:Q
CONTROL
1
51 Ct 4l C1 J 1 C1
V937 V37 V3B

20 20 20
VTIBR VT - VTlOR
I
• S219
I
V937
20
VTIBR
30 !...- - -
'(
-v- -
51 '(
- - - - - - - -
52 Y
C219
T---------- -'"
V931 V37 VJ8
20 20 20
VTIBR I 2 VT , 25 VTJOR
-l " .l
I 15
I I 26
V
r,- - - 1B I' H J. C130
18
VTfBR
I
• S033
I
V937 V37 V38
18 18 20
VTIBR VT VTIOR
33 -l C2 40 J.. C2
56 C2 A I MIT
r- SIC - - - SIC - - - - - - - - -
Sic - ..., IODULE· " AIT
I SWITCH SWITCH NO. t SWITCH NO.2 I EIII GIlliE
I
f-
RETURN SIGNAL
_________________ ~
SIGNAL COITROL I

• When Monitored:
• Set Condition:
Speed control MUX switch below 1.0 volts for 5 seconds.
Possible Causes
SIC WIRING HARNESS OBSERVABLE PROBLEM

SIC SWITCH (ON/OFF)
STEERING COLUMN CONTROL MODULE
SIC SWITCH (RESUME/ACCEL)
(V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO GROUND
(V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
ECM
Diagnostic Test
1. SIC SWITCH VOLTAGE BELOW 1.0 VOLT

With the scan tool, read the SIC Switch volts status in the ECM.
Is the SIC Switch voltage below 1.0 volt?
Yes »Go To 3
No »Go To 2
2. SIC WIRING HARNESS OBSERVABLE PROBLEM

Using the Schematics as a guide. inspect the Wiring and Connectors.
Were any problems found?
Ves »Repair as necessary.
DURE)
No »Go To 3
3. SIC SWITCH (ON/OFF)

Disconnect the SIC ONIOFF Switch harness connector.
With the scan tool in Sensors. read the SIC Switch volts in the ECM.
Did the SIC Switch volts change to 5.0 volts?
Yes »Replace the SIC ON/OFF Switch.
DURE)
No »Go To 4
9 • 2086 ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
4. SIC SWITCH (RESUMEIACCEL)

Disconnect the SIC RESUMEIACCEL Switch harness connector.
With the scan tool in Sensors, read the SIC Switch volts in the ECM.
Did the SIC Switch volts go above 4.0 volts?
Yes »Replace the Resume/Aceel Switch.
DURE)
No »Go To 5
5. SCCM SHORTED TO GROUND

Disconnect the C1 SCCM harness connector (instrument panel wiring side).
Yes »Replace the Steering Column Control Module in accordance with the Service Information.
DURE)
No »Go To 6
6. (V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the SIC ON/OFF Switch harness connector.
Measure the resistance between the (V37) SIC Switch 1 Signal circuit
g -@lID
~JG~
and ground (6-) at SIC ON/OFF Switch harness connector. c c
~ ~IJ ~
Yes »Repair the short to ground in the (V37) SIC Switch 2 Signal
circuit.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). [I •
(Refer to 9 - ENGINE· STANDARD PROCEDURE) SWITCH- SWITCH-
SPEED ,PEED
No »Go To 7 CONTROL- CONTROL-
RIGHT LEFT
81336cab
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 - 2087
7. (V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO THE (V937) SIC SWITCH RETURN CIRCUIT
Measure the resistance between the (V37) SIC Switch Signal circuit and
the (V937) SIC Switch Return circuit at the ONIOFF switch harness
connector. -@lID
Yes »Repair the short between the (V37) SIC Switch 1 Signal cir-
::~
cuit and the (V937) SIC Switch Return circuit.
~~
No »Replace and program the ECM in accordance with the Ser-
vice Information.
SWITCH- SWlTCM-
(Refer to 9 - ENGINE· STANDARD PROCEDURE) SPEED SPEED
CONTROL· CONTROL·
RIGHT LEfT
81336cb7
P0581-SPEED CONTROL SWITCH 1 CIRCUIT HIGH
SWlrCH·
SPEED
CONTROL·
RIGHT
1 ACCEL
2 RESUME
3 DECEL
r--------------------, SWITCH.
SPEED
CONTROL·
LEFT
1 CRUISE CONTROL ON
2 CRUISE CONTROL OFF
V937
22
08106
By
V9l1 V3l V38 V37 V38
22 22 22 22 22
DBIDG VT VTlOR VT VTlOR
1,---! ---------
r....-_ _---"', J.-,-----I
C. -----I 3~
rl-II:TOEDE~~:~
I
~ ______________ ~_I CONTROL
51 C1 '1 Ct 31 CI
V937 V31 V38
M m m
VTIBR VT VTlOR
I
• 1211
I
V937
20
VTIBR
10
V937
t- -y-----
51 '(
V31
-52 '(
V38
cut
20 20 20
VTIBR 2 VT I 25 VTIOR
• 15 ,l 18,l - - - - I I 24 J. CUI
•• 26 1'-- I: - ---"
T
V937
18
VTIBR
I
• S033
I
V937 V37 V3B
18 18 20
VTJIlR Vl VTIOR
31 ,l CI 40 ,l CZ 5Ll C2 • MIT
r- - - - - - - - - - - - - - - - - - ..., IIODULE. . , Aff
I SIC SIC SIC I ENGIIE
SWITCH SWITCH NO 1 SWITCH NO, 2 CONTROL
I RETURN SIGNAL
L..-. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ......
SIGNAL I

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 - 2089
• When Monitored:
Key on or Engine running.
• Set Condition:
Speed Control MUX switch above 11.5 volts for 5 seconds.
Possible Causes

SPEED CONTROL ON/OFF SWITCH
(V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO VOLTAGE
(V37) SIC SWITCH 1 SIGNAL CIRCUIT OPEN ECM TO CLOCK SPRING
(V37) SIC SWITCH 1 SIGNAL CIRCUIT OPEN CLOCKSPRING TO SIC SWITCH
(V937) SIC SWITCH RETURN CIRCUIT OPEN CLOCKSPRING TO SIC SWITCH
(V937) SIC SWITCH RETURN CIRCUIT OPEN ECM TO CLOCKSPRING
ECM
DIA~NOSIS AND TESTING)
Diagnostic Test
1. SCAN TOOL SHOWS SPEED CONTROL SWITCH ONIOFF

With the scan tool in Inputs/Outputs, read the Speed Control inputs state in ECM.
While monitoring the scan tool, push the Speed Control On/Off Switch several times, then leave it on.
Did the scan tool show Speed Control Switch off and on?
Yes »Go To 2
No »Test Complete.

Using the Schematics as a guide, inspect the Wiring and Connectors.
DURE)
No »Go To 3
3. STEERING COLUMN CONTROL MODULE

Disconnect the C1 and C3 SCCM harness connectors.
Measure the resistance of the (V937) SIC Switch Return circuit between
the C1 and C3 SCCM harness connectors.
Measure the resistance of the (V37) SIC Switch 1 Signal circuit
between the C1 and C3 harness connectors.
Was the resistance above 5.0 ohms for either circuit?
Yes »Replace the Steering Column Control Module.
Periorm POWERTRAIN VERIFICATION TEST (DIESEL).
e 4
No » Go To 4 '-------'1
ClOCKlPltIMG C1 ClOCKSPRINo. cs
81336d32
,-",~,
ClOClalPRiNO C1
81336d2e
4. SPEED CONTROL ON/OFF SWITCH

Disconnect the Speed Control OnlOff Switch 2-way harness connector only.
Measure the resistance across the SIC On/Off Switch.
Is the resistance between 20.3K and 20.7K ohms?
Yes »Go To 5
No »Replace the On/Off Switch.
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6. 7L DIESEL 9 • 2091
5. (V37) SIC SWITCH 1 SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the (V37) SIC Switch 1 Signal circuit at the
OnlOff Switch connector.
Yes »Repair the (V37) V37 Switch 1 Signal circuit for a short to
voltage.
(Refer to 9 ~ ENGINE - STANDARD PROCEDURE)
No »Go To 6
SWITC .... SWITCH·

SPEED SPEED
CONTROL. CONTROL·
FUGHT LEFT
81336cfb
6. SIC SWITCH 1 SIGNAL CIRCUIT OPEN ECM TO SCCM

Measure the resistance of the (V37) SIC Switch 1 Signal circuit between the ECM connector and the C1 SCCM
harness connector.
Yes . »Go To 7
No »Repair open in the (V37) SIC Switch 1 Signal circuit between the ECM and SCCM.
DURE)
7. (V37) SIC SWITCH 1 SIGNAL CIRCUIT OPEN BETWEEN THE SCCM AND SIC SWITCH
Measure the resistance of the (V37) SIC Switch 1 Signal circuit from the
C3 SCCM harness connector to the SIC switch harness connectors.
Yes »Go To 8
No » Repair the open in the (V37) SIC Switch 1 Signal circuit c
~
between the SCCM and SIC Switches.
3
c
JlJlL .=g
~SWITCH·
8PEEC
CONTftOL- CLOCI(8PFllNO C3
RIGHT 81336d21
8. (V937) SIC SWITCH RETURN CIRCUIT OPEN SCCM TO SIC SWITCH

Measure the resistance of the (V937) SIC Switch Return circuit between
the SIC Switch harness connectors to the SCCM harness connector.
Yes »Go To 9
~
No »Repair open in the (V937) SIC Switch Return circuit
between the SCCM and the SIC Switches.
B 2
~c:~:-,~,
SPEED
CONTROL- Cl.OCKSPRING C3
RIGHT 81336d2a
9. (V937) SIC SWITCH RETURN CIRCUIT OPEN BETWEEN THE ECM AND SCCM
Measure the resistance of the (V937) SIC Switch Return circuit between the ECM harness connector to the C1
SCCM harness connector.
DURE)
No »Repair open in the (V937) SIC Switch Return circuit from between the ECM and SeCM.
DURE)
POS85-SPEED CONTROL SWITCH 1/2 CORRELATION
SWITCH·
SPEED
COInROL·
RIGHT
1 ACCEL
2 RESUME
3 DECEl
swnCH·
SPEED
CONTROL·
LEFT
1 CRUISE CONTROL ON
2 CRUISE CONTROL Off
V9l7
22
DBIUG
By
V937 V38 V37 VJ8
22 22 22 22 22
DBIDG VT VTlOR VT VT/OR
3~ J-3---1---1
-----,
',---!--------
I
~
h
_______________ I
-+-II::EDE~~:~
CONTROL
51 Ct 41 Ct J l Ct
V937 V37 V38

20 20 20
VTI13R VT VTlOR
I
• 821.
I
V931
20
VTIBR
30 1-- - -
'(
--...r-
51 '(
- - - - - - -
52 Y
CUI
V937 V37 V38

20 20 20
VTIBR I 2 VT • 25 VTlOR
I:~: t- _I~ 1T8.L -

V937
_____ ~~4--.! CUD
18
VTIBR
I
• SD33
I
V9J7 V37 V38
18 18 20
VTIBR VT VTJOR
~1~ ~.L~ Hl~ I MIT
,.- Sic - - - SIC- - - - - - - - - - SIC - .., MODULE· .1 AIT
t SWITCH SWITCH NO.1 SWITCH NO, 2 I ENGINE
I RETURN SIGNAL SIGNAL ICONTROL
' - - - - - - - - - - - - - - - - - - _ .....
• When Monitored:
Ignition on .
• Set Condition:
Speed control switches do not correlate with each other.
Possible Causes
SPEED CONTROL SWITCHES

Diagnostic Test
1. SPEED CONTROL SWITCHES

View repair?
Repair
Replace both speed control switches.
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 • ENGINE - STANDARD PROCEDURE)
P0592-SPEED CONTROL SWITCH 2 CIRCUIT LOW
. . . . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . •••,CH·
SPEED
CONTROL·
RllHl
1 ACCEl
2 RESUME
3 DECEL
.WITCH-
.PEED
CONTROL·
LEFT
1 CRUISE CONTROL ON
V931
22
OBIDG
AI
vm V37 V38 V37 VJ8
22 22 22 22 22
oBlDG VT VTIOR VT VTIOR
-----~,.1 3~
I1,--
J-2----'-.. .1
-! ---------,-II
. :~~~~:Q
conROL
~
51 r ---
CI 4
-----_____
CI 3
1
_I
Ct
V931 V37 V38

20 20 20
VTIBR VT VTIOR
I
• S2U
I
V037
20
VT/BR
3oL- '(
-y--------
51 '( -52 '( C219
V937 VJ7 V38
20 20 20
.: :::t -.:
VTIBR 2 VT I 25 VT/OR
_ _24 - A
II .l C131
'T8 1 - - - - - -
• •033
I
V937 V37 vau
18 1B 20
VT /BR VT VTIOR
331 C2 40 1 CI 56 AC2 I Mn
,.- Sic- - - SIC- - - - - - - - - - Sic - I.ODULE. II An
I SWITCH SWITCH NO.1 SWITCH NO.2 I EIIIIE
I RETURN SIGNAL SIGNAL I COITROL
~-----------------~

• When Monitored:
• Set Condition:
Speed control MUX switch below 1.0 volts for 5 seconds.
Possible Causes

SIC SWITCH (ON/OFF)
SIC SWITCH (RESUMEIACCEL)
(V3S) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO GROUND
(V3S) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO (V937) SIC SWITCH RETURN CIRCUIT
ECM
Always perform the Pre-Diagnostic Troubleshooting pro~edure before proceeding. (Refer to 9 - ENGINE -
Diagnostic Test
1. SIC SWITCH VOLTAGE BELOW 1.0 VOLT

With the scan tool, read the SIC Switch volts status in the ECM.
Is the SIC Switch voltage below 1.0 volt?
Yes »Go To 3
No »Go To 2

Perlorm POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
No »Go To 3
3. SIC SWITCH (ON/OFF)

Disconnect the SIC ONIOFF Switch harness connector.
Yes »Replace the SIC ONIOFF Switch.
DURE) .
No »Go To 4
DR - - - - - - - - - ENGINE· ELECTRICAL'DIAGNOSTICS ·6.7L_DIESEL 9 .. 2097
4. SIC SWITCH (RESUMEJACCEL)

Disconnect the SIC RESUME/ACCEL Switch harness connector.
Ignition on, engine not running,
With the scan tool in Sensors, read the SIC Switch volta tn the ECM.
Did the SIC Switch volts go above 4.0 volts?
Yes »Replace the Resume/AcceI Switch,
DURE) ,
No »Go To 5

Disconnect the C1 SCCM harness connector (instrument panel wiring side).
With the scan tool in Sensors, read the SIC Switch volts in the ECM,
Old the SIC Switch volts change to 5.0 volts?
Perform POWERTRAIN VERIFICATION TEST (DIESEL), (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
No »Go To 6
6. (V38) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the SIC ON/OFF Switch harness connector.
Measure the resistance between the V3S) SIC Switch 2 Signal circuit
and ground (B-) at SIC ONIOFF Switch harness connector.
Yes »Repair (V3S) SIC Switch 2 Signal circuit for a short to
ground.
No » Go To 7 .WlTCH.
aPEED
COHTROI.-
LI!FT 81498028
7. (V38) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO (V937) SIC SWITCH RETURN CIRCUIT
Measure the resistance between the (V38) SIC Switch 2 Signal circuit
and the (V937) SIC Switch Return circuit at the ONIOFF switch harness
-§JID
connector.
[] @)
:I
G
Yes »Repair the short between the (V38) SIC Switch 3 Signal cir-
cuit and the (V937) SIC Switch Return circuit. A B
~
A B
~
No »Replace and program the ECM in accordance with the Ser- A C
vice Information.
A C
Perform POWERTRAIN VERIFICATION TEST (DIESEL). SWITCH·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) SPEED
SWITCH- CONTROl·
SPEED RIGHT
CONTROL·
LEFT 81498027
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 ·2099
P0593-SPEED CONTROL SWITCH 2 CIRCUIT HIGH
. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , •• ITCH·
SPEED
COITROL·
RIGItT
1 ACCEl
2RESUME
3 DECEL
c A
,.lfCH.
SPEED
COITRaL-
LEn
1 CRUISE COMmOl ON
Vll7
22
D81t)G
BI
V937 V31 V38 V37 Y38
22 22 22 22 22
DBJDG VT VTIOR VT VTIOR
,~
""----""':
1,---! --------
I
~
5 Tet
U
___
4 TCt
-,-II::~~~:Q
__________ _I CONTROL
.t-3-----'---1
J I Ct
Y937 V37 V38

20 20 2n
VT IBR VT VT /OR
I
• 811.
I
V937
20
VTIBR
30 1--
Y
- --v- -
51 Y
- - - - - - -
52 Y
CUt
V937 V37 V38

20 2D 20
VTIBR 2 VT
.: ;: t- -.:
• 25 VTIOR
l8 1 ____ _'~4j C130
T
ym
18
YTIBR
I
• soaa
I
11937 V17 V38
18 18 20
VTIBR liT VT/OR
r-
33 '" CI 40 1 C2
SIC - - - SIC- - - - - - - - - - Sic - .., .aDULE·
Sfi 1 Cf • MIT
•• AIT
I SWITCH SWITCH NO.1 SWITCH NO.2 IIIIIGIIilE
I RETURN SIGNAL SIGNAL I COITROL
'----------------------* It ..... t

g .. 2100 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - - DR
• When Monitored:
Key on or Engine running .
• Set Condition:
Speed Control MUX switch above 11.5 volts for 5 seconds.
Possible Causes

SPEED CONTROL ONIOFF SWITCH
(V38) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO VOLTAGE
(V38) SIC SWITCH 2 SIGNAL CIRCUIT OPEN ECM TO CLOCK SPRING
(V38) SIC SWITCH 2 SIGNAL CIRCUIT OPEN CLOCKSPRING TO SIC SWITCH
(V937) SIC SWITCH RETURN CIRCUIT OPEN CLOCKSPRING TO SIC SWITCH
(V937) SIC SWITCH RETURN CIRCUIT OPEN ECM TO CLOCKSPRING
ECM
Diagnostic Test
1. SCAN TOOL SHOWS SPEED CONTROL SWITCH ONIOFF

With the scan tool in Inputs/Outputs, read the Speed Control inputs state in ECM.
While monitoring the scan tool, push the Speed Control OnlOff Switch several times, then leave it on.
Did the scan tool show Speed Control Switch off and on?
Yes »Go To 2
No »Test Complete.

DURE)
No »Go To 3

Disconnect the C1 and C3 SCCM harness connectors.
Measure the resistance of the (V93?) SIC Switch Return circuit between
the C1 and C3 SCCM harness connectors.
Measure the resistance of the (V38) SIC Switch 2 Signal circuit
between the C1 and C3 SCCM harness connectors.
Was the resistance above 5.0 ohms for either circuit?
No »Go To 4
CLOCI<IIPRINQ C1
CLOCKIPRING C3
81336d32
CLOCKSPRING-C1
CLOCKSPRINO C3
813393ca
4. SPEED CONTROL ON/OFF SWITCH

Disconnect the Speed Control OnlOff Switch harness connector only.
Measure the resistance across the SIC OnlOff Switch.
Is the resistance between 20.3K and 20.7K ohms?
Yes »Go To 5
No »Replace the On/Off Switch.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE • STANDARD PROCE-
DURE)
9 - 2102 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7l DIESEL - - - - - - - - - DR
5. (V3S) SIC SWITCH 2 SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the (V3S) SIC Switch 2 Signal circuit at both SIC Switch harness connectors.
Yes »Repair the (V3S) SIC Switch 2 Signal circuit for a short to voltage.
DURE)
No »Go To 6
6. (V3S) SIC SWITCH 2 SIGNAL CIRCUIT OPEN ECM TO SCCM

NOTE: Check connectors ... Clean/repair as necessary.
Measure the resistance of the (V38) SIC Switch Signal 2 circuit between the ECM connector and the C1 SCCM
harness connector.
Yes »Go To 7
No »Repair open in the (V38) SIC Switch 2 Signal circuit between the ECM and the SCCM.
DURE)
7. (V3S) SIC SWITCH 2 SIGNAL CIRCUIT OPEN SCCM TO SIC SWITCH

Measure the resistance of the (V38) SIC Switch 2 Signal circuit from the C3 SCCM harness connector to the SIC
Switch harness connectors.
Yes »Go To S
No »Repair the open in the (V38) SIC Switch 2 Signal circuit between the Steering Column Control Module
and the SIC switches.
DURE)
8. (V937) SIC SWITCH RETURN CIRCUIT OPEN BETWEEN THE SCCM AND SIC SWITCHES
Measure the resistance of the (V937) SIC Switch Return circuit between the SIC harness connectors to the C3
Yes »Go To 9
No »Repair open in the (V937) SIC Switch Return circuit from Steering Column Control Module to the SIC
switches.
DURE)
9. (V937) SIC SWITCH RETURN CIRCUIT OPEN BETWEEN THE ECM AND SCCM
Measure the resistance of the (V38) SIC Switch Return circuit between the ECM harness connector and the C1
DURE)
No »Repair open in the (V937) SIC Switch Return circuit between the ECM and Steering Column Control
Module.
DURE)
9 - 2104 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l D I E S E l - - - - - - - - - DR
P0601-INTERNAL MEMORY CHECKSUM INVALID
• When Monitored:
While the ignition is on .
• Set Condition:
A deviation between the ECM memory and a stored calibration.
I~~SH
Possible Causes
ECM
ECM
Diagnostic Test
1. FLASH ECM
Using the scan toolt reflash the ECM with the proper calibration for the particular truck.
Is the flash successful?
No »Go To 2
2. ECM
With the scan toolt read DTCs.
Did P0602 set after the reflash?
DURE)
No »Test Complete.
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 2105
P0604-INTERNAL CONTROL MODULE RAM
• When Monitored:
• Set Condition:
Intemal ECM software error.
Possible Causes
IREFLASH ECM
ECM
Always perform the Pra.Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE·
Diagnostic Test
1. REFLASH ECM
Using the scan tool, reflash the module with latest calibration
Was the flash successful?
Ves »Go To 2
DURE)
2. ECM
Run the engine for one minute and shut off.
Did P0604 set?
DURE)
No »Test Complete.
P0606-INTERNAL CONTROL PROCESSOR
Theory of Operation
This fault code is triggered when the internal PCM diagnostics detect a read or write error internal to the module.
The PCM illuminates the MIL light immediately when the diagnostic runs and fails. The PCM will turn off the MIL
light immediately after the diagnostic runs and passes. This fault code can only be caused by an internal PCM
problem and may prevent the engine from starting .
• When Monitored:
With ignition on .
• Set Condition:
ECM has detected internal failures.
Possible Causes
ENGINE OR FUEL MODIFICATIONS THAT EXCEED OEM SPECIFICATIONS.

ECM
Diagnostic Test
1. ECM
Verify all chassis grounds are properly connected. Refer to BW-91 - CONNECTOR/GROUND/SPLICE LOCATION
Is P-0606 stored?
No »Replace and program the ECM in accordance with the Service Information.
P0607 ECU INTERNAL PERFORMANCE
Theory of Operation
The purpose of this test is to check the internal ECM fuel system diagnostic (ASIC) for proper operation by falsely
inducing a failure and looking for the proper ECM response. At key off, the diagnostic overwrites injector on time
and falsely cycles the injectors. If the internal ECM detection chip (ASIC) detects the firing and sets an error than
the diagnostic passes. This diagnostic initially only runs at key off. If the diagnostic failed at the last key off cycle,
then it will also run at the next cranking event. If the driver stalls the engine (manual transmission only) at the same
moment that the key is turned off this diagnostic could fail. When the diagnostic fails, the ECM will flash the ETC
lamp.
• When Monitored:
Initially at key off. If the diagnostic fails at last key off then it wiU also run at the next cranking event.
• Set Condition:
Induced failure does not set the internal ECM detection chip (ASIC) error.
Possible Causes
UPRATE KIT THAT MODIFIES INJECTOR ON TIME

ECM
Diagnostic Test
Interview the customer. Ask if the truck was stalled at key off shortly before the ETC lamp started flashing.
Was the truck stalled at a recent key off event?
Yes »Explain diagnostic to customer. Repair complete.
No »Go To 2
2. ECM
Investigate truck for signs of a performance enhancement kit.
Are there signs that the customer has used a performance enhancement kit?
Yes »Repair complete. Return vehicle to owner.
No »Replace the ECM
P061A-ETC LEVEL 2 TORQUE PERFORMANCE
Theory of Operation
This algorithm monitors the control system to ensure that the fueling output is consistent based on the operating
conditions. The ECM will light the ETC lamp immediately after the diagnostic runs and fails. During this time the
customer may experience an engine derate or engine running rough. The ECM will turn off the ETC lamp once the
diagnostic passes in one drive cycle .
• When Monitored:
Engine running.
• Set Condition:
Varies with operation. Verifies the control system fueling output is consistent based on the operating condi-
tions.
Possible Causes
SOFTWARE REVISIONrrSBS
OTHER DTCS
EXHAUST MANIFOLD PRESSURE SENSOR
INTAKE MANIFOLD PRESSURE SENSOR
INTAKE MANIFOLD PRESSURE SENSOR
BRAKE SWITCH
ENGINE OR FUEL MODIFICATIONS THAT EXCEED OEM SPECIFICATIONS
ECM
Diagnostic Test
1 . SOFTWARE REVISIONITSBS
Check TSBs for software releases.
Are there any new software releases?
Yes »Reflash the ECM.
No »Go To 2
2. OTHER DTCS
Are there any other DTCs?
No »Go To 3

With the scan tool, read the Freeze frame data.
Is the coolant temperature reading uncharacteristically low for the operating conditions?
Yes »Replace Coolant Temperature Sensor
No »Go To 4
4. EXHAUST MANIFOLD PRESSURE SENSOR

Is the exhaust manifold pressure sensor reading higher than intake manifold pressure reading (boost
pressure)?
Yes »Replace the Exhaust Manifold pressure sensor.
No »Go To 5
5. INTAKE MANIFOLD PRESSURE SENSOR

Is the intake manifold pressure (boost pressure) sensor reading lower than the exhasut manifold pres-
sure reading?
Yes »Replace the Intake Manifold pressure sensor.
Perform POWERTRAIN VERIFICATION TEST; (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No »Go To 6
6. BRAKE SWITCH
Using a scan tool monitor brake switch position while cycling the brake pedal.
Is the brake switch status changing correctly?
Yes »Go To 7
No »Replace the brake switch or repair the wiring.
7. ENGINE OR FUEL MODIFICATIONS THAT EXCEED OEM SPECIFICATIONS

An Engine or Fuel modification that exceeds OEM specifications can affect the parameters that this diagnostic mon-
itors.
Any device/software that modifies the values reported by any of the Cummins actuators/sensors could fail this diag-
nostic.
Any device that puts a high parasitic load on the engine could also cause this diagnostic to fail.
Is there evidence of Engine or Fuel modifications that exceed OEM specifications?
Yes »Return vehicle to customer.
No »Replace ECM.
P061 C-ETC LEVEL 2 RPM PERFORMANCE
Theory of Operation
This diagnostic is testing for an internal ECM failure. The ECM redundantly calculates engine speed based crank-
case speed sensor. This calculation is done in a different part of the ECM than the primary calculation. It detects if
the primary engine speed calculation is lower than the redundant calculation by more than a calibrated amount 675
rpm for a calibrated amount of time 2 sec. The ECM will light the ETC lamp when the diagnostic runs and fails. The
light will remain on for the drive cycle or until both calculations agree for 2 seconds .
• When Monitored:
Engine speed is detected .
• Set Condition:
The primary engine speed calculation differs from the redundant engine speed calculation (internal calculation)
by a calibrated amount for a calibrated amount of time.
Possible Causes
OTHER CRANKCASE SPEED SENSOR RELATED DTC'S

ECM
Diagnostic Test
1. ECM
Are the other OrCs?
P0622-GENERATOR FIELD CONTROL CIRCUIT/OPEN
r -- --- - GENERATOR
GEN I
I GEN FIELD I
I"':ENSE _ _ C~TROl ..J
" "
A804 K20
18 18
RD BRIGY
r - - - - - - - - -, IODULE·
28 Cf 40 Cf
GEN EIIGIIIE
GEN I
I SENSE FiElD I COIITROL
I COOmM I
L ________ .J
,..... ....,
~
10 00000 ~oooo' I
20 00000 00000 II
30 00000 00000 11
40
SO
00000
00000
0 00000
00000
31
41
&0 00000 00000 51
.A ~
'-' ~
IODULE·
IIGII.
COITROLCt
GEIERATOR CI.fL,

g'- 2112 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
There are two communication lines between the ECM and alternator. Based on sensed battery voltage, the ECM
commands the alternator to charge the batteries to a desired voltage. The max voltage the ECM will command the
alternator to charge is 14.75 volts. The ECM then receives feedback from the alternator on the voltage level it is
charging the batteries through a sense line. The ECM will not light a MIL lamp for this fault.
• When Monitored:
• Set Condition:
The feedback signal does not match the commanded signal for the voltage regulator.
Possible Causes
GENERATOR
(K20) GEN FIELD CONTROL CIRCUIT OPEN
(A11) BATTERY POSITIVE SHORTED TO BATTERY NEGATIVE
(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE
(A11) BATTERY POSITIVE CIRCUIT OPEN
ECM
Diagnostic Test
1 . GENERATOR
Disconnect the Generator field harness connector.
Measure the resistance between the generator field terminals.
Is the resistance between .5 and 15 Ohms?
Yes »Go To 2
No »Replace the Generator.
DURE)
2. (K20) GEN FIELD CONTROL CIRCUIT OPEN

Measure the resistance of the (K20) Gen Field Control circuit between the Generator harness connector and the
Is the resistance less than ,10 ohms.
Yes »Go To 3
No »Repair the open in the (K20) Gen Field Control circuit.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 - 2113
3. GENERATOR FIELD OPEN

Measure the resistance of the generator field return circuit between the generator harness connector and battery
negative.
Is the resistance less·,'than 10 ohms.
,~ ~ ~b \.(
No »Repair the Generator field return shorted to Battery negative.
DURE)
Yes »Go To 4
4. (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage on the (K20) Gen Field Control circuit at the Generator harness connector.
Yes »Repair the short to voltage in the (K20) Gen Field Control circuit.
No »Go To 5
5. ECM
While monitoring with scan tool, connect a jumper wire between the (K20) Gen Field Control circuit and the (A804)
Gen Sense circuit in the alternator connector.
Did the DTC return?
DURE)
DURE)
P0628-FUEL PUMP CONTROL CIRCUIT LOW
r - - - - - - - - - - - - -- - - - -lIODULE.
I I TOULLY
I - - - - - - - - - - .., ELECTRONICS IIITEGUTED
I I I'OWIR
I I FUEl I I
I I PUMP FUEL I I
I I CONTROL PUMP I
I L _OUTPU2- _ _ _ _ _ CONTROL I I
~ __ 1________ -- ___ ,
llr' I 6
4 YC1
K31
20
BR
1 CiaD
16
AI09 II 7 t
K31
ORIRD
1 t
Al00
CII.
18
BR
2AC2
IFUEl -, 10DULE·
14 PUMP I EIIGIIIE
ORiRO I CONTROL I CO.TROL
4-'" 1__ _
IOIULE·
fUEL
PUlP
ZQ27 N4 Z210
12 18 18
8K DBfNT BK
I
• laOI 5 A 4 A CtlS
I t------t
Z927 N4 Z210
12 20 20
10 t
BK
Z927
Ct35 54
DBNH
N4
t- - -54
BK
Z210
C211
14 20 20
BK OBfNT BK
7 -'" C4 7 A C3
r- FUEL- - I GROUND CLUSTER
I LEVEL I
I SENSOR
I MIT
II All
... CUll
I '-:16NAl _ _ _ _ .J
1
GMY 11
ai
21
31
41
51
IODULE·
IODULE· ENGIINE
FUEL PUlP COITAOL C2 CLUSTER C4
(l.lL)

DR - - - - - - - - - ENGINE .. ELECTRICAL ·DIAGNOSTICS .. 6.7L DIESEL g .. 2115
Theory of Operation
The fuel lift pump is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12 volt
electric pump is operate and controlled by the ECM. The ECM controls a circuit in the TIPM for transfer pump
operation. Maximum current flow to the pump is 5 Amperes. With the engine running, the pump has a 1000/0 duty
cycle. The MIL lamp will illuminate immediately after this diagnostic runs and fails. During this time. the customer
may experience engine stumble/stall or low power due to tack of fuel supply to the high pressure system. The ECM
will turn off the MIL lamp once the diagnostic runs and passes in 4 consecutive drive cyc1es .
• When Monitored:
White the key is on .
• Set Condition:
The commanded signal to the fuel lift pump relay does not match the feedback signal from the fuel lift pump
relay.
Possible Causes
DAMAGED WIRING HARNESS

(K31) FUEL LIFT PUMP CONTROL CIRCUIT SHORTED TO GROUND
ECM
TIPM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Reter to 9 .. ENGINE ..
Diagnostic Test
1. (K31) FUEL LIFT PUMP CONTROL CIRCUIT SHORTED TO GROUND
Disconnect the C2 ECM and C1 TIPM connectors.
Using an ohmmeter, measure the resistance between ground and the
(K31) Fuel Lift Pump Control circuit at the ECM connector.
7
Yes »Fix or repair the wire harness.
Perform POWERTRAtN VERIFICATION TEST (DIESEL).
No » Go To 2 10
20 11
30 21
40 31
50 31
MODULE·
ENGINE
CONTROLC2
(B.7L)
81772c6b
2. ECMITIPM
Turn Ignition off.
Connect the C2 ECM harness connector.
Turn the ignition on, engine off.
Using a 12-volt test light connected to battery negative, probe the (K31)
the Fuel Lift Pump Control circuit at the C1 TIPM connector. 18
Toggle the lift pump actuator with the scan tool.

NOTE: The test light must illuminate brightly.
Compare the brightness to that of a direct connection to the battery.
Does the test light cycle on and off and illuminate brightly?
Yes »Replace the TI PM

Perform POWERTRAIN VERIFICATION TEST (DIESEL). MODULE·
(Refer to 9 - ENGINE - STANDARD PROCEDURE) TOTALLY
IN1'@GRATED
PQWERC10 81772c6f
P0629-FUEL PUMP CONTROL CIRCUIT HIGH
r - - - - - - - - - - - - - - - - - - )IODULE.
I TOTALLY
- - - - - - - - - - -, ELECTRONICS I.NTEGRATED
I I I I POWER
, I I
I FUEl I
I PUMP FUEl , f
I I CONTROL PUMP I
I L OUTPU~ _______ ~NTROL_I I
~ __ 1_________ I _____ I
lara 4 Y01
K31
20
BR
• 6 ~ CiaO
A109 •• 7 l'
16 K31
ORIRD
I tCI~ 18
BR
2 J.02
I-FUEL -, MODULE·
Aleg
14 PUMP I EIIOIIiE
ORIRD I CONTROL I CONTROL
4A 1__ -
Z927 N4 Z210
12 111 18
OK DOIWT BK
I
• S30. 5 ~ 4 ~ et3S
I t-----t
Z927 N-4 zm
12 20 20
10
1927
t
BK
Ot35 S4
DBIWT
t- __5~
N4 Z210
BK
e2i.
14 20 20
BK DBIWT BK
7 AC4 7 AC3
r- FliEl- - GROUND- f CLUSTER
I LEVEL 1
• MfT ",OtO&
I SENSOR
•• AfT L_.:t~l ____ ~
10 1
10 11
30 21
40 31
~o 41
60 51
10DULE.
10DULE. EIOIlIE
FUEL PUlP COITROL C2 CLUSTER C4
(l.fLl Itdtdl

9 • 2118 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The fuel lift pump is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12 V
electric pump is operate and controlled by the ECM. The ECM controls a circuit in the TIPM for transfer pump
operation. Maximum current flow to the pump is 5 Amperes. With the engine running, the pump has a 100% duty
cycle. The MIL lamp will illuminate immediately after this diagnostic runs and fails. During this time, the customer
may experience engine stumble/stall or low power due to lack of fuel supply to the high pressure system. The ECM
will turn off the MIL lamp once the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
• Set Condition:
The commanded signal to the fuel lift pump circuit in the TIPM does not match the feedback signal from the
fuel lift pump circuit.
Possible Causes
WIRING HARNESS
TIPM
(K31) FUEL LIFT PUMP CONTROL CIRCUIT SHORTED TO EXTERNAL VOLTAGE
(K31) FUEL LIFT PUMP CONTROL CIRCUIT OPEN
FUEL LIFT PUMP GROUND CIRCUIT OPEN
FUEL LIFT PUMP GROUND CIRCUIT SHORTED TO EXTERNAL VOLTAGE
ECM
Diagnostic Test
1. POWER AT TIPM
Using a voltmeter, measure the voltage on the Battery Supply wire to the TIPM.
Turn the ignition on, engine off.
Does the voltmeter show battery voltage?
No »Fix or replace the open circuit in the Battery Supply Circuit.
DURE)
Ves »Go To 2
2. DAMAGED WIRING HARNESS

Turn Ignition off.
Disconnect the ECM and TIPM connectors. Inspect the connectors for signs of damage or corrosion.
Are any pins damaged?
Yes »Fix or replace the harness
DURE)
No »Go To 5
3. (K31) FUEL LIFT PUMP CONTROL CIRCUIT OPEN

Using an ohmmeter, measure the resistance of the (K31) Fuel Lift Pump Control circuit between the C2 ECM con-
nector and the C1 TfPM connector.
Yes »Go To 4
No »Repair the open in the (K31) Fuel Lift Pump Control circuit.
DURE)
4. (K31) FUEL LIFT PUMP CONTROL CIRCUIT SHORTED TO EXTERNAL VOLTAGE

Using a voltmeter, measure the voltage between battery negative and the (K31) Fuel Lift Pump Control circuit at the
C1 TIPM connector.
No »Go To 5
Yes »Fix or replace the harness.
Perform POWERTRAIN VERIFICATION TEST {DIESEL}. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
5. (K31) FUEL LIFT PUMP CONTROL CIRCUIT SHORTED TO OTHER CIRCUITS

USing an ohmmeter, measure the resistance between the (K31) Fuel Lift Pump Control circuit in the ECM connector
and all other circuits in the ECM connectors.
Yes »Fix or replace the harness.
DURE)
No »Go To 6
6. ECM
Connect the ECM and TIPM connectors.
Using a back probing tool 6801, back probe the lift pump control circuit in from TIPM connector.
Toggle the lift pump actuator with the Electronic Service Tool.
Using a 12-volt test light connected to battery negative, probe the (K31) Fuel Lift Pump Control circuit at the TIPM
connector.
DURE)
Yes »Go To 7
9·2120 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
7. (K31) FUEL LIFT PUMP DRIVER CIRCUIT SHORTED TO OTHER CIRCUITS

Using a back probing tool, back probe the (K31) Fuel Lift Pump Control circuit in the TIPM connector.
Toggle the lift pump actuator with the scan Toot.
Using a 12-volt test light connected to battery negative, check the lift pump control circuit at the TIPM connector.
Yes »Test complete.
DURE)
No »Replace the TIPM
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9·2121
P062C-ETC LEVEL 2 MPH PERFORMANCE
Theory of Operation
While in cruise control, this diagnostic verifies that vehicle speed stays within 5 mph (8 kmh) of cruise control set-
point. The diagnostic will abort if during this condition engine speed is decreasing by more than 13 rpm/sec. This is
meant to detect a condition when the vehicle is travelling downhill as that could cause an increase in overall vehicle
speed. This diagnostic will abort if the driver goes out of cruise mode by pressing the brake or accelerator pedal.
Cruise will be disabled the rest of the drive cycle (until key off) .
• When Monitored:
Engine in cruise control mode but not travelling downhill.
• Set Condition:
Vehicle speed is more than 5mph (8 kmh) over targeted cruise control speed.
Possible Causes
VEHICLE SPEED SENSOR DTC'S

SPEED CONTROL DTC'S
ECM
DIAGNOSIS ANO TESTING)
Diagnostic Test
1. ECM
Are the other DTCs?
9 - 2122 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l D I E S E l - - - - - - - - - DR
P0630-VIN NOT PROGRAMMED IN PCM
For a complete wiring diagram Refer to Section 8W .
• When Monitored:
• Set Condition:
The VIN was not calibrated into the ECM.
Possible Causes
VIN NOT CALIBRATED INTO ECM

Diagnostic Test
1. VIN NOT CALIBRATED INTO ECM

Using the scan tool, recalibrate the ECM with the proper VIN.
Did the DTC P0630 reset?
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 M ENGINE - STANDARD PROCE·
DURE)
No »Test Complete.
DR ENGINE • ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 - 2123
P0633-SKIM SECRET KEY NOT STORED IN PCM
• When Monitored:
While the key is on.
• Set Condition:
The SKIM secret key was not calibrated into the ECM.
Possible Causes
IMPROPER IGNITION KEY IS BEING USED

SKIM DTC'S
SKIM NOT CALIBRATED PROPERLY
Diagnostic Test
1. SKIM DTC'S
With the scan tool, read SKIM DTCs.
Are any SKIM DTC's present?
Yes »Repair all SKIM DTCts first.
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 • ENGINE - STANDARD PROCE-
DURE)
No »Go To 2
2. IMPROPER IGNITION KEY IS BEING USED

Verify that the proper ignition key is in the ignition lock on the steering column.
Are the proper keys being used?
Yes »Go To 3
No »Use the proper key for the vehicle.
DURE)
3. SKIM NOT CALIBRATED PROPERLY

Using the scan tool, recalibrate the ECM with the proper SKIM secret key.
Cycle the ignition switch from on to off to on.
Did the DTC reset?
No »Test Complete.
DURE)
Yes »Verify information is correct and replace ECM.
PROCEDURE)
9 • 2124 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
P063C-GENERATOR VOLTAGE SENSE LOW
,- - - - -
-GENERATOR
GEN I
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Theory of Operation
alternator to charge is 14.75 volts. The ECM then receives feedback from the alternator on the voltage level it is
charging the batteries. The ECM will not light a MIL lamp for this fault.
Engine running .
• Set Condition:
Battery voltage exceeds charging voltage by more than a calibrated amount for a calibratable period of time.
Possible Causes
DAMAGED, CORRODED, OR LOOSE CONNECTIONS

(A804) GENERATOR SENSE CIRCUIT SHORTED TO GROUND
(A804) GENERATOR SENSE CIRCUIT OPEN
OPEN CIRCUIT BETWEEN GENERATOR AND AUXILIARY BATTERY
GENERATOR
ECM
Diagnostic Test
1. BATIERY TERMINALS DAMAGED, CORRODED, OR LOOSE CONNECTIONS

NOTE: Batteries must be fully charged and capable of passing a battery load test. The generator belt ten-
sion must be within specification. Inspect the vehicle for any aftermarket equipment that may exceed the
maximum generator output.
Visually inspect the positive and negative connections at the battery. Visually inspect the battery negative connec-
tions at the engine block.
Yes »Go To 2
No »Clean and/or tighten the connections.
DURE)
2. (A804) GENERATOR SENSE CIRCUIT SHORTED TO GROUND

Measure the resistance between the (AB04) Generator Sense circuit at the ECM harness connector and ground.
Yes »Go To 3
No »Repair/replace harness for a short to ground.
DURE)
9·2126 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. (A804) GENERATOR SENSE CIRCUIT OPEN

Measure the resistance of the (A804) Generator Sense circuit from the alternator harness connector to the ECM
harness connector.
Yes »Go To 4
No »Repair/replace harness for an open circuit.
DURE)
4. OPEN CIRCUIT BETWEEN GENERATOR AND AUXILIARY BATTERY

Disconnect the positive battery cables from both the primary and auxiliary battery.
Disconnect the harness from the auxiliary battery to the generator.
Measure the resistance in the harness that connects the auxiliary battery to the generator.
Yes »Go To 5
No »Repair/replace open circuit in wiring harness.
DURE)
5. GENERATOR
Measure the resistance between the generator output stud and the generator Sense circuit on the generator con-
nector.
Yes »Replace ECM.
DURE)
No »Replace generator.
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 - 2127
P063D-GENERATOR VOLTAGE SENSE HIGH
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9·2128 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
There are two communication lines between the ECM and generator. Based on sensed battery voltage, the ECM
commands the generator to charge the batteries to a desired voltage. The max voltage the ECM will command the
generator to charge is 14.75-volts. The ECM then receives feedback from the generator on the voltage level it is
charging the batteries. The ECM will not light a MIL lamp for this fault, but the ETC lamp will be on solid.
• When Monitored:
Engine running .
• Set Condition:
Charging voltage exceeds battery voltage by more than a calibrated amount for a calibratable period of time.
Possible Causes
OTHER DTC'S
SHORT CIRCUIT BETWEEN THE AUXILIARY BATTERY AND THE ECM
OPEN CIRCUIT BETWEEN THE PRIMARY BATTERY AND THE AUXILIARY BATTERY
SHORT CIRCUIT BETWEEN THE GENERATOR AND PRIMARY BATTERY
OPEN CIRCUIT BETWEEN THE GENERATOR AND PRIMARY BATTERY
ECM
Diagnostic Test
1. OTHER DTC'S
NOTE: Batteries must be fully charged and capable of passing a battery load test. The generator belt ten-
sion must be within specification. Inspect the vehicle for any aftermarket equipment that may exceed the
maximum generator output.
Are there any other charging related faults?
Yes »Troubleshoot other charging related DTC's first.
No »Go To 2
2. SHORT CIRCUIT BETWEEN THE AUXILIARY BATTERY AND THE ECM

Using the scan tool, monitor battery voltage in the ECM module.
Measure battery voltage of the primary battery (one that powers ECM) using a voltmeter.
Is the reported voltage from the scan tool equal to both battery voltages?
Yes »Go To 3
No »Repair or replace open/short circuit in harness from battery to ECM
DURE)
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6'.7L DIESEL 9 - 2129
3. CIRCUIT BETWEEN THE PRIMARY BATTERY AND THE AUXILIARY BATTERY

Using a voltmeter, measure battery voltage of the auxiliary battery (one that generator charges).
Is the measured voltage of the auxiliary batter equal to the measured voltage of the primary battery?
NOTE: Primary battery voltage was measured in step 2
Yes »Go To 6
No »Go To 4
4. OPEN CIRCUIT BETWEEN THE PRIMARY BATTERY AND THE AUXILfARY BATTERY
Disconnect the cable that connects the primary battery to the auxiliary battery.
Measure the resistance in the cable that connects the primary battery to the auxiliary battery.
Yes »Go To 5
No »Repair/replace open circuit in the wiring harness.
DURE)
5. SHORT CIRCUIT BETWEEN THE GENERATOR AND PRIMARY BATTERY

Disconnect the battery cable that connects the primary battery to the auxiliary battery.
Measure the resistance between each end of the harness and battery ground.
Is the measured resistance greater than 100k ohms?
Yes »Go To 6
No »Repair/replace short circuit in the wiring harness.
DURE)
6. OPEN CIRCUIT BETWEEN THE GENERATOR AND PRIMARY BATTERY

Measure the resistance in the harness that connects the auxiliary battery to the generator.
Yes »Go To 7
No »Repair/replace open circuit in the wiring harness.
DURE)
7. ECM
Disconnect the generator harness connector.
Disconnect the power cable from the generator stud to the auxiliary battery.
Measure the resistance between the generator output stud and the generator Sense circuit in the generator harness
connector.
DURE)
No »Replace the Generator.
DURE)
DR ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 2131
P0642-SENSOR REFERENCE VOLTAGE 1 CIRCUIT LOW
1"- - 1lEI lOR·

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Theory of Operation
This sensor supply circuit provides a 5-volt supply to the engine speed sensor. A MIL lamp will be lit immediately
after this diagnostic runs and fails. The MIL lamp will turn off once the diagnostic runs and passes in 4 consecutive
drive cycles .
• When Monitored:
With the key on .
• Set Condition:
Voltage detected on the #2 sensor supply circuit is below a calibrated value.
Possible Causes
CRANKSHAFT POSITION SENSOR

(K824) 5-VOLT SHORTED TO GROUND
(K824) 5-VOLT SUPPLY SHORTED TO ANOTHER CIRCUIT
ECM
Diagnostic Test
1. CRANKSHAFT POSITION SENSOR

While monitoring with the scan tool, disconnect the Crankshaft speed sensor.
Did P0483 set?
Yes »Replace Crankshaft speed sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE • STANDARD PROCE·
DURE)
No »Go To 2
2. 5-VOLT SHORTED TO GROUND

Measure the resistance between the (K824) #2 5-volt supply circuit in the sensor harness connector and battery
negative.
Yes »Go To 3
No »Repair the #2 (K824) 5-volt supply shorted to ground.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGINE - STANDARD
PROCEDURE)
3. (K824) 5..VOLT SUPPLY SHORTED TO ANOTHER CIRCUIT

Measure the resistance between the sensor (K824) #2 5-volt supply circuit in the ECM harness connector to all
other circuits in the ECM harness connectors
Yes »Go To 4
No »Repair the 5-volt supply shorted to another circuit.
DURE)
4. CRANKCASE POSITION SENSOR DTC

Reconnect the disconnected Crankcase position sensor harness connector.
Is DTC P0483 set?
Yes »Repair the Crankcase position sensor DTC.
DURE)
No »Go To 5
5. ECM
Disconnect the Crankcase position sensor harness connector.
Measure the voltage between the sensor (K824) #2 5-volt supply circuit at the Crankcase position sensor harness
connector and the Crankcase position sensor ground.
DURE)
P0643-SENSOR REFERENCE VOLTAGE 1 CIRCUIT HIGH
1- -,IEI'OR.
CRANKSHAFT
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(DIESEL) CONTROL Ct
(S.7l)

Theory of Operation
This sensor supply circuit provides a 5-volt supply to the engine speed sensor. A MIL lamp will be lit immediately
after this diagnostic runs and fails. The MIL lamp will turn off once the diagnostic runs and passes in 4 consecutive
drive cycles .
• When Monitored:
With the key on .
• Set Condition:
Voltage detected on the #2 sensor supply circuit was above a calibrated value.
Possible Causes
(K824) 5-VOLT SHORTED TO VOLTAGE

ECM
Diagnostic Test
1. (K824) 5-VOLT SHORTED TO VOLTAGE

Measure the resistance between the #2 sensor supply circuit and all other circuits in the ECM connectors.
No »Go To 2
2. (K824) 5-VOLT SHORTED TO VOLTAGE

Disconnect the Crankcase position sensor harness connector.
Measure the voltage between the Crankcase position sensor (K824) 5-volt supply circuit and battery negative.
Ves »Repair the (K824) 5-volt supply shorted to voltage.
DURE)
No »Go To 3
9·2136 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
3. ECM
Measure the voltage between the (K824) 5-volt supply circuit in the sensor harness connector and battery negative.
DURE)
P0646-A/C CONTROL CIRCUIT LOW
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9 .. 2138 ENGINE· ELECTRICAL DIAGNOSTICS· B.7l DIESEL - - - - - - - - - DR
Theory of Operation
The clutch on the AlC compressor controls the drive of the Freon compressor. The clutch is driven by a signal from
the TIPM. The TIPM receives a signal from the ECM. The ECM receives various information from the operator
controls and AlC system to determine when the clutch should be turned on. The system will activate the AlC clutch
during AlC or defrost use. You will not receive a MIL lamp for this fault, but the customer may complain of poor AlC
performance.
• When Monitored:
• Set Condition:
When the signal from the AlC Clutch circuit output does not match the signal from the AlC Clutch feedback
Possible Causes
LOW VOLTAGE SUPPLY TO THE TIPM

(C13) AlC CLUTCH CONTROL CIRCUIT OPEN
(C13) AlC CLUTCH CONTROL CIRCUIT SHORTED TO GROUND
TIPM
ECM
Diagnostic Test
1 . TIPM GROUND OPEN

Using a voltmeter, connect one voltmeter lead to Battery Positive and the other on TIPM ground.
Does the voltmeter show battery voltage?
Yes »Go To 2
No »Fix or replace the open circuit in the Battery Return Circuit
DURE)
2. AlC CLUTCH CONTROL CIRCUIT OPEN

Disconnect the ECM and TI PM connectors.
Using an Ohmmeter, measure the resistance of the (C13) AlC Clutch Control circuit between the TIPM and the C2
No »Fix or replace the harness.
DURE)
Yes »Go To 3
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6,.7L DIESEL 9· 2139
3. (C13) AlC CLUTCH CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (C13) AlC Clutch Con-
trol circuit at the TIPM harness connector.
Yes »Go To 4
No »Fix or replace the harness. 10
8164B78e
4. ECMITIPM
Connect the C2 ECM harness connector.
Using a 12 volt test light connected to battery negative, probe the (C13)
k
AlC Clutch Control circuit at the TIPM harness connector while actuat-
ing the AlC clutch circuit with the scan tool.
Does the test light illuminate brightly?
Yes »Replace the TIPM.
13
9 - 2140 ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
P0647-AlC CONTROL CIRCUIT HIGH
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Theory of Operation
"The clutch on the AlC compressor controls the drive of the Freon compressor. The clutch is driven by a signal from
the TIPM. The TIPM receives a signal from the ECM. The ECM receives various information from the operator
controls and AlC system to determine when the clutch should be turned on. The system will activate the AlC clutch
during AlC or defrost use. You will not receive a MIL lamp for this fault, but the customer may complain of poor A1C
performance ."
• When Monitored:
• Set Condition:
When the signal from the AlC Clutch output does not match the signal from the AlC Clutch feedback.
Possible Causes
WIRING HARNESS OR CONNECTIONS

(C13) A1C CLUTCH CONTROL CIRCUIT SHORTED TO EXTERNAL VOLTAGE
TIPM
ECM
Diagnostic Test
1. (C13) AlC CLUTCH CONTROL CIRCUIT SHORTED TO EXTERNAL VOLTAGE

Ignition off.
Disconnect the C2 ECM and TIPM harness connectors.
Using a Voltmeter, measure the voltage on the (C13) AlC Clutch Control
circuit at the TIPM hamess connector.
Is the voltage less than 1 volt? 10
Yes »Go To 2
Yes »Repair or Replace the wiring harness.
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TOTALLY
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2. ECM
Ignition off.
Connect the C2 ECM and harness connector.
Using a 12-volt test light connected to ground, probe the (C13) AlC
Clutch Control circuit at the TIPM connector while actuating the AlC
Clutch with the scan tool.
Does ,the test light illuminate brightly?
Yes »Go To 3
81640084
3. TIPM
Using a back probing tool 6801, back probe the AlC clutch power circuit in the TIPM connector
Using a 12-volt test light connected to ground, probe C3 AlC Clutch Output Control at the TIPM connector while
actuating the AlC Clutch Circuit with the scan toot
Yes »Perform INTERMITTENT CONDITION (DIESEL) test. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING) .
No »Replace the TIPM.
DURE)
P0652-SENSOR REFERENCE VOLTAGE 2 LOW

Theory of Operation
This sensor supply circuit provides a 5-volt supply to: 1. Engine position sensor 2. Intake manifold temperature/
pressure sensor 3. Exhaust pressure sensor 4. Fuel pressure sensor 5. Ambient temperature/pressure sensor 6.
EGR valve
• When Monitored:
With the keyon .
• Set Condition:
Voltage detected on the sensor supply is below a calibrated value.
Possible Causes
ECM
(F855) #1 5-VOLT SUPPLY SHORTED TO GROUND
(F855) #1 5-VOLT SUPPLY SHORTED
FUEL RAIL PRESSURE SENSOR
EGR VALVE
FAN CLUTCH ASSEMBLY
INLET AIR TEMPERATURE/PRESSURE SENSOR
MAP SENSOR
CAMSHAFT POSITION SENSOR
Diagnostic Test
1. ECM
Measure the voltage between the Sensor (F855) #1 5-volt Supply and the Sensor (K916) #1 Return circuit at the
ECM.
Yes »Go To 2
PROCEDURE)
9 - 2144 ENGINE· ELECTRICAL 'DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
2. (F855) #1 5-VOLT SUPPLY SHORTED TO GROUND

the Pressure sensors harness connectors and the engine position sensor.
Measure the resistance between the (F855) #1 sensor supply circuits at the C1 ECM harness connector and battery
negative.
Is the resistance greater than 100K Ohms?
Yes »Go To 3
No »Repair the harness.
DURE)
3. CAMSHAFT POSITION SENSOR

While monitoring with the scan tool, disconnect the camshaft position sensor.
Is DTC P0652 set?
Yes »Go To 4
No »Replace the camshaft position sensor.
DURE)
4. INTAKE MANIFOLD TEMPERATURE/PRESSURE (MAP) SENSOR

While monitoring with the scan tool, disconnect the Intake manifold temperature/pressure (MAP) sensor.
Is DTC P0652 set?
Yes »Go To 5
No »Replace the Intake manifold temperature/pressure (MAP) sensor.
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 - ENGINE a STANDARD PROCE·
DURE)
5. EXHAUST PRESSURE SENSOR 1/2

While monitoring with the scan tool, disconnect the Exhaust pressure sensor 1/2.
Is DTC P0652 set?
Yes »Go To 6
No »Replace the Exhaust pressure sensor 1/2.
DURE)

While monitoring with the scan tool, disconnect the Fuel rail pressure sensor.
Is DTC P0652 set?
Ves »Go To 7
No »Replace the Fuel rail pressure sensor.
PROCEDURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6~7L DIESEL 9 - 2145
7. INLET TEMPERATURE/PRESSURE (TBAP) SENSOR

While monitoring with the scan tool, disconnect the Inlet temperature/pressure (TBAP) sensor.
Is DTC P0652 set?
Yes »Go To 8
No ,» Replace the Inlet temperature/pressure (TBAP) sensor.
DURE)
8. EGR VALVE
While monitoring with the scan tool, disconnect the EGR valve.
Is DTC P0652 set?
Yes »Go To 9
No »Replace the EGR valve.
DURE)
9. FAN SPEED SENSOR

While monitoring with the scan tool, disconnect the Fan clutch assembly.
Is DTC P0652 set?
Yes »Go To 10
No »Replace the Fan clutch assembly.
Perform POWERTRAIN VERIFICATION TEST - 6.7l). (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)

While monitoring with the scan tool, disconnect the Crankcase pressure sensor.
Is DTC P0652 set?
Yes »Go To 11
No »Replace the Crankcase pressure sensor:
DURE)
11. (F855) #1 5-VOLT SUPPLY SHORTED

Measure the resistance between the (F855) #1 sensor supply circuit of the ECM harness connector and an other
circuits in both ECM hamess connectors.
No »Repair the shorted circuit.
PROCEDURE)
P0653-SENSOR REFERENCE VOLTAGE 2 HIGH
Theory of Operation
This sensor supply circuit provides a 5 volt supply to: 1. Engine position sensor 2. Intake manifold temperaturel
pressure sensor 3. Exhaust pressure sensor 4. Fuel pressure sensor 5. Ambient temperature/pressure sensor 6.
EGR valve 7. Fan clutch assembly 8. Crankcase pressure sensor A MIL lamp will be lit immediately after this diag-
nostic runs and fails. The MrL lamp will turn off once the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
• Set Condition:
Voltage detected on the sensor supply is above a calibrated value.
Possible Causes
ECM
(F855) 5-VOLT SUPPLY SHORTED TO VOLTAGE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGIN E -
Diagnostic Test
1. ECM
Disconnect the ECM 60 pin harness connector.
Measure the voltage between the Sensor (F855) #1 5-volt Supply and the Sensor #1 Return pin at the ECM.
Yes »Go To 2
DURE)
2. 5-VOLT SUPPLY SHORTED TO VOLTAGE

Key off.
Disconnect the sensor connectors for each pressure sensor, and the engine position sensor.
Disconnect the ECM 50 way harness connector.
Ignition on, engine off.
Measure the voltage between the supply circuit at each pressure sensor harness connector and battery negative.
Measure voltage between the (F855) 5-volt supply circuit at the engine position sensor harness connector and bat-
tery negative.
Yes »Go To 3
No »Repair the (F855) 5-volt supply shorted to voltage.
PROCEDURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 -'2147
3. SENSOR SUPPLY SHORTED TO VOLTAGE IN HARNESS

Measure the resistance between the #1 sensor supply circuit and all other circuit in the ECM connectors.
Yes »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
No »Repair the harness shorted to voltage.
DURE)
9 - 2148 ENGINE· ELECTRICAL DIAGNOSTICS . 6.7L DIESEL - - - - - - - - - - DR
P065A-GENERATOR SYSTEM PERFORMANCE
1- - - - - -GENERATOR
GEN I
I GEN FiElD I
I ...!ENSE _ _ CONTROL .J
'I
A804 K20
18 18
RD BRKJY
r - 7EN- -28 C1
-
40 C1
GEN - - -, MODULE·
EIIIGIIIIE
I SENSE FiElD ICOITROL
I CONTROL I
L ________ -1
10 1
20 11
30 11
40 31
50 ~ I
SG 51
MODULE·
EIIIGIIIIE
CONnOL C1
GEIIIERATOR
(S.lL)
.11"""

• When Monitored:
Engine running .
• Set Condition:
Generator output does not meet demand.
Possible Causes
GENERATOR
BATTERY
Diagnostic Test
1. BATTERY
Load test batteries.
Did both batteries pass load test?
Yes »Replace the Generator.
DURE)
No »Replace the weak battery (5).
DURE)
9 - 2150 ENGINE _. ELECTRICAL DIAGNOSl'lCS -. 6~7L DIESEL - - - - - - - - - - DR
P0698-SENSOR REFERENCE VOLTAGE 3 CIRCUIT LOW
Theory of Operation
The throttle pedal produces two voltage signals proportional to the pedal movement. The voltages are created by
electronic circuitry within the pedal assembly. The primary signal varies between 0 and 5 volts and the secondary
signal varies between 0 and 2.5 volts. The Engine Control Module uses the two signals to validate throttle pedal
position to control engine fueling. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails.
The ETC lamp will also flash. During this time the customer will be in a limp home mode. The ECM will turn off the
MIL lamp after the diagnostic runs and passes. in 4 consecutive drive cycles ..
• When Monitored:
With engine running .
• Set Condition:
Low voltage detected at the APPS supply circuit or low voltage detected at the APPS 1 5-volt supply.
Possible Causes
(F855) APPS 5-VOLT SUPPLY OPEN

APPS HIGH RESISTANCE
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K922) RETURN CIRCUIT
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS
APPS
1. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE

Disconnect the APPS harness connector.
Measure the resistance of the APPS 1 (F855) 5-volt supply circuit 6
between the sensor harness connector and battery negative
Is the resistance greater than 100 k ohms?
Yes »Go To 2
No »Repair the (F855) 5-volt supply circuit shorted to battery
6
negative.
SENSOR·
ACCELERATOR
PEDAL
POSfTlON
(S.7UDIESEL) 8168c883
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL g. 2151
2. (F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (F855) APPS 1 5-volt supply circuit at the ECM harness connector and all
other circuits in the ECM connector.
Yes »Go To 3
No »Repair the APPS #1 (F855) 5-volt supply circuit shorted to other circuits.
DURE)
3. INTERNAL ECM
Turn ignition on, engine off.
While monitoring with the scan tool, connect a jumper wire between the
(K23) APPS 1 signal circuit at the sensor harness connector and the
(F855) APPS 1 supply circuit at the sensor harness connector.
NOTE: With the APPS disconnected it is normal to have a APPS 1
and APPS 2 low voltage DlC set.
Did a APPS 1 voltage too high DTC set?
Yes »Go To 4
No »Replace and program the ECM in accordance with the Ser-
vice Information.
Sf:N8OR·
Perform POWERTRAIN VERIFICATION TEST (DIESEL). ACCELeRATOR
PEDAL
(Refer to 9 - ENGINE - STANDARD PROCEDURE) POSITION
(5.7UOII!!II!!L) 8168c9e4
4. APPS
Reconnect the APPS harness connector.
Monitor the APPS 1 and APPS 2 voltage with the scan tool while depressing the throttle pedal.
Is the voltage transition shown on the scan tool smooth while depressing the throttle and is the volt
swing smooth?
Yes »Refer to the INTERMITIENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
No »Replace the APPS.
DURE)
9'- 2152 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L D I E S E L - - - - - - - - - DR
P0699-SENSOR REFERENCE VOLTAGE 3 CIRCUIT HIGH
Theory of Operation
MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles.
While engine is running .
• Set Condition:
High voltage detected at the APPS supply circuit.
Possible Causes

(F855) 5-VOLT SUPPLY SHORT TO VOLTAGE
ECM

Measure the voltage between the (F855) APPS #1 5-volt supply circuit
at the sensor connector and battery negative.
Yes »Replace the APPS.
No »Go To 2
POSITIQN
81690c9a
2. (F855) 5-VOLT SUPPLY SHORT TO VOLTAGE

-@lID
~ 6
::~
in the sensor harness connector and battery negative.
Yes » Go To 3
No » Repair or replace the wiring harness.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) ••N8Oft..
ACCI!LI!!.....:rQll
!'tiDAL
POemOH
(5.'1l..iDIEIEL) 81690c9a
3. ECM
Reconnect the ECM harness connector(s).
~ID
at the sensor harness connector and battery negative.
~ 6
~:~
Yes » Replace and program the ECM in accordance with the Ser-
vice Information.
No » Refer to the INTERMITTENT CONDITION Symptom (Diag-
8ENIOIl·
nostic Procedure). (Refer to 9 - ENGINE - DIAGNOSIS ACCELI!!ItATOIt
AND TESTING) Pl!l)AL
POeI1'IOM
(!I.7L1D1UEL1 81690c9a
9 - 2154 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
P06A4-SENSOR REFERENCE VOLTAGE 4 CIRCUIT LOW
For a complete wiring diagram Refer to Section SW.
Theory of Operation
The throttle pedal produces two voltage signals proportional to the pedal movement The voltages are created by
signal varies between 0 and 2.5 volts. The Engine Control Module uses the two Signals to validate throttle pedal
MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
With engine running .
• Set Condition:
Low voltage detected at the APPS supply circuit or low voltage detected at the APPS 1 5-volt supply.
Possible Causes
(F855) APPS 5-VOLT SUPPLY OPEN

APPS HIGH RESISTANCE
(F855) S-VOLT SUPPLY CIRCUIT SHORTED TO (K922) RETURN CIRCUIT
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS
APPS
1. (FS55) 5-VOlT SUPPLY CIRCUIT SHORTED TO BATTERY NEGATIVE

Measure the resistance of the APPS 1 (F855) 5-volt supply circuit between the sensor harness connector and bat-
tery negative
Is the resistance greater than 100 k ohms?
Yes »Go To 2
No »Repair the (F855) 5-volt supply circuit shorted to battery negative.
DURE)
2. (FS55) 5-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (F855) APPS 1 5-volt supply circuit at the ECM harness connector and all
other circuits in the ECM connector.
Yes »Go To 3
No »Repair the APPS #1 (F855) 5-volt supply circuit shorted to other circuits.
DURE)
3. INTERNAL ECM
Turn ignition on, engine off.
While monitoring with the scan tool, connect a jumper wire between the (K23) APPS 1 signal circuit at the sensor
harness connector and the (F855) APPS 1 supply circuit at the sensor harness connector.
NOTE: With the APPS disconnected it is normal to have a APPS 1 and APPS 2 low voltage DTC set.
Old a APPS 1 voltage too high DTC set?
Yes »Go To 4
DURE)
4. APPS
Reconnect the APPS harness connector.
Monitor the APPS 1 and APPS 2 voltage with the scan tool while depressing the throttle pedal.
Is the voltage transition shown on the scan tool smooth while depressing the throttle and Is the volt
swing smooth?
Yes »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DURE)
9 - 2156 ENGINE - ElEC"rRICAl DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P06A5..SENSOR REFERENCE VOLTAGE 4 CIRCUIT HIGH
Theory of Operation
MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
While engine is running .
• Set Condition:
High voltage detected at the APPS supply circuit.
Possible Causes

(F854) 5-VOLT SUPPLY SHORT TO VOLTAGE
ECM

Measure the voltage between the (F854) APPS #1 S-volt supply circuit at the sensor connector and battery nega-
tive.
DURE)
No »Go To 2
2. (F854) 5-VOLT SUPPLY SHORT TO VOLTAGE

Measure the voltage between the (F854) APPS #1 S-volt supply circuit in the sensor harness connector and battery
negative.
Yes »Go To 3
No »Repair or replace the wiring harness.
DURE)
3. ECM
Reconnect the ECM harness connector(s).
Measure the voltage between the (F854) APPS #1 5-volt supply circuit at the sensor harness connector and battery
negative.
DURE)
No »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
P0700-TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
• When Monitored:
Ignition on and battery voltage greater than 10 volts .
• Set Condition:
An active DTC is stored in the TCM. One Trip Fault. Three good trips to turn off the MIL.
Possible Causes
DTC PRESENT IN THE TRANSMISSION CONTROL MODULE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.' (Refer to 9 .. ENGINE -
Diagnostic Test
1. DlC PRESENT IN EATX CONTROLLER

This is an informational DTC letting you know that a DTC(s) is stored in the Transmission Control Module.
Erase this DTC from the ECM after all Transmission DTC(s) have been repaired.
Using a scan tool, read the Transmission Controller DTC and refer to the Transmission Category and perform the
appropriate symptom.
PCM Diagnostic Information complete.
Continue
Test Complete.
P0850-PARKlNEu-rRAL SWITCH PERFORMANCE
Theory of Operation
The transmission PRNDL diagnostics will detect transmission stuck in park error, if the vehicle speed is greater than
a calibrated threshold and selected gear is PARK according to the received CAN message. It will also detect trans-
mission stuck in drive error, if the engine crank state is seen while the selected gear is DRIVE according to the
received CAN message .
• When Monitored:
• Set Condition:
The transmission module has a transmission related fault.
Possible Causes
TRANSMISSION STUCK IN PARK OR DRIVE

Diagnostic Test
1 _TRANSMISSION STUCK IN PARK OR DRIVE

See repair.
Repair
Repair the transmission/CAN related problem.
g.• 2160 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P113C-02 SENSOR POWER SUPPLY CIRCUIT PERFORMANCE
I
lilT AI
L- - - - - -IIODULE.
1 8(+)
c-=- - ..., ElECTRONICS
I'OULLY
'ITI!I.AT!'
- - - - - - - - - - - - - - - - - , IODULI!·
I II!II'IE
I I FUSED IGNITION I I ,own I DIAGNOSTIC DIAGNOSTIC conROL
I I SWITCH OUTPUT I I I PORT LOW PORT HIGH I
I ___ __ D!!.A~ _ _ ....£ATALlN~ _G~N~ _G~N~ _GROUN~ J
L ~N-STA~ ~
1"_____ _I 51 Ct 31 CI 47 yet 48 yel 57 yel
2D yet Z902 Z902 1902
16 16 16
F9SlJ BK BK BK
20
------e lUI e---e---e Ii ..

I f
F96D 0132 0.133 Z902
20 18 18 10
PKft.G WT WTIOR BK
r- -
I
'---------v----
32
-
J.
FUSED IGNITION
-
I
.....,.o.UU.
IUTI-LOCI
. ,t.n.
F960
I
.A.Gt14
SWITCH OUTPUT lRA11!I

I
...... _-_
(RUN-START) IIIW ALI
.......
18
PK4.G
10-J.,---- - - - 8 v Ct"
'I 7'1 I
F960 D132 0133
20 20 20
PKA.G WT WTIOR
9A 3A llA
DIAGNOSTIC
IOGULE·
FUSED IGNITION DIAGNOSTIC
01 nUOR
(RUN·STARn DATA LINK DATA LINK
II.n DII!SI!L)
021/1 02111 02111 02112 021f2 02112

02111 HEA TER HEA TER PUMP CELL 02112 HEATER HEATER PUMP CELL
PUMP 02111 CONTROL CONTROL CURRENT 02111 CURRENT 02112 CONTROL CONTROL CURRENT 021/2
lOT 14'( 16,( 1T 15T 6T 5T 12T aT 13T
2902 K902 K79 K99 Kl03 K41 K734 K904 K80 K299 K733 K141
20 20 20 20 20 20 20 20 20 20 20 20
BK BRlDG BR!8 BRA.G BRA.B DBA.B BR.oUG DBIDG BRiTN 8RIWT BR DBlYl
"t.
.I .I .I .I j .I
11
Z902
20
9K
02112 02112 02112 02112 02112 02112 UIIOR·

CURRENT RETURN HEATER HEATER PUMP CELL SIGNAL OIYlU itt
I IU.
e
PUMP CONTROL
RETURN
CONTROL
SUPPLY
CURRENT
TRIM
It.7L DI!lEL)
02111 02111 021/1 02111 02111 02 til II!IIOR·

PUMP RETURN HEATER HEA TER PUMP CELL SIGNAL OIYIII iii
CURRENT CONTROL CONTROL CURRENT II.n DII!ULI
RETURN SUPPL V TRIM
Z902
10
BK
I
.... H.
,,-,
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL g. 2161
Theory of Operation
The oxygen sensor is controlled by the smart oxygen module (smart 02 module). This module is a smart device
that receives information, such as dew point flag, engine speed, etc., via the J1939 datalink,from the primary engine
electronic control module (ECM). It provides ECM with the oxygen concentration signal. It also performs its own
diagnostics and reports failures back to the primary engine ECM using the J1939 datatink. The ECM then decodes
the error message and converts it to a fault code.
• When Monitored:
Ignition on or engine started .
• Set Condition:
Supplied voltage to the smart 02 module is below 9.5 volts OR ,above 13.5 volts.
Possible Causes
POWER SUPPLY TO SMART 02 MODULE OPEN

POWER SUPPLY TO SMART 02 MODULE SHORTED TO GROUND
SMART 02 MODULE
Diagnostic Test
1. OTHER DTC'S
Are there any Alternator Voltage errors or low voltage errors for the Mass Airflow sensor or EGR Air-
flow Controller?
Yes »Repair the Alternator error or Smart Power Relay power supply.
DURE)
No »Go To 2
2. P113C ACTIVE
Is DTC P113C Active?

Yes »Go To 3
No »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST·
ING)
9 .. 2162 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L D I E S E l - - - - - - - - - DR
3. POWER SUPPLY TO SMART 02 MODULE OPEN

Disconnect the smart 02 module harness connector.
2902
Measure the voltage between the smart 02 module power Supply cir-
cuit and the smart 02 module Ground circuit at the smart 02 module
harness connector.
Is the voltage greater than 9.5 volts and less than 16.5 volts?
Yes »Go To 4
No »Repair/Replace the Smart Power Relay harness for an 8
open.
Perform POWERTRAIN VERIFICATION TEST 6.7L. 16 9
MODULE.Q2
SENSOR
(6.7L DIESEL) 81c968a6
4. SMART 02 MODULE
Reconnect the smart 02 module harness connector.
Is DTC U010C Active?
Yes »Replace the smart 02 module
DURE)
No »Test Complete. The removal and installation of the connector corrected the problem.
Perform POWERTRAIN VERIFICATION TEST - 6.7l. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P125A-POWER ENABLE CONTROL CIRCUIT LOW
r ------
SMART SMART S.IRT
1RELlY·
IPOWER POWER POWER I
I RELAY RElAY I
_~U~ _ _ !!E~..J
5'( 41
K348 F348
18 16
BR PKIOR
I
II l1
11 I
26
II 42
- ----t
1 Ciao
F348
16
PKIOR
10 + C112
F348
16
PKfOR
I
• 1040
I
F348
16
PKJOR
1~
I-SMART -,ACTUITOR-
POWER I ELECTROI.O
I RELAY TURIO
I FEED 1(I.ll,
1_ _ _ 1
K348
18
BR
431c2
r SMART - - 1.0DULE·
EIOIIE
I POWER I COITROL
RELAY 1
I_RETURN
____ J I MIT
II Aff
r1 ...,
10 oooo~ 00000 1
20 00000 00000 11
30 00000 00000 21
40
10
00000
00000
0 00000
00000
31
41
50 00000 00000 51
A
~ .....
MODULE·
RELAY· EIIOIIiE
•• IRT OOInROL C2
POWER (S.U)
,1.7L DIESEL)
tt .......

9·2164 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The Smart Power Relay supplies 12-volts to the Mass Airflow Sensor, the EGR Airflow Control Valve and the Vari-
able Geometry Turbocharger. The Smart Power Relay Driver circuit is a low side driver for the Smart Power Relay.
The Smart Power Relay Driver circuit is controlled by the ECM via a low side driver. The Smart Power Relay is
powered up at key on, and remains powered until just after key off. The power supply to the Smart Power Relay is
wired directly from the TIPM. The ECM will fight the MIL lamp immediately after this diagnostic runs and fails. During
this time there will likely also be voltage supply faults for the Mass Airflow Sensor, the EGR Airflow Control Valve
and the Variable Geometry Turbocharger. The ECM will turn off the MIL lamp once the diagnostic runs and passes
in four consecutive drive cycles.
• When Monitored:
Keyon .
• Set Condition:
The ECM detects the Smart Power Relay driver feedback is off for more than a calibrated period of time.
Possible Causes
VOLTAGE SUPPLY TO SMART POWER RELAY

(K348) SMART POWER RELAY DRIVER CIRCUIT OPEN
SHORTED POWER RELAY DRIVER CIRCUIT
ECM
Diagnostic Test
1. OTHER DTC'S
Ignition anI engine not running.
Is P125A active?
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
2. VOLTAGE SUPPLY TO SMART POWER RELAY

Measure the voltage between Smart Power Relay supply circuit and ground.
Yes »Go To 3
No »Repair open circuit to Smart Power Relay supply.
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL g. 2165
3. (K348) SMART POWER RELAY DRIVER CIRCUIT OPEN

Disconnect the Smart Power Relay harness connector.
Disconnect the (C2) ECM harness connector.
Measure the resistance between the Smart Power Relay harness connector Power Relay Driver circuit and the (C2)
ECM harness connector Power Relay Driver circuit.
Yes »Go To 4
No »Repair the open (K348) Smart Power Relay Driver circuit.
4. ECM
Measure the resistance between the (K348) Smart Power Relay Driver circuit in the ECM harness connector and all
other circuits in the ECM harness connector.
Yes »Replace ECM
No »Repair Complete.
P125B-POWER ENABLE CONTROL CIRCUIT HIGH
1- - - - - -lRE"".
SMART SMART .1 ART
IPOWER POWER POWER I
I RELAY RElAY I
_~U~ _ _ ~E~.J
5'1 4'1
K348 F348
18 16
BR PKIOR
"
I 1 ~~
37 / ' - -
,
I' 42
-
26
1
--t
C110
F348
16
PK/OR
10 t Ctta
F348
16
PKIOR
I
• S040
I
F348
16
PKJOR
11
I-SMART -I ACTUATOR·
POWER 1 ELECTROIIC
1 RElAY TURIO
1 FEED 1 (l.lL)
1 1
K34a
18
BR
43,l C2
r SMART - - 1 IODULE·
Elalll1E
I POWER 1 COITROL
RElAY 1
I'- _ _ _ _
RETURN
J , MIT
" AfT
~ 3 n
=
FaOOO'~"'"
~
10 00000' I
20 00000 00000 II
30 00000 00000 21
2 5
40
50
00000
00000
0 00000
00000
11
41
60 00000 00000 - 51
~ \..
.1 ~ ~
IODULE·
RELA'· EIGIIE
.IART COITROL C2
POWER (l.lL)
(l.lL DIESELI
11.1II~"

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 .. 2167
Theory of Operation
The Smart Power Relay supplies 12-volts to the Mass Airflow Sensor. the EGR Airflow Control Valve and the Vari-
able Geometry Turbocharger. The Smart Power Relay Driver circuit is a low side driver for the Smart Power Relay.
The Smart Power Relay Driver circuit is controlled by the ECM via a low side driver. The Smart Power Relay is
powered up at key on, and remains powered until just after key off. The power supply to the Smart Power Relay is
wired directly from the TIPM. The ECM will light the MIL lamp immediately after this diagnostic runs and fails. During
this time there will likely also be voltage supply faults for the Mass Airflow Sensor, the EGR Airflow Control Valve
and the Variable Geometry Turbocharger. The ECM will turn off the MIL lamp once the diagnostic runs and passes
• When Monitored:
Key on .
• Set Condition:
The ECM detects the Smart Power Relay driver is on for more than a calibrated period of time.
Possible Causes
VOLTAGE SUPPLY TO SMART POWER RELAY

(K348) SMART POWER RELAY DRIVER CIRCUIT OPEN
SHORTED POWER RELAY DRIVER CIRCUIT
ECM
Diagnostic Test
1. OTHER DTC'S
Is P125A active?
Ves »Go To 2
ING)
2. VOLTAGE SUPPLY TO SMART POWER RELAY

Measure the voltage between Smart Power Relay supply circuit and ground.
Yes »Go To 3
No »Repair open circuit to Smart Power Relay supply.
3. (K348) SMART POWER RELAY DRIVER CIRCUIT OPEN

Disconnect the Smart Power Relay harness connector.
Measure the resistance between the Smart Power Relay harness connector Power Relay Driver circuit and the (C2)
ECM harness connector Power Relay Driver circuit.
Yes »Go To 4
No »Repair the open (K348) Smart Power Relay Driver circuit.
4. ECM
Measure the resistance between the (K348) Smart Power Relay Driver circuit in the ECM harness connector and aU
other circuits in the ECM harness connector.
Yes »Replace ECM
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL ., . 2169
P1272-AlC CLUTCH CONTROL CIRCUIT 2 LOW
IBATT 10
. - -L..: - - - - - - - - - - - - - - - - - - - - - lIiODULE.
I r "8(+)
I
- r - = - - - - - - - - - - · - - - - - - l ElECTRONICS 1:::El~~!TED
1 POWER
I I I 1
I I CL~~CH AlC I 1
.:_~-_ 0"I'--'--_-_-_-_-_-_-_-_-_-_-_-_ C~I'_J_____ :

3
Cl
1 C9 10
l
C13
e2
20 20
DBlYL LB
.1r-------------lJ el30
3 t
D8IVL
C112
C13
18
LB
.L
C3
20
D8lYL
rn
1,.l
LiJ CLUTCH·l/C
C•• P••••••
r
I
MC -
CLUTCH E•• UIE
1IiODULE·
I
CONTROL COITROL
1___ 1
2'1
ZlS3
20
BK/GY
I
• 1041
I
IB16
14
BKNH
I
..... GUO
,..., ~
10 ~ooo~ ~oooo'\ 1
20 00000 00000 11
21
~ACK
lO 00000 00000
40
50
00000
00000
0 00000
00000
JI
41
SO 00000 00000 ,1
~
~
'-'
1I0DULE.
ENGIME
CLUTCH.l/C
conROL C2
COIIPRESSOR (1.7L1
12
MODULE· 1I0DULE·
TOTALLY TOTALLY
INTEGR1TED INTEGRATED
POWER C2 POWER C9

• When Monitored:
With the ignition on. Battery voltage greater than 10 volts. AlC Switch on .
• Set Condition:
A shorted condition is detected in the AlC clutch relay control circuit. One Trip Fault. Three good trips to turn
off the MIL.
Possible Causes
(C3) AlC COMPRESSOR CLUTCH CONTROL CIRCUIT SHORTED TO GROUND

AlC COMPRESSOR CLUTCH
TIPM
Diagnostic Test
1. AlC COMPRESSOR CLUTCH OPERATION

With a scan tool under the PCM Actuators, actuate the AlC Clutch.
Is the Ale Clutch actuating?
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
DURE)
No »Go To 2
2. AlC CLUTCH CONTROL OPERATION FROM THE PCM

Using the scan tool under the PCM Actuators, actuate the AlC Clutch.
With a 12-volt test light connected to ground, probe the (C13) AlC
Clutch Control circuit in the C2 TIPM harness connector.
10
Does the test light illuminate brightly and flash on an off?
Yes »Go To 3
.r-~1~1'
"[,0 0ol;o~ l'
No »Perform the Diagnostic Procedure for P0646-AlC CLUTCH
CONTROL CIRCUIT. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
81840084
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 .. 2171
3. (C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT SHORTED TO GROUND

Turn the ignition off
Disconnect the AlC Compressor Clutch harness connector.
Measure the resistance between ground and the (C3) AlC Clutch Con-
trol Output circuit at the AlC Compressor Clutch harness connector.
Yes »Repair the short to ground in the (C3) AlC Clutch Control
Output circuit.
2
No »Go To 4
CLUTCH-AIC
COMPRESSOR
81640228
4. AlC COMPRESSOR CLUTCH

Connect the C2 and C9 TIPM harness connectors.
Using the scan tool under the TIPM Actuators, actuate the AlC Clutch.
With a 12-volt test light connected to ground, probe the (C3) AlC Clutch
Control Output circuit at the AlC Compressor Clutch harness connector.
Does the test light illuminate brightly and flash on and off?
. Yes »Replace the Ale Compressor Clutch per Service Informa-
tion.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to
9 - ENGINE - STANDARD PROCEDURE)
2
No »Go To 5
CWTCH-AIC
COMPRESSOR
81640243

Using the schematics as a guide, inspect the wire harness and connectors.
Pay particular attention to all Power and Ground circuits.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
Perform the BODY VERIFICATION TEST - VER 1. (Refer to 8 - ELECTRICAUELECTRONIC CON-
TROL MODULES - STANDARD PROCEDURE)
P1273-AlC CLUTCH CONTROL CIRCUIT 2 HIGH
IIAn 10
1- -E --------------------- ~~::A~~;'
1 I- B(+) - - - - - - - - - - - - - - - - - l ELECTRONICS 1~N;:::ATED

1 I I 1
1 I CL~/;CH AlC I 1
1 I CONTROL CLUTCH I I
1 L - ~uITPUT- - - - - - - - - - - - - ~oINTR~ J I
1_ _ _ _ _ _ - - - - - - - - - - - - - ______ 1
3YCI 10 YC2
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20 20
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18
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C•• PRESsaR
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CLUTCH
ENGIIIIE
I CONTROL
CONTROL 1
1__ -
2'(
Z153
20
BKIGY
1
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I
Z816
14
BKM'T
1
..... G12D
10 1
lD II
21
~ACK
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40 31
50 41
60 51
IIODULE·
ENGINE
CLUTCH.A/C
CONTROL C2
COIIPRESSOR
(I.n)
13
12
IODULE· IODULE·
TOUllY
TOULLY
.NTEGRATED INTEGRATED
POWER C2
POWER CI

• When Monitored:
With the ignition on. Battery voltage greater than 10 volts. AlC Switch on .
• Set Condition:
A shorted high condition has been detected in the AlC Clutch Control output circuit by the TIPM. One Trip
Fault. Three good trips to turn off the MIL.
Possible Causes
(C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE

EXCESSIVE RESISTANCE IN THE (Z1S3) AlC CLUTCH GROUND CIRCUIT
TIPM
Diagnostic Test
1 . AlC CLUTCH OPERATION

Is the AlC Clutch actuating?
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 - ENGINE - DIAGNOS'S
AND TESTING)
No »Go To 2

With a 12-volt test light connected to ground, probe the (C13) AlC
Clutch Control circuit in the TIPM C2 harness connector.
10
Yes »Go To 3
No »Perform the Diagnostic Procedure for P064S-AIC CLUTCH
AND TESTING)
81640084
9 - 2174 ENGINE .. ELECTRICAL" DIAGNOSTICS - ·6.7L DIESEL - - - - - - - - - DR
3. (C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE

Disconnect the AlC Compressor Clutch harness connector.
Measure the voltage on the (C3) AlC Clutch Control Output circuit at the
AlC Compressor Clutch harness connector.
Is any voltage present?
Yes »Repair the short to battery voltage in the (C3) AlC Clutch
Control Output circuit.
9 - ENGINE - STANDARD PROCEDURE) 2
No »Go To 4
CLUTCH-NC
COMPRESSOR 816402af
4. AlC CLUTCH GROUND CIRCUIT OPEN

Using a 12-volt test light connected to 12-volts, probe the (2153) AlC
Clutch ground circuit at the AlC Compressor Clutch harness connector.
Yes »Go To 5
2
No »Repair the excessive resistance in the (2153) AlC Clutch
ground circuit.
CLUTCH-A/C
COMPRESSOR 816403fD
5. AlC COMPRESSOR CLUTCH

Control Output circuit at the AlC Compressor Clutch harness connector.
Yes »Replace the AlC Compressor Clutch per Service Informa-
tion.
No »Go To 6
2
CLUTCH-A./C
COMPRESSOR
81640243

g.• 2176 ENGINE - ELECTRICAl DIAGNOSTICS ~ 6.7l DIESEL - - - - - - - - - DR
P1274-A/C CLUTCH CONTROL CIRCUIT 2 OPEN
E I ------------ --- -- -
\IlTT AO
---~~::A~~~
r B(+)
- - - - - - - - - - - - - -lHECT~ONICS IITEGRATED
I POWER
I I I
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I' CONTROL ClUTCH I I
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40 31
50 41
60 51
BLACK
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IODULE·
ENGINE
CLUTCH·A/C CONTAOL C2
COIPREISOR ,1.'lL)
13
12
IOIULE· IOIULE·
TOTALLY TOTALLY
INTEGRATED INTEGRATED
POWER C2 POWER CI

DR - - - - - - - - - ENG1NE • ELECTRICAL DIAGNOSTICS .. 6~7l DIESEL g-- 2177
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts. TIPM requesting AlC Clutch operation .
• Set Condition:
An open condition has been detected in the AlC Clutch Control Output circuit by the TIPM. One Trip Fault.
Three good trips to turn off the MIL.
Possible Causes
(C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT OPEN

AlC CLUTCH
TIPM
Diagnostic Test
1. AlC CLUTCH OPERATION
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 .. ENGINE - DIAGNOSIS
AND TESTING)
No »Go To 2

With a 12-volt test light connected to ground, probe the (C13) Ale
Clutch Control circuit in the C2 TIPM harness connector.
Ves »Go To 3
No »Perform the Diagnostic Procedure for P064S-AIC CLUTCH
13
AND TESTING)
81640084
9 .. 2178 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. (C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT OPEN

Disconnect the TIPM C9 harness connector.
Disconnect the AlC Clutch harness connector.
Measure the resistance of the (C3) AlC Clutch Control Output circuit
between the TIPM C9 harness connector and the AlC Clutch harness
connector.
Yes »Go To 4
No »Repair the open in the (C3) AlC Clutch Control Output cir- 3
cuit. CLUTCH-AIC
COMPIm88QR
12
MODULe-
TOTALLV
POWER CI 8164054c
4. AlC CLUTCH
Control Output circuit at the AlC Clutch harness connector.
Yes »Replace the Ale Clutch in accordance with the Service
Information.
2
No »Go To 5
CLUTCH-AIC
COMPRESSOR
81640243
DR - - - - - - - - - ENGINE ~ ELECTRICAL- DIAGNOSTICS - 6.7l-DIESEl 9 - 2179
5. TOTALLY INTEGRATED POWER,MODULE

No »Replace the Totally Integrated Power Module in accordance with the Service Information.
g .. 2180 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P1275-AlC CLUTCH CONTROL CIRCUIT 2 OVERCURRENT
IIATT" I
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ELECTRONICS
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AlC I 1
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I L_ ~UTPUT _ _ _ _ _ _ _ _ _ _ ~ONTRO-,=- J I
,__ __T_______________1 ____ __ I
3y CI 10 yC!
C3 elJ
20 20
DBIVL lB
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C3
18
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CLUTCH.A/C
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1 CONTROL
CONTROL I
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21
llS3
20
BKIGV
I
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I
ZSIS
14
BKNH
I
"'0120
10 1
'300 11
21
~ACK
40 31
50 41
60 51
IODULE.
ENGINE
CLUTCH·A/C CONTROL C2
COIPRESIOR ,I.n)
13
12
IIODULE· IIODULE.
TOTALLY TOTALLY
INTEGRATED INTEGRATED
POWER C2 POWER C9 .1 ..5th

• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts. TIPM requesting AlC Clutch operation .
• Set Condition:
An overcurrent condition is detected in the AlC Clutch control output circuit. One Trip Fault. Three good trips
to turn off the MIL.
Possible Causes
TERMINAL DAMAGE OR CORROSION

AlC CLUTCH GROUND HIGH RESISTANCE
(C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT HIGH RESISTANCE
TIPM
Diagnostic Test
1 . AlC CLUTCH OPERATION

Ignition on l engine not running.
With a scan tool in the TIPM Actuators, actuate the AlC Clutch.
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
No »Go To 2
2. VISUAL AND PHYSICAL CONNECTOR AND TERMINAL INSPECTION

Disconnect the TIPM C9 harness connector.
Disconnect the AlC Clutch harness connector.
Inspect the terminal and connector condition. Check for signs of corrosion build up or damage the would compro-
mise the terminal to controller pin connector.
NOTE: Make sure that all in-line connectors are inspected for corrosion and/or damage.
VisuaUy inspect the wiring harness. Look for any chafed, pierced. pinched or partially broken wires hidden in the
wire insulation.
Were any of the above conditions found?
No »Go To 3
9 .; 2182 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
3. (C3) AlC CLUTCH CONTROL OUTPUT CIRCUIT EXCESSIVE RESISTANCE

With a jumper wire, connect one end to the (C3) AlC Clutch Control
Output circuit in the AlC Clutch harness connector and the other to a
clean chassis ground.
Using a 12-volt test light connected to battery voltage, probe the (C3)
AlC Clutch Control Output circuit in the TIPM C9 harness connector.
NOTE: The test light should be illuminated and bright. Compared 3
the brightness to that of a direct connection to the battery.
Does the test light illuminate brightly.
Yes »Go To 4
No »Repair the excessive resistance in the (C3) AlC Clutch Con-
trol Output circuit.
9 - ENGINE - STANDARD PROCEDURE).
81640S7a
4. AlC CLUTCH GROUND CIRCUIT

Using a 12-volt test light connected to battery voltage, probe the (Z153)
AlC Clutch Ground circuit in the AlC Clutch harness connector.
" , I , ..
NOTE: The test light should be illuminated and bright. Compared

Does the test light illuminate brightly_
Yes »Go To 5
r\
B+
I I
2
No »Repair the excessive resistance in the (Z153) AlC Clutch
Ground circuit.
2
CLUTCH-NC
COMPRESSOR 816403m
5. AlC CLUTCH CONTROL OUTPUT FROM TIPM

Reconnect the TIPM C9 harness connector.
With a scan tool ·in the TIPM Actuators, actuate the AlC Clutch.
Using the 12-Volt test light connected to ground, probe the (C3) AlC
Clutch Control Output circuit in the AlC Clutch harness connector.
Yes »Replace the AlC Clutch.
No » Replace the TIPM in accordance with the Service Informa- 2
tion.
Perform the BODY VERIFICATION TEST - VER 1. (Refer CLUTCH-A/C
to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - COMPRESSOR
STANDARD PROCEDURE) 81640243
P1277-STARTER CONTROL CIRCUIT 2 LOW (TIPM)
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts and the ASD sense switch is on .
• Set Condition:
Actual Starter state is not equal to desired state. One Trip Fault. Three good trips to turn off the MIL.
Possible Causes
(T750) STARTER CONTROL OUTPUT CIRCUIT SHORTED TO GROUND

STARTER
TIPM
Diagnostic Test
1. ACTIVE DTC
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
2. (T7S0) STARTER CONTROL OUTPUT CIRCUIT SHORTED TO GROUND

Disconnect the Starter Solenoid connector.
Measure the resistance between ground and the (T750) Starter Control
Output circuit in the Starter Solenoid harness connector.
Yes »Repair the short to ground in the (T750) Starter Control
Output circuit.
No »Go To 3
STARTER
(DIESEL)
81921f81
3. TIPM OPERATION
Using a 12-volt test light connected ground, probe the {T750} Stafer
Control Output circuit terminal at the C9 TIPM connection.
Crank the engine.
Ves »Go To 4 2
No »Replace the TIPM in accordance with the Service informa-

tion
Peliorm the POWERTRAIN VERIFICATION TEST. (Refer to
1:2
MOI)UU;.
TOTALLY
INTEGRATED
POWERee 819221d6
4. STARTER
Connect the C9 TIPM harness connector.
NOTE: The Stater Solenoid harness connector must remain dis-
connected at this time.
Have an assistant turn the ignition key to the CRANK position.
Using a 12-volt test light connected ground, probe the {T750} Stater
Control Output circuit in the Starter Solenoid harness connector while
the ignition key is in the CRANK position.
Ves »Replace the Starter.
No » Replace the Powertrain Control Module per Service Infor-
mation.
Peliorm the POWERTRAIN VERIFICATION TEST. (Refer to STARTER
9 - ENGINE - STANDARD PROCEDURE) (DIESEL)
819221da
P1278-STARTER CONTROL CIRCUIT 2 HIGH (TIPM)
• When Monitored:
W_ith the ignition on. Battery voltage greater than 10.4 volts and the ASD sense switch is on .
• Set Condition:
Actual Starter state is not equal to desired state. One Trip Fault. Three good trips to turn off the MIL
Possible Causes
(T750) STARTER CONTROL OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE

STARTER
TIPM
Diagnostic Test
1. ACTIVE DTC
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 w ENGINE - DIAGNOSIS
AND TESTING)
2. (T750) STARTER CONTROL OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE

Disconnect the C9 TI PM harness connector.
Using a 12~volt test light connected to ground. probe (T750) Starter 2
Control Output circuit in the Starter Solenoid harness connector.
Ves »Repair the short to voltage in the (T750) Starter Control
Output circuit.
No » Go To 3
IIQDUI..E.
TOTALLY
INTEGRATED
POWeRCI 81927934
g .. 2186 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
3. STARTER
Connect the C9 TIPM harness connectors.
Using a 12-volt test light connected ground, probe the (T750) Stater
Yes »Replace the Starter in accordance with the Service informa-
tion
No »Go To 4
STARTER
(DIESEL)
819221da

No »Replace the Totally Integrated Power Module per Service rnformation.
Perform the BODY VERIFICATION TEST - VER 1. (Refer to 8 - ELECTRfCAUELECTRONIC CON-
P1279-STARTER CONTROL CIRCUIT 2 OPEN (TIPM)
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts and the ASD sense switch is on .
• Set Condition:
Actual Starter state is not equal to desired state. One Trip Fault. Three good trips to turn off the MIL.
Possible Causes
(T752) STARTER OVERRIDE CIRCUIT OPEN

(T750) STARTER CONTROL OUTPUT CIRCUIT OPEN
STARTER
TIPM
Diagnostic Test
1. ACTIVE DTC
Is the OTC active at this time?
Ves »Go To 2
2. (T750) STARTER CONTROL OUTPUT CIRCUIT OPEN

Measure the resistance of the (T7S0) Starter Control Output circuit
between the Starter Solenoid harness connector and the C11 TIPM har-
ness connector.
2
Yes »Go To 3
No »Repair the open in the (T750) Starter Control Output circuit.
12
MQDULIi·
TOTALLY
INTEORAftD
POWElilct B19221dS
9 - 2188 ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL - - - - - - - - - DR
3. STARTER
Reconnect the C9 TI PM harness connector.
Using a 12-volt test light connected ground, probe the (T7S0) Stater
Yes »Replace the Starter Assembly per Service Information.
No »Go To 4
STARTER
(DIESEL)
819221da

USing the schematics as a guide inspect the wire harness and connectors.
j

Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 ~ ENGINE - STANDARD PROCEDURE)
Perform the BODY VERIFICATION TEST - VER 1. (Refer to a - ELECTRICAUELECTRONIC CON-
P127A-STARTER CONTROL CIRCUIT 2 OVERCURRENT (TIPM)
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts .
• Set Condition:
The TIPM has detected on overcurrent condition in the Starter Control circuit. One Trip Fault. Three good trips
to turn off the MIL.
Possible Causes

(T750) STARTER CONTROL OUTPUT CIRCUIT EXCESSIVE RESISTANCE
STARTER
TIPM
Diagnostic Test
1. ACTIVE DTC
Yes »Go To 2
No »Refer to the INTERMITIENT CONDITION Diagnostic Procedure.

Disconnect the Starter Solenoid harness connector.
NOTE: Make sure that all in-line connectors are inspected for corrosion anellor damage.
Visually inspect the wiring harness. Look for any chafed, pierced, pinched or partially broken wires hidden in the
wire insulation.
No »Go To 3
9·2190 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
3. EXCESSIVE RESISTANCE IN THE (T750) STARTER CONTROL OUTPUT CIRCUIT

With a jumper wire, connect one end to the (T750) Starter Control Out-
put circuit in the Starter Solenoid harness connector and the other to a
clean chassis ground.
Using a 12-volt test light connected to battery voltage, probe the (T750)
Starter Control Output circuit in the C9 TIPM harness connector.
Yes »Go To 4
2 STARTER
No »Repair the short to ground in the (T750) Starter Control (DIESEL)
Output circuit.
12
MODULE·
TOTAllY
INTEGRATED
POWERCI
81929702
4. STARTER
Reconnect the C9 TI PM harness connector.
Using a 12-volt test light connected ground, probe the (T750) Stater
the ignition key is in the Crank position.
Yes »Replace the Starter Assembly per Service Information.
No »Go To 5
STARTER
(DIESEL)
819221da

P127C-FUEL PUMP CONTROL CIRCUIT 2 LOW (TIPM)
r- - - - - - - - - - - - - - - - - - - 'MODULE.
I . I 'OTALLY
1 - - - - - - - - - .., ElECTRONICS IITE.RATE.
I I IPOWER
I I I
I FUEl I
I PUMP FUEL I f
1 I CONTROL PUMP I
1 L _ OUTPUT ____ ~NTROl_1 I
~ __ ] _________I _____ ,
18,C10 4Y Cj
K31
20
SR
Al09
I 6
II 7
1i CUO
16 K31
,t
ORIRD 18
SR
CIII
2 AC2
Al09 IFUEl -, MODULE·
14 PUMP I EN.INE
ORtRO I CONTROL CONTROL
4A 1__ - I
Z927 N4 Z210
12 18 18
5K DBmT BK
I
• saOI
I
Z927
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Z210
12 20 2n
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DBmT BK
10 CtaS 53 1 ctte
S4
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Z927 N4 Z210
14 20 20
BK Dsmr BK
1 AC4 7),. C3
r- FUEl- - GROUND ICLunER
I LEVEL I
1 SENSOR
I MIT
II AIT
.... to.
I --':IGNAl _ _ _ _ J
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10 ~
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30 00000 00000 il
40
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60 00000 00000 51
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MODULE·
MODULE· EIGIIE
FUEL PUMP CONTROL 02 CLUSTER C4
(l.lL) ........
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts.
• Set Condition:
A shorted low condition in the Fuel Pump Control circuit has been detected by the TIPM. One Trip Fault. Three
Possible Causes
(K31) FUEL PUMP CONTROL CIRCUIT SHORTED TO GROUND

FUEL PUMP
TIPM
Diagnostic Test
1. FUEL PUMP OPERATION
With a scan tool under the PCM Actuators. actuate the Fuel Pump.
Is the Fuel Pump operating?
AND TESTING)
No »Go To 2
2. FUEL PUMP CONTROL OPERATION FROM THE PCM

Using the scan tool under the PCM Actuators, actuate the Fuel Pump.
With a 12-volt test Ught connected to ground. probe the (K31) Fuel
4
Pump Control circuit in the TIPM C1 harness connector.
Yes »Go To 3
No »Pertorm the Diagnostic Procedure for P0627-FUEL PUMP
u eeeeoco •
AND TESTING)
~Cl 81641262
3. (Al09) FUEL PUMP CONTROL OUTPUT CIRCUIT SHORTED TO GROUND

Disconnect the Cl0 TIPM harness connector.
Disconnect the Fuel Pump Module harness connector.
Measure the resistance between ground and the (A 109) Fuel Pump
Control Output circuit at the Fuel Pump Module harness connector.
4
Yes »Repair the short to ground in the (A 109) Fuel Pump Control
Output circuit.
No » Go To 4 4
MODULE.
FUEL PUMP
816415b1
4. FUEL PUMP MODULE

Using the scan tool under the TI PM Actuators, actuate the Fuel Pump.
With a 12-volt test light connected to ground, probe the (A 109) Fuel
Pump Control Output circuit at the Fuel Pump Module harness connec-
tor.
Ves »Replace the Fuel Pump Module per Service Information.
4
No »Go To 5
MODULE-
FUI!LPUMP
816415dB

P127D-FUEL PUMP CONTROL CIRCUIT 2 HIGH (TIPM)
r - - - - - - - - - - - - - - - - - - 1IODULE.
I I- - - - - - - - - - - - - I ElECTRONICS ::::!~!TED
II POWER
I
1 I I
1 FUEL I I
I PUMP FUEL I 1
I I CONTROL PUMP I
I L _OUTPU~ _______ ~NTROL_I I
~ __ ] _________I _____ I
18 C10 4 YC1
K31
1
A109
15
I 6
II 7
20
BR
,t
t
K31
C130
ORIRD 18
1 7 CllS 2
BR
J.. C2
Al09 I-FUEL --, MODULE·
14 PUMP 1ENGINE
ORIRD I CONTROL CONTROL
4)... 1 __ - 1
Z927 N4 Z210
12 18 18
BK DHIWT BK
I
• 130. 5 ,t 4 ,l C135
I 1'"----4"
Z921 N4 Z210
12 20 20
10
1927
t
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CUS 54
DBM'T
t- - -54
N4
BK
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C2te
14 20 20
BK DBIWT HI<
7)... C4 7)... C3
r- FUEL- - GROUND-' CLUSTER
1 LEVEL I
I SENSOR
• MfT
I . AfT
... enDS
1 ~IGNAL _ _ _ _ J
10 00000 ~oooo'" ,
20 00000 00000 11
JO 00000 00000 21
40
50
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O 00000
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31
41
60 00000 00000 5f
~ ~
II ODU LE·
MODULE· ENGINE
FUEL PUM' COIITROL C2 CLUSTER C4
(1.7L)
.11.....

9 - 2196 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts .
• Set Condition:
A shorted high condition in the Fuel Pump Control circuit has been detected in the TIPM. One Trip Fault. Three
Possible Causes
(A 109) FUEL PUMP CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE

EXCESSIVE RESISTANCE IN THE FUEL PUMP GROUND CIRCUITS
FUEL PUMP MODULE
TIPM
Diagnostic Test

With a scan tool under the ECM Actuators, actuate the Fuel Pump.
No »Go To 2

Using the scan tool under the ECM Actuators, actuate the Fuel Pump.
With a 12-volt test light connected to ground, probe the (K31) Fuel
Pump Control circuit in the C1 TIPM harness connector.
Yes »Go To 3
No »Perform the Diagnostic Procedure for P0627-FUEL PUMP
14 DDDD::JCD 6
AND TESTING)
MODULE·
TOTALLY
_Re, 81641262
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS" 6.7L DIESEL 9 - 2197
3. (A109) FUEL PUMP CONTROL OUTPUT CIRCUIT SHORTED TO BATTERY VOLTAGE

Ignition on engine not running.
l
Using a 12-volt test light connected to ground. probe the (A 109) Fuel
Pump Control Output circuit at the Fuel Pump Module harness connec- 4
tor.
Yes »Repair the short to battery voltage in the (A109) Fuel Pump
Control Output circuit.
4
MODULE·
No » Go To 4 FUEL PUMP
816415d8
4. FUEL PUMP GROUND CIRCUITS OPEN

Using a 12-volt test light connected to 12-volts, probe the (Z927) and
(2210) Fuel Pump ground circuits at the Fuel Pump Module harness
connector.
Yes »Go To 5 2
No »Repair the excessive resistance in the Fuel Pump ground

circuits.
MOOULE.
FUEL PUMP
81641acb
5. FUEL PUMP MODULE

on engine not running.
l
Using the scan tool under the TIPM Actuators, actuate the Fuel Pump.
tor.
Does the test light illuminate brightly and flash on and off? 4
Yes »Replace the Fuel Pump Module per Service Information.

No »Go To 6
4
MODULE·
FUEL PUMP
816415d8
9 - 2198 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR

P127E-FUEL PUMP CONTROL CIRCUIT 2 OPEN (TIPM)
r - - - - - - - - - - - - - - - - - - I MODULE.
I I TOTALLY
I 1- - - - - - - - - - - - -I ELECTRONICS I ~.~:::ATED
I I I
I FUEl I
I PUMP FUEL I I
I I CONTROL PUMP I
1 L _ OUTPU~ _______ ~NTROL_I 1
~ __1_________I _____ I
18 rcto ·YCtK31
20
BR
, 6 J.. e130
Al0Q
16
" 7 t
K31
OR~D
18
't .tI.
Al09
BR
2 J..C2
I-FUEL --, MODULE·
14 PUMP I ENGINE
ORIRD I CONTROL CONTROL
4).. 1_--I
1927 N4 Z210
12 18 18
BK DBiWT BK
Z927
I
I
• S308 5 t- __ ~
N4 Z210
C135
12 20 20
t- __
BK
1
DBiWT BK
10 et35 54 5~ C2tl
Z927 N4 Z210
14 20 20
BK DBiWT BK
7).. Cf 7).. C3
r- FUEL- - GROUND-I CLUSTER
I LEVEL I
I SENSOR
.... G108
I ~IGNAL _ _ _ _ J
" "
10 ~ooo~ ~ooo~ 1
20 00000 00000 11
30
40 ggggg 0 ggggg 21
31
SO 00000 00000 41
60 00000 00000 51
~~
MODULE·
MODULE· ENGINE
FUEL PUMP COMTROL C2 CLUSTER Cf
,1.7L)

• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts. TIPM requesting Fuel Pump operation .
• Set Condition:
An open condition has been detected in the Fuel Pump Control circuit by the TIPM. One Trip Fault. Three
Possible Causes
(A 109) FUEL PUMP CONTROL OUTPUT CIRCUIT OPEN

FUEL PUMP
TIPM
Diagnostic Test

With a scan tool under the ECM Actuators, actuate the Fuel Pump.
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 - ENGfNE - DIAGNOSIS
AND TESTING)
No »Go To 2

Using the scan tool under the ECM Actuators, actuate the Fuel Pump.
With a 12-volt test light connected to ground, probe the (K31) Fuel
Pump Control circuit in the C1 TIPM harness connector.
Yes »Go To 3
No » Perform the Diagnostic Procedure for P0627-FUEL PUMP
CONTROL CrRCUIT. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
MOWLe·
lOTN.l.V
III'I1!GMTII)
POWI!R C1 a1641262
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 .. 2201
3. FUEL PUMP CONTROL OUTPUT CIRCUIT OPEN

Measure the resistance of the (A 109) Fuel Pump Control Output circuit
between the C10 TIPM harness connector and the Fuel Pump Module
harness connector.
Yes »Go To 4 18
No » Repair the open in the (A 109) Fuel Pump Control Output

circuit.
17
1Il01'l4Jl.E·
TOTALLY
INTEGItA'TWD
POWeRC10
816421c6
4. FUEL PUMP MODULE

Using the scan tool under the TI PM Actuators, actuate the Fuel Pump.
tor. 4
Yes »Replace the Fuel Pump Module in accordance with the Ser-
vice Information.
4
No »Go To 5
MODULE-
FUEL PUMP
816415d8

DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS -. 6.7l DIESEL 9 - 2203
P0127F-FUEL PUMP CONTROL CIRCUIT 2 OVERCURRENT (TIPM)
r - - - - - - - - - - - - - - - - - - IIODULI.
I I TOTALLY
- - - - - - - - - - - - - --, ELECTRONICS .NTEGRATED
I I I I~H
I I I
I FUEL ' I
I PUMP FUEL I I
I I CONTROL PUMP I
I L _OUTPU~ _ _ _ _ _ _ _ ~NTROL_I I
~ __ 1________ -[ _----'
18 C10 4 Y Ct
K31
1
A1D9
16
• 0
•• 7
20
BR
,1,.
i
K31
Cl1•
ORnm
f
18
BR
I CtlS 2 ACt
Al09 (FUEL -, IODULE·

14 PUMP I EIGIIE
I CONTROL CONTROL
I __ J
ORIRD
4)...
Z921 N4 Z216
12 18 18
8K DBINT 8K
I
• 1101 5 ,l 4 ,l ctas
I t------t
1921 N4 1210
12 20 20
10 t
BK
1927
Ctl. 54 t- __
OBINT
N4
5~ C2t.
Z210
BK
14 20 211
BK DBNlT BK
7AC", 7Aca
r-------
FUEL GROUND I CLUITER
I LEVEL I
, SENSOR
• MIT
•• AfT
"'11" I ~I~l _ _ _ _ -.J
..., ....
.G:' 10 00000
r00000......, 1
lQ 00000 00000 11
~ 00000 00000 21
40
50
00000
00000
0 00000
00000
31
41
eo 00000 00000 51
~ ~
L..J L..J
IODULE·
IODUlE· I •• IIE
FUEL PUI' CO.TROl C2 CLUITER Col
('.lLl '1.-..
9·2204 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
• When Monitored:
With the ignition on. Battery voltage greater than 10.4 volts. TIPM requesting Fuel Pump operation.
• Set Condition:
An overcurrent condition is detected in the fuel pump control output circuit. One Trip Fault. Three good trips to
turn off the MIL.
Possible Causes

FUEL PUMP MOTOR GROUND HIGH RESISTANCE
(A109) FUEL PUMP CONTROL OUTPUT CIRCUIT HIGH RESISTANCE
FUEL PUMP MOTOR
TIPM
Diagnostic Test

With a scan tool in the TIPM Actuators, actuate the Fuel Pump.
Ves »Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
No »Go To 2

NOTE: Make sure that all in-line connectors are inspected for corrosion and/or damage.
Visually inspect the wiring harness. Look for any chafed, pierced, pinched or partially broken wires hidden in the
wire insulation.
No »Go To 3
3. (A109) FUEL PUMP CONTROL OUTPUT CIRCUIT HIGH RESISTANCE

With a jumper wire, connect one end to the (A 109) Fuel Pump Control
Output circuit in the Fuel Pump Module harness connector and the
other to a clean chassis ground.
Using a 12·volt test light to battery voltage, probe the (A 109) Fuel Pump
Control Output circuit in the C10 TIPM harness connector.
NOTE: The test light should be illuminated and bright. Compared 18
Ves »Go To 4
No »Repair the excessive resistance in the (A 109) Fuel Pump
Control Output circuit. If

9 - ENGINE - STANDARD PROCEDURE).
816425e1
4. FUEL PUMP MOTOR GROUND CIRCUITS

Using a 12-volt test light to battery voltage, probe the (Z927) and (Z21 0)
Fuel Pump Motor Ground circuits in the Fuel Pump Motor harness con-
nector.
Yes »Go To 5 2
No »Repair the excessive resistance in the Fuel Pump Motor

Ground circuit.
MODULE.
FUEL PUMP
81641acb
5. FUEL PUMP CONTROL OUTPUT FROM TIPM

Reconnect the C10 TIPM harness connector.
With a scan tool in the TIPM Actuators, actuate the Fuel Pump.
Using the 12-Volt test light connected to ground, probe the (A 109) Fuel
Pump Control Output circuit in the Fuel Pump Module harness connec-
tor. 4
Yes »Replace the Fuel Pump Module
4
No » Replace the TIPM in accordance with the Service Informa-
tion. MODULE.
Peliorm the BODY VERIFICATION TEST - VER 1. (Refer FUELPU. .
to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - 816415d8
STANDARD PROCEDURE)
P141A-EXHAUST GAS TEMPERATURE SENSOR 1 AND 2 SIGNALS SWAPPED
. - - - - - . - - - - - - - . - - - - - - - . St09

~~~
I I I I I I
K900 K900 KGOO K900 K900 K900 K901l
18 20 18 20 18 20 18
DBIOG DBIOG DBIOG DBIDG DBIO G DBID G DBIOG
I I I I I I
~~~
rn'l SENIOR·
ElHAUST
TEMPERATURE 1/1 rn
,1 SEIISOR·
EXHAUST
TEMPERATURE 1/2
1
rn
2
SEIISOR·
EXHAUST 1
TEMPERATURE 1/3

~~~
I I I I I I
K185 KI85 K372 K372 K186 K186
20 1B 20 18 20 18
BRltB BRA.B BRIDG BRID G BRIDB BRIDB
I I I I I I
~~~
A A A
4
1---1-----1----, 5 6 Il CUI
K900 KIS5 K372 K186

18 18 18 18
DBIOG BRILB BRIIlG BR/oR
291c2 201c2 101c2 91c2

r SENSOR - - EXHAuST - - - - ExHAUST - - - - -EXHAUST - lMODULE.
I GROUND TEM PERA TUR E TEMPERA TURE 1/3 TEM PERA TURE 1/2 I :::~·REOL
SENSOR 1 SENSOR SENSOR
L_____________________ J
to I
20 II
lO 21
40 31
50 41
60 51
1 2
IIODULE·
Ell GIIil E
IE •• OR· SEIISOR· SElSOR· COITROL C2
EIHAUST EXHAUST EIHAUST (1.1L,
TEMPERATURE 1/i TEMPERATURE 1./2 TEMPERATURE 1/3
CI.lL, (1.1L, (1.1L,
11111101

DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9·2207
Theory of Operation
The aftertreatment temperature sensors are used by the electronic control module (ECM) to monitor the engine
exhaust temperatures in the aftertreatment system. The aftertreatment diesel oxidation catalyst inlet temperature
sensor measures the temperature of the exhaust gas entering the aftertreatment system. The aftertreatment diesel
particulate filter inlet temperature sensor measures the temperature of the exhaust gas entering the diesel particu-
late filter. This diagnostic monitors and compares the temperatures being measured by the aftertreatment diesel
oxidation catalyst inlet temperature sensor and the diesel particulate inlet temperature sensor to ensure that the
temperature sensor readings match the antiCipated temperature rise as the exhaust gases flow through the diesel
oxidation catalyst. This fault code is logged if the ECM detects that the reading from the aftertreatment diesel oxi-
dation catalyst inlet temperature sensor is higher than the readings from the aftertreatment diesel particulate filter
inlet temperature sensor during an active regeneration event of the aftertreatment diesel particulate filter. The ECM
will illuminate the amber check engine light immediately when the diagnostic runs and fails. Active regeneration of
the aftertreatment diesel particulate filter will be disabled. The ECM will turn off the amber CHECK ENGINE light
immediately after the diagnostic runs and passes .
• When Monitored:
Engine Running and Performing an Active Regeneration of the aftertreatment diesel particulate filter.
• Set Condition:
This fault code is logged if the ECM detects that the reading from the aftertreatment diesel oxidation catalyst
inlet temperature sensor is higher than the readings from the aftertreatment diesel particulate filter inlet tem-
perature sensor during an active regeneration event of the aftertreatment diesel particulate filter.
Possible Causes
EXHAUST TEMPERATURE SENSOR 1/1 AND EXHAUST TEMPERATURE SENSOR 1/2 HARNESS
CONNECTORS ARE SWAPPED
DAMAGED/NONFUNCTIONAL AFTERTREATMENT DIESEL OXIDATION CATALYST
1. P141A ACTIVE
Turn the ignition on. Wait 5 seconds after the ignition is turned ON.
Using the scan tool, read DTCs
Repair all other DTCs first.
Is P141A Active?
Ves »Go To 2
No »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
The Exhaust Temperature Sensor 1/1 and the Exhaust Temperature Sensor 1/2 readings are reversed.
Swap the wiring harness connections of the Exhaust Temperature Sensor 1/1 and the Exhaust Temperature Sensor
1/2.
Did the Fault Code clear?
DURE)
No »Replace the Both temperature sensors.
PROCEDURE)
P144E-EGR COOLER BYPASS STATUS LINE CIRCUIT LOW
- - - - - - - 1RELlY·
I 1811 &11
I POWEA
I SMART I
POWER I
I RElAY I
L ____ -lEE!. _
4'(
F348
16
PKIOR
, 261
" 42 t Ct30
F34S
16
PKIOR
10 t C112
F3U
16
PK/OR
I
• S040
I
F348
16
PKIOR
31 VALIE.f.!GR
SMART
POWER EGR COOLER
RElAY EGR BYPASS BYPASS
FEED BYPASS VALVE ACTUATOR (1.1LIDHJD1,
STATUS SIGNAL GROUND
K972
18
DBITN
I
• soso
I
K671 K67D K972
18 18 18
BRID8 BRitS DBITN
171 C1 91 CI 331 Cf
I EGR - - - EGR - - AcTUATOR --, IIODULE·
EIIIGIIIIE
I BYPASS BYPASS GROUND I CONTROL
I STA TU S il~~VAEL I , MIT
L __________ --1 " AIT
~ rL
/r. ~
10
20
oooo~ 00000 11
00000 00000
30
40
00000
00000 0
00000
00000
'311
50 00000 00000 ~1
60 00000 00000 51
.A ~
~ ...... ~
L...J
IIODULE· VALVE·EGR RELAY·

EIG.IE COOLER SIlART
COITROL CI BYPASS POWER
11.1L) IS.lL DHIDII IS.ll DIESEL)
.......
Theory of Operation
The EGR Cooler bypass valve is used to bypass the EGR cooler when the engine is in an active regeneration
mode. This is to prevent EGR cooler fouling. At key on the ECM drives the control line low and then high and
monitors the correct status response. Throughout engine operation looks for status response voltage to be within
5-8 volts. This fault code will not light a MIL. The valve will continue to operate properly if it is not the cause of the
fault. This fault may also be accompanied with a P245A .
• When Monitored:
Keyon.
• Set Condition:
The voltage detected at the ECM for the EGR Bypass Status line is below a calibratable threshold for a cali-
bratable amount of time.
Possible Causes
(F348) SMART POWER RELAY COIL FEED SHORTED TO BATTERY

(F348) SMART POWER RELAY COIL FEED OPEN CIRCUIT
(K671) STATUS LINE SHORTED TO GROUND
EGR COOLER BYPASS VALVE
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Reter to 9 - ENGINE -
Diagnostic Test
1. OTHER DTC'S
Are there faults present for the VGT, EGR Airflow Control Valve or Mass Airflow sensor?
Yes »Repair the open or short to ground in (F348) Smart Power Relay COil Feed circuit.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE • STANDARD PROCE-
DURE)
No »Go To 2
2. (K671) EGR COOLER BYPASS STATUS CIRCUIT SHORTED TO GROUND

Disconnect the EGR Cooler Bypass valve harness connector.
17
Measure the resistance between the (K671) EGR Cooler Bypass Valve
Status circuit at the ECM engine harness connector and ground
Yes »Go To 3
10
No »Repair the short to ground. 20 11
30 21
Perform POWERTRAIN VERIFICATION TEST - 6.7L. .w 31
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81bbf537
3. P144E ACTIVE
Reconnect all harnesses.
Is P144E active?
Yes »Go To 4
4. ECM
Use a jumper wire to connect the 12-volt supply to the valve to the
(K671) EGR bypass status circuit.
Did P144E go inactive? ..
Yes »Replace the EGR Bypass Valve.
VALVE·EGR
(Refer to 9 - ENGINE - STANDARD PROCEDURE) COOLER
BYPASS
No » Replace ECM. (8.1l DHID1)
Replace and program the Engine Control Module (Refer to
81bbf53e
DR - - - - - - - - - ENGINE .. ELECTRICAL 'DIAGNOSTICS - 6.7L DIESEL 9 - 2211
P144F-EGR COOLER BYPASS STATUS LINE CIRCUIT HIGH
- - - - - - - , RELAY·
I IIM1RT
1 POWER
r I SMART
I POWER
I' RELAV
L ____ -lEED _I
4l
F348
16
PKJOR
, 261
" 42 t C130
Fa48
16
PKJOR
10 t C112
F348
16
PKJOR
I
• lOCO
I
F348
16
PK/OR
II VALVE-EGR
SMART
POWER EGR COOLER
RELAY EGR BYPASS BYPASS
BYPASS VALVE ACTUATOR (I.UjDH/D1)
FEED
4'(
K972
18
DBITN
I
• S050
I
K671 K610 K972
18 18 18
BRIDB BRILB OB/TN
11 10f 9 101 3310t

I EGR - - - EGR - - AcTUATOR -, 10DULE·
I BYPASS BYPASS GROUND I EIIGIlIE
STATUS VALVE COII'ROL
I SIGNAL I , MIT
L __________ .J , . AfT
I"""l rl
// Y .....,'.'.
10 ~
20
00000 00000 11
00000 00000
30 00000 00000 21
40 00000
00000
0 00000
00000
31
50 41
SO 00000 00000 51
..,j ~
~
-=- L...J
""
10DULE· VALYE.eGR REL1Y·
Ell GillE COOLER SMUT
COIITROL Ct ."AS8 POWER
,I.U, (I.U OH/D1, (S.7L DIESELI
In. . . .

9 .. 2212 ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
The EGR Cooler Bypass valve is used to bypass the EGR cooler when the engine is in an active regeneration
mode. This is to prevent EGR cooler fouling. At key on the ECM drives the control circuit low and then high and
5-8 volts. The status line is the feedback from the EGR Cooler Bypass Valve to the ECM. There is no action taken
if this fault goes active .
• When Monitored:
Key on .
• Set Condition:
Voltage on status line is detected above battery voltage
Possible Causes
(K671) EGR COOLER BYPASS VALVE STATUS OPEN

ECM
Diagnostic Test
1. P144F ACTIVE
Is DTC P144F active?
No »Repair the intermittent condition.
Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
Yes »Go To 2
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9·2213
2. (K671) EGR COOLER BYPASS STATUS CIRCUIT OPEN

Measure the resistance between the (K671) status circuit in the EGR
Cooler Bypass Valve connector with the (K671) status circuit in the
Ves »Go To 3
No »Repair the open circuit or high resistance. 4
VALVE-EQR
COOLER
10
20 11
30 21
40 31
so 41
80 51
MODULE-
ENGINE
CONTROLCt
(8.7L)
81bc48b4
3. P144F ACTIVE
Is P144F active?
Ves »Go To 4
4. ECM
Use a jumper wire to connect the (K671) EGR bypass status circuit to
ground.
Did P144F go inactive?
4
Yes »Replace the, EGR Bypass Valve.

VALVE-EaR
BYPASS
No » Replace ECM. (1.1L DH/D1)
Replace and program the Engine Control Module (Refer to
9 - ENGINE· STANDARD PROCEDURE)
81bbf53e
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l D'ESEl 9 - 2215
P1451-DIESEL PARTICULATE FILTER SYSTEM PERFORMANCE
Theory of Operation
The engine Exhaust system monitors the soot load in the Aftertreatment diesel particulate filter. Under normal oper-
ating conditions the Aftertreatment diesel particulate filter is self-cleaning, where accumulated soot is converted to
ash. Under light load operating conditions, the driver may be notified via the vehicle's EVIC message center ("CAT-
ALYST FULL: SEE OWNERS MAN" message will be displayed) that it is necessary to modify the vehicles driving
routine/duty-cycle (see Owner's Manual for details) in order to allow the Aftertreatment diesel particulate filter system
to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the
engine and set a fault, requiring service. The soot load in the Aftertreatment diesel particulate filter is estimated by
the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code
will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the
Aftertreatment diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the tur-
bocharger are not high enough to allow active regeneration of the soot that is trapped in the Aftertreatment diesel
particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot
accumulation and plugging of the Aftertreatment diesel particulate filter. The ECM will set this fault if it detects that
the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver
intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via
the EVIC message .
• When Monitored:
Engine Running
• Set Condition:
The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by
a sufficient amount to indicate that the driver intervention is required.
Possible Causes
ENGINE HAS BEEN OPERATING IN LIGHT LOAD CONDITIONS THAT PREVENT EXHAUST TEMPERATURES
FROM BEING HIGH ENOUGH TO ACTIVELY REGENERATE THE AFTERTREATMENT PARTICULATE FILTER
PROGRESSIVE DAMAGE TO THE AFTERTREATMENT SYSTEM FROM AN ENGINE FAILURE, INCLUDING
BUT NOT LIMITED TO EXCESSIVE FUEL, OIL OR COOLANT IN THE AFTERTREATMENT SYSTEM
EXHAUST LEAK PREVENTING DIESEL PARTICULATE FILTER REGENERATION TEMPERATURES FROM
BEING ACHIEVED
Diagnostic Test
1. OTHER DTCS
Ignition an, engine not running.
Are any other DTCs Active?
Yes »Repair aU other DTC's.
No »Go To 2
9·2216 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L D I E S E l - - - - - - - - - DR
2. BASE ENGINE FAILURE

Check for base engine failures.
Check for potential cause of excessive soot generation in the engine.
Potential causes include a stuck open exhaust gas recirculation valve or a variable geo'metry turbocharger actuator
that is not moving correctly, faulty fueling or oil intrusion into the Aftertreatmentlexhaust system.
Was a base engine failure found?
Yes »Replace the failed base engine component causing the high black smoke levels. Replace the Exhaust
diesel particulate filter.
No »Go To 3
3. CYLINDER MISFIRE
Start the engine.
Allow the engine to idle.
With the scan tool, read the Misfire counter status.
Is an engine misfire detected?
Ves »Determine the cause of the engine misfire. Use scan tool Cylinder Cutout Test to isolate a failed injector.
Replace the failed injector if necessary. Inspect the Aftertreatment system for possible damage.
No »Go To 4
4. EXHAUST TEMPERATURE SENSOR(S)

Turn the ignition off for 5 minutes.
With the scan tool check the temperature values of the Exhaust Temperature Sensors.
Are the Exhaust Temperature Sensors reading within 6 degrees C of each other?
Yes »Go To 5
No »Replace the Exhaust Temperature Sensor that is out of context.
5. EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE
ENGINE
Remove the turbocharger outlet and inspect for signs of oil, fuel or moisture being introduced into the Aftertreatment
system from the engine.
Was engine oil, fuel or moisture found in the turbocharger exhaust outlet?
Ves »Locate the cause of possible diesel fuel or engine oil being carried from the engine into the Exhaust
system. Inspect the Exhaust for possible damage.
DURE)
No »Go To 6
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS - &.1l DIESEL 9 - 2217
6. REGENERATION OF AFTERTREATMENT PARTICULATE: FILTER

Technician should drive vehicle per service information in response to level of EVIC Message Center Notification to
facilitate Active Regeneration of the Aftertreatment Particulate Filter.
After the Active Regeneration of the Aftertreatment Particulate Filter, Clear DTC with Service Tool Is
DTC P1451 still Active?
Yes »Go To 7
No »Repair completed, inform Owner of vehicle duty cycle requirements
DURE)

Inspect the Exhaust Pressure Sensors and lines for signs or wear, damage or blockage.
Are the Exhaust Pressure Sensors or their lines worn, damaged or blocked?
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE STANDARD PROCE·
DURE)
No »Go To 8
8. DTC STORED
Is DTC Stored?
Yes »Erase DTC. Repair complete
DURE)
No »Go To 1
P1484-CATALVST OVERHEAT DETECTION
• - - - - - . - - - - - - - . - - - - - - - . S1.1

~~~
I I I I I I
K900 K900 K900 K90D K900 K900 K90D
18 20 18 20 18 20 18
DBI1lG DBJDO DBI1lG DBI1lG DBJDG DBI1lG DBI1lG
I I I I I I
~~~
1
rn
21 SENlOR.
EIHAUST
TEMPERATURE 111 rn 2
SENSOR·
EXHAUST
TEIPERATURE t/2
rn
2
8ENSOR. 1)
ElHtulT
TEMPERATURE 1/3

~~~
I I I I I I
K185 K185 K372 K372 K186 K186
20 1a 20 18 20 18
BMB BRitS BRI1lG BRID G BRIDB BRIDB
I I 1 I I I
~~~
A A ~
4
1---1-----1----1 5 6 11 CtG8
K900 K185 K372 K1B6

18 18 18 18
DBIOG BRIlB BRJ1lG BRIOR
201c2 201c2 101c2 91c2

r SENSOR - - EXHAUST - - - - ExHAUST - - - - -EXHAUST - lIODULE.
I GROUND TEMPERATURE TEU PERA TURE 1/3 TEM PERA TURE 112 I :::~NREOL
L _____________________ J
10 I
20 II
lO 21
40 31
50 41
60 51
IODULE·
ENGINE
SEIIlIOR· SEIIlIOR· SENIOR· CONTROL C2
ElHAUST EIHAUST ElHiUBT 11.1L,
TEMPERATURE 1/1 TEMPERATURE 1/2 TEMPERATURE 1/3
11.7L) (1.1L) (1.1L,

Theory of Operation
The Aftertreatment Diesel Oxidation Catalyst is designed to react with hydrocarbons in the exhaust stream. this
reaction produces heat. The heat can become excessive if too much hydrocarbon enters the Aftertreatment Diesel
Oxidation Catalyst too quickly. Excessive heat can damage the diesel aftertreatment components, so the tempera-
ture of the aftertreatment system is closely monitored by the ECM. The Exhaust Temperature Sensors are used by
the ECM to monitor the temperatures throughout the aftertreatment system. The Exhaust Temperature Sensors are
thermistors and change resistance based on the temperature being measured. The ECM provides a calibratable
reference voltage to the sensor. The ECM monitors the voltage on the signal pin and converts this to a temperature
value. When the exhaust gas temperature is cold, the sensor or thermistor resistance is high. The ECM signal volt-
age only pulls down a small amount through the sensor to ground. Therefore, the ECM senses a high signal voltage
or low temperature. When the exhaust gas temperature is hot, the sensor resistance is low. The signal voltage pulls
down a large amount. Therefore. the ECM senses a low signal voltage, or a high temperature. The ECM will illu-
minate the MIL lamp immediately when the diagnostic runs and fails. The ECM will also disable active regeneration
of the aftertreatment diesel particulate filter. This DTC will not self clear and must be cleared by a scan tool.
• When Monitored:
Ignition ON .
• Set Condition:
The ECM detects that the Exhaust Temperature Sensor 1/1 temperature is greater than calibratable tempera-
ture for longer than a calibratabJe time.
Possible Causes
A FAULTY FUEL INJECTOR CAUSING EXCESSIVE UNBURNED FUEL TO ENTER THE EXHAUST SYSTEM.
IMPROPER FUEL
TEMPERATURE SENSOR 1/1 FAILED IN-RANGE
EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE ENGINE.
1 . TEMPERATURE SENSOR(S)
Turn ignition switch off.
Disconnect all three Exhaust Temperature Sensor harness connectors.
Measure the resistance between the Signal circuits and the (K900) Sensor ground circuit of the each Exhaust Tem-
perature Sensor.
Is the measured resistance between 82k and 300k ohms at ambient temperature?
Yes »Go To 2
No »Replace the out of range Exhaust Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE ~ STANDARD PROCEDURE)
2. VOLTAGE HIGH
Ignition on, engine running.
NOTE: Vehicle coolant must be at a minimum of 120 degrees coolant temperature for a minimum of 5 min-
utes.
Using a scan tool, monitor the Exhaust Temperature Sensor Signal voltage of all three sensors.
Is the Exhaust Temperature Sensor signal voltage 4.75 VDC or greater for any of the temp sensors?
Yes »Go To 4
No »Go To 3
3. ECM
Disconnect the engine wiring harness 12 way harness connector from the aftertreatment wiring harness 12 way
harness connector.
USing a scan tool, monitor the EGR Temperature Sensor Signal voltage.
Is the EGR temperature sensor signal voltage 4.75 VDC or greater?
Ves »Repair or replace engine harness
4. OPEN HARNESS
Turn the ignition switch on.
Using the scan tool, monitor the Exhaust Temperature Sensor Signal voltage
Is the temperature sensor signal voltage 4.75 VDC or greater?
Ves »Repair or replace engine harness
No »Replace The ECM.
P1506-CRANKCASE DEPRESSION REGULATOR VALVE PERFORMANCE
Theory of Operation
Crankcase Depression Valve is used to ensure the crankcase pressure does not go below a certain limit. It is a
mechanical valve in the closed crankcase ventilation system. It is designed to maintain crankcase pressures above
-7 inH20. This diagnostic will not run if there are any other Crankcase Pressure Sensor errors. The ECM does not
illuminate the MIL or ETC lamp for any of the crankcase pressure faults .
• When Monitored:
Engine running
• Set Condition:
The ECM detects the crankcase pressure exceeds a calibratable limit.
Possible Causes
CRANKCASE DEPRESSION VALVE

Diagnostic Test
1. DTC ACTIVE
Is fault code P1506 active?
Ves »Replace the Breather Filter Cover (the Crankcase Depression Valve is a part of this cover and is not
serviceable). Check the system for any progressive damage due to excessively low crankcase pres-
sures
Perform POWERTRAIN VERIFICATION TEST VER (DIESEL). (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
No »Clear DTC, repair complete
P1507-CRANKCASE FILTER RESTRICTION
Theory of Operation
case pressure sensor a 5-volt reference voltage. When the crankcase pressure is low. the sensor signal voltage is
• When Monitored:
Engine speed greater than 500 rpm .
• Set Condition:
Possible Causes
CRANKCASE FILTER NEEDS TO BE REPLACED

OBSTRUCTIONS IN CRANKCASE OUTLET
CRANKCASE DEPRESSION VALVE
Diagnostic Test
1. CRANKCASE OBSTRUCTIONS
Disconnect the crankcase outlet hose.
Are there any obstructions in the crankcase outlet hose or port?
Yes »Clear the obstructions.
Go To 2
No »Go To 2
2. CRANKCASE DEPRESSION VALVE

Is the crankcase depression valve stuck shut?
Yes »Replace the Breather Filter Cover (the Crankcase Depression Valve is a part of this cover and is not
serviceable). Check the system for any progressive damage due to excessively low crankcase pres-
sures.
Go To 3
No »Go To 3
3. P1507 ACTIVE
Yes »Replace the crankcase breather filter.
No »Clear DTC, repair complete.
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9·2223
P1508-CRANKCASE FILTER RESTRICTION - REPLACE FILTER
Theory of Operation
• When Monitored:
Engine speed greater than 500 rpm .
• Set Condition:
Possible Causes
CRANKCASE FILTER NEEDS TO BE REPLACED

PROGRESSIVE DAMAGE
Diagnostic Test
1. P1508 ACTIVE
Yes »Replace the crankcase breather filter and check for progressive engine damage due to high crankcase
pressures.
No »Clear DTC, repair complete.
9 - 2224 ENGINE·' ELECTRICAL DIAGNOSTICS· .. -6.7L DIESEL - - - - - - - - - DR
P2000-NOX ADSORBER EFFICIENCV BELOW THRESHOLD - BANK 1
IIAn 11
L-.. - - - - -'IODULI-
~ _ ITOTILLY 1- - - - -'- - - - - - - - - - - - , 10DUU·
I B(+) "'1 ELECTRONICS IlTltRATID
I I FUSEO IGNITION I I POWIR I DIAGNOSTIC DIAGNOSTIC ' :::~R~L
, I SWITCH OUTPUT I ,I I PORT lOW' PORT HIGH I
J
,_ _-_1'_-_ ___ _I
DATA LINK DATA LINK GROUND GROUND GROUND
L (RUN· START) ..J
-M'~--~~~~~~~'(~~'(~
20'( Ci Z902 Z902 Z902
16 16 16
F960
BK BK BK
20
PKitG
1
EXCEPT
SHIFT ON SHIFT ON
THE FLY THE FLY
r-:--'~
• - - - - - - . 1171 • - - - . - - - . lilt
I I I
F960 F960 DI32 D133 Z902
20 20 18 IB 10
PKA.G m.G WT WTIOR BK
~ 1 I
.a. GUt
A41 CU'
r- - - - ....., 10DULI. j
, FUSED IGNITION I
AlTI-&'OCI F960
SWITCH OUTPUT IRAI!' 18
I (RUN·START) 'I'WALI PKA.G
'----_ ....... 10 ,J..,- - - -
y 7y
-..J,r- - - -.--
By Ct ••
F960 0132 0133
20 20 20
PKA.G WT WTlOR
9A 3A llA
FUSED IGNITION DIAGNOSTIC DIAGNOSTIC 10DUL!·
OIUUOR
(RUN· START) DATA LINK DATA LINK II.7L DIIULI
02111 02111 02111 02112 0211'2 02112

PUMP 02111 CONTROL CONTROL CURRENT 02111 CURRENT 02112 CONTROL CONTROL CURRENT 021n
5T 5T 21 1 4T
8 13
lOT
Z902
7T
K89
14 T
K902
16 T
K79
IT
K99
15 T
KI03 K41 K734

12T
K904
1
KBD K299 K733 K141
20
BK
20
BRJlG
20
BRI1)G
20
BRotB
20
BR..tG
20
BRJlB
20
OBILB
20
BIWG
20
DMlG
20 20 20 20
BRITN BRM'T BR OBIYL
t.,"
J J J .I j .I
11
Z902
20
BK
02112 02112 02112 02 In 02112 02112 IIIIOR·

CURRENT RETURN HEATER HEATER PUMP CELL SIGNAL onG .. 1/2
I
• • tl4
?UMP CONTROL
RETURN
CONTROL
SUPPLY
CURRENT
TRIM
II.nDIEIELI
1 ,
2" 3I ~ , 5" 6,
02111 021/1 02111 02111 02111 02111 I ... OR·
PUMP RETURN HEATER HEATER PUMP CELL SIGNAL OnGII tit
CURRENT CONTROL CONmOL CURRENT ,I.7&. DIIIELI
RETURN SUPPLY TRIM
Z902
10
BK
I
.a. Ittt
.n.... l

DR - - - - - - - - - ENGINE ," ELECTRICAL DIAGNOSTICS ~,6:7L DIESEL 9 .. 2225
Theory of Operation
exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust sys-
tem. This diagnostic measures the Oxygen storage capability of the NOx Adsorber Catalyst. The ECM will set the
fault if it detects that the Nox Adsorber performance is lower than expected. The ECM will illuminate the MIL lamp
immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in
four consecutive drive cycles .
• When Monitored:
This diagnostic will run during deNOx events .
• Set Condition:
The ECM will set the fault if it detects that the Nox Adsorber performance is lower than expected.
Possible Causes
EXHAUST, EGR OR INTAKE LEAKS

DEGRADED OR POISONED NAC
USE OF HIGH SULFUR FUEL
TAMPERING OR REMOVAL OF THE NAC
02 SENSOR FAILED IN-RANGE
MASS AIR FLOW SENSOR
Diagnostic Test
1. OPEN CIRCUIT
Disconnect the Oxygen sensor harness connector.
Disconnect the Smart 02 Sensor Module from the Aftertreatment Wiring
Harness.
Is the resistance less than 10 Ohms on all circuits?
Yes »Go To 2
:GE-:':~~2
8
~ OOCCCO 0 1
16 CCCCCOOC 9
MODULE'()2
SENSOR
(6.7L DIESEL)
81bce437
SENSOR.
5
OXYGEN iN
(e.n DIESEL)
16 9
MODULE-02
SENSOR
(6.7L DIESEL)
81bce445
SENSOR-
16
OXYOEN111
(l.lL DIESIL)
16 9
MODULE-02
SENSOR
(6.7L DIESEL) 81b4007c
SENSOR-
12
OXYGEN 111
(8.7t. DIUeLl
16 CCC C
IIODUlE.Q2
SENSOR
(6.7l DIESEL)
81bce44f
SENSOR·
4
OXYCJEN 111
(8.7L DIESEL)
8 ecce
16 cccccccc 9
IIODUlE.Q2
SENSOR
(1.7L DIESEL)
81bce456
2. OXYGEN SENSOR
Using an ohmmeter check the resistance of the sensor heater circuit.
Yes »Replace Smart 02 Sensor Module
No »Replace the oxygen sensor.
16 ClClClClClClClCl 9
MODULE..Q2
SENSOR
(6.7L DIESEL.) 81b40078
4
SI!HSOR·
OXYGEN1H
(S.7L DIESEL)
(COMPONENT SIDE)
81b400ab
P2002-DIESEL PARTICULATE FILTER EFFICIENCY BELOW THRESHOLD
Theory of Operation
The aftertreatment diesel particulate filter is designed to physically filter soot and to eliminate hydrocarbons from the
engine exhaust gases through catalyst reactions in the exhaust stream. Federal law requires that the filter's effi-
ciency be monitored for signs of degradation that would compromise the efficiency of the filter. The ECM monitors
the efficiency of the aftertreatment diesel particulate filter via interpretation of data received from the Diesel Partic-
ulate Filter Pressure Sensor, which monitors the restriction across the aftertreatment diesel particulate filter. The
ECM monitors the restriction in the aftertreatment diesel particulate filter at various engine speeds/loads and will set
the fault if the restriction is below a calibrated threshold minimum value. The ECM will illuminate the MIL light Imme-
diately when the diagnostic runs and fails in two consecutive drive cycles. Active regeneration of the aftertreatment
Diesel particulate filter will also be disabled for the remainder of the drive cycle. The ECM will try to regenerate the
aftertreatment diesel particulate filter on the next subsequent drive cycle. The ECM win turn off the MIL light imme-
diately after the diagnostic runs and passes in four consecutive drive cycles.
• When Monitored:
This diagnostic runs when the engine is running and after an active regeneration of the aftertreatment diesel
particulate filter has completed .
• Set Condition:
The ECM will set the fault if the diagnostic fails in two consecutive drive cycles.
Possible Causes
FAILED DIESEL PARTICULATE FILTER PRESSURE SENSOR

FAILED AFTERTREATMENT DIESEL PARTICULATE FILTER
EXHAUST SYSTEM LEAK
BOOST LEAK
EGR LEAK
EXHAUSTPRESSURESENSOR1~
SWAPPED OR LEAKING PARTICULATE FILTER PRESSURE SENSOR LINES

Diagnostic Test
1. OTHER DTCS
Are any other DTCs Active?
Yes »Repair all other DTCs first.
No »Go To 5
9 - 2230 ENGINE - ELECTRICAL DIAGNOSIICS - 6.7L DIESEL - - - - - - - - - DR
2. AFTERTREATMENT DIESEL PARTICULATE FILTER PRESSURE SENSOR

Inspect the Particulate filter pressure sensor tubes.
Are leaks or blockages found or tubes swapped?
Perform POWERTRAIN VERIFICATtON TEST (DIESEL). (Refer to 9 ~ ENGINE - STANDARD PROCE-
DURE)
No »Go To 3
3. EGR LEAK
Look for visible signs (soot streaks) of an external EGR leak.
Are there any EGR leaks?
Ves »Repair the leak
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 ENGINE ~ STANDARD PROCE-
DURE)
No »Go To 4
4. BOOST LEAK
Check system for leaks. Perform "*INTAKE AIR SYSTEM PRESSURE TEST - DIESEL",
Ves »Repair the leak.

Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 - ENGINE - STANDARD PROCE4
DURE)
No »Go To 5
5. EXHAUST LEAKS
Check the aftertreatment system for exhaust leaks.
Does the aftertreatment system leak?
Ves »Repair the exhaust leaks.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ENGINE - STANDARD PROCE·
DURE)
No »Go To 6
6. P2002 ACTIVE
Ves »Replace the afiertreatment diesel particulate filter.
DURE)
No »Go To 7
7. AFTERTREATMENT DIESEL PARTICULATE FILTER

Remove and inspect the aftertreatment diesel particulate filter.
Does aftertreatment diesel particulate filter show evidence of failure?
Ves »Replace the aftertreatment diesel particulate filter.
DURE)
ING)
P200C-DIESEL PARTICULATE FILTER OVER TEMPERATURE - BANK 1
e-----e-------. -------e 1109

~~~
I I I I I I
K900 K900 K900 K900 K900 K900 K900
18 20 18 20 1B 20 i8
OBIDG DBIOG IlBIDG DBIDG DBt1)G DBIDG DBIDG
I I
~
21
[E
SEISOR'
EIHAUST
[E
TEMPERATURE 1/1 SEIISOR'
EIHAUST
TEMPERATURE 1/2
[E
2 SElSOR· 1)
EIHAUST
TEMPERATURE t/3

~
I I
~~
I I I I
KIS5 K1S5 K372 K312 K186 K1S6
20 18 20 18 20 18
BRJLB BRIl.B BRt1)G BRIDG BRIDB BRIDB
I I
~
11 1 C101
K900 K185 K372

I K1SS
18 18 18 18
DBIOG BRJl..B BRIDG BR/OR
291 C2 20 1 C2 10 1
C2 9 1 C2
r SENsOR - - EXHAUST - - - - ExHAUsT- - - - -EXHAUST - 1 MODULE·
I GROUND TEMPERATURE TEMPERATURE 1/3 TEMPERATURE 112 I ~::~IIIREOL
L_____________________ J
10 i
20 11
10 11
~O l!
50 4'
60 S'
1 2
IIODUlE·
EIIGIIIE
IEI.OR· 8E1I80R· SEIIISOR· CONTROL C2
EIHAUST EIHAUST EXHAUST 11·7L1
TEMPERATURE 1/t TEMPERATURE 1/2 IE.PERATUAE 1/3
IG.lLI (G.lL) ,1.7L)
.""...
DR - - - - - - - - - ENG'INE ",ELECTRICAL DIAGNOSTICS" 6.7L DIESEL 9 - 2233
Theory of Operation
The Exhaust Temperature Sensors are used by the electronic control module (ECM) to monitor the engine exhaust
temperatures in the aftertreatment system. The Exhaust Temperature Sensors are thermistors and change resis-
tance based on the temperature being measured. The ECM provides a 5-volt reference voltage to the sensor. The
a
ECM monitors the voltage on the signal pin and converts this to temperature value.' When the exhaust gas tem-
perature is cold, the sensor or thermistor resistance is high. The ECM signal voltage only pulls down a small
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will illuminate the MIL lamp
immediately when the diagnostic runs and fails. Active regeneration of the aftertreatment particulate filter win be
disabled. This DTC can only be cleared with a scan tool.
• When Monitored:
The diagnostic runs continuously when the engine is running.
• Set Condition:
The ECM detects that the aftertreatment diesel particulate filter outlet temperature is greater than a calibrated
temperature for a calibrated period.
Possible Causes
EXHAUST TEMPERATURE SENSOR FAILED IN-RANGE

EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE ENGINE.
Diagnostic Test
1. OTHER DTCS
Are any fuel injector DTCs Active?
Yes »Repair any fuel injector DTCs
No »Go To 2
2. CYLINDER MISFIRE
the engine.
Yes »Determine the cause of the engine misfire. Use scan tool Cylinder Cutout Test to isolate a failed injector.
Replace the failed injector if necessary. Inspect the aftertreatment system for possible damage.
DURE)
No »Go To 3
3. EXHAUST TEMPERATURE SENSOR 1/3

Turn ignition off for 5 minutes.
Check the temperature values of the Exhaust Temperature Sensor 1/3 and Exhaust Temperature Sensor 1/1.
Are the aftertreatment diesel particulate filter and diesel oxidation catalyst temperature sensors reading
within 6° C (42.8° F) of each other?
Yes »Go To 4
No »Replace the Exhaust Temperature Sensor 1/3. Inspect the aftertreatment system for possible damage.
Perform POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 . ENGINE· STANDARD PROCE-
DURE)
ENGINE.
Remove the turbocharger outlet and inspect for signs of oil, fuel or moisture being introduced into the aftertreatment
Yes »Locate the cause of possible diesel fuel or engine oil being carried from the engine into the aftertreat-
ment system. Inspect the aftertreatment for possible damage.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 . ENGINE - STANDARD PROCE·
DURE)
No »Go To 5

Remove and inspect the Aftertreatment diesel particulate filter.
Yes »Replace the Aftertreatment diesel particulate filter.
DURE)
No »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST·
ING)
DR - - - - - - - - - ENGINE· ELECTRICAL D1AGNOSTICS . 6.7L DIESEL 9 • 2235
P200E-CATALYST SYSTEM OVER TEMPERATURE - BANK 1
• - - - - - . - - - - - - - . - - - - - - - . S101

~~~
I I I I I I
K900 K9DO K900 K900 K900 K900 K9DO
18 20 18 20 18 20 18
DBIDG DBAlG DBIDG DBIDG DBIUG DBIDG DBItlG
I I I I I I
~~~
1
rn
21 IIlIOR.
EIHAUST
TEll PERATURE 1/1 rn2
IE. 'OR·
EIHAUST
TEIIPERATURE 1J2
1
rn
2
IEIIOR·
EIHIUST 1
TEIlPERiTURE 1/3
EXCEPT 1 I EXCEPT EXCEPT

~~~
I I I I I I
K18S K18S K372 K372 K186 K186
20 18 20 18 20 18
BRltB BR.II.B BRItlG BRJDG BRIDB BRIDB
I I I I I I
~~~
1 1 1
4
1---1-----1----1 5 6 11 CtO'
K900 K1SS K372 K186

18 18 18 18
DB!UG BRA.B BRIDG BRIOR
r
291 C2
SENSOR - -
20
EXHAUST -
1 C2
- - -
10
ExHAuST -
1 -
C2
- - -EXHAUST -
91 C2
lIODULE-
I GROUND TEMPERA TURE TEMPERATURE 113 TEMPERA TURE 112 I

EI QliE
SENSOR 1 SENSOR SENSOR COITROL
L_____________________ J
,.., r--.
10 00000 00000 1
20 00000 00000 11
30 00000 00000 l!
40
50
00000
00000
0 00000
00000
JI
41
60 00000 00000 51
~ ~
1 2 L..J L..J
IIODULE·
EIGIIE
IE. lOR· lENIOR- lEI lOR· COITROL C2
EIHIUST I!IHIUBT EIHIUll (1.7L)
TEMPERITURE 1/t TEMPERATURE til TEIIPERATURE 1/3
(I.U, (1.7L, 11.7L,
~.III.U

Theory of Operation
The Aftertreatment Diesel Oxidation Catalyst is designed to react with hydrocarbons in the exhaust stream, this
reaction produces heat. The heat can become excessive if too much hydrocarbon enters the Aftertreatment Diesel
Oxidation Catalyst too quickly. Excessive heat can damage the diesel aftertreatment components, so the tempera-
ture of the aftertreatment system is closely monitored by the electronic control module (ECM). The Exhaust Tem-
perature sensors are used by the ECM to monitor the engine exhaust temperatures in the aftertreatment system.
The Exhaust Temperature sensors are thermistors and change resistance based on the temperature being mea-
sured. The ECM provides a 5 volt reference voltage to the sensor. The ECM monitors the voltage on the signal pin
and converts this to a temperature value. When the exhaust gas temperature is cold, the sensor or thermistor resis-
tance is high. The ECM signal voltage only pulls down a small amount through the sensor to ground. Therefore, the
ECM senses a high signal voltage or low temperature. When the exhaust gas temperature is hot, the sensor resis-
tance is low. The signal voltage pulls down a large amount. Therefore, the ECM senses a low signal voltage, or a
high temperature. The ECM illuminates the CHECK ENGINE light immediately when the diagnostic runs and fails.
Active regeneration of the aftertreatment particulate filter will be disabled. The DTC can only be cleared by a scan
tool.
• When Monitored:
The diagnostic runs continuously when the engine is running .
• Set Condition:
The ECM detects that the aftertreatment diesel oxidation catalyst outlet temperature is greater than a cali-
brated temperature for a calibrated period.
Possible Causes
EXCESSIVE FUEL ENTERING THE AFTERTREATMENT I EXHAUST SYSTEM

EXHAUST TEMPERATURE SENSOR FAILED IN-RANGE
EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE ENGINE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Reter to 9 .. ENGINE ..
Diagnostic Test
1 . OTHER DTCS
Are any Fuel injector DTCs Active?
Yes »Repair any DTCs.
DURE)
No »Go To 2
2. CYLINDER MISFIRE
Start the engine.
DURE)
No »Go To 3
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9·2237

With the scan tool check the temperature values of the Exhaust Temperature sensors.
Are the Exhaust temperature sensors reading within 6° C (42.8° F) of each other?
Yes »Go To 4
No »Replace the Exhaust temperature sensor that is out of context.
DURE)
4" EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE
ENGINE
DURE)
No »Go To 5
5. AFTERTREATMENT SYSTEM
Remove and inspect the Aftertreatment system.
Does aftertreatment diesel oxidation catalyst show evidence of failure?
Yes »Replace the Aftertreatment diesel oxidation catalyst.
DURE)
ING)
P2032·EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW· BANK 1 SENSOR 2
e-----e-------e-------e S10t

~~~
I I I I I I
K900 K900 K900 K900 K9DO KDOD K900
18 20 18 20 18 20 i8
OBIOG DBIDG DBIDG DBItlG DBItlG DBItlG DBIDG
I I
~
21
m SENSOR.
EXHAUST
. TEIPERllURE 1/1
m SENSOR.
ElHAUST
TEIP!RATURE 1/2
~
I
EXCEPT
I
m 1Y
I
SEll OR·
EXHAUST
TEl PERATURE 1/3
~
I
1)
EXCEPT
I
K185 K185 K312 K312 K186 K1S6
20 18 20 18 20 18
BRA.B BRIlB BRIDG BRIDG BRIDB BRIDB
I I I I
~ ~
A 51 1 C10'
4
1---1 ----I 6 11
I
K9l10 KISS K372 KISS
18 18 18 18
DBItlG BRII.B BRIDG BRIOR
291 C2 20 1 C2 10 1 02 91c2
r SENSOR - - EXHAUST - - - - UHAUST- - - EXHAUST - lIODULE.
ENGIIiE
I GROUND TEMPERATURE TEMPERA TURE 113 TEMPERATURE 112 I CONTROL
L__________________ _ _J
j
11
21
31
~1
51
1 2
10DULE·
EIIGtllE
SENSOR· SElSOR· SENSOR· CONTROL C2
EXNAUST EINAUST EIHAUST (1.1L1
TEIPERATURE 1/t TEIPERATURE 1/2 TEll PERATURE 'f3
,'.n) ,I.ll) ,'.1L)
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 2239
Theory of Operation
The Exhaust Temperature sensors are used by the electronic control module (ECM) to monitor the engine exhaust
temperatures in the aftertreatment system. The Exhaust Temperature sensors are thermistors and change resis-
ECM monitors the change in signal voltage and converts this to a temperature value. When the exhaust gas tem-
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will set the fault code if it detects
that the afiertreatment diesel particulate filter inlet exhaust gas temperature sensor signal voltage is less than a
calibrated voltage for longer than a calibrated period. The ECM illuminates the MIL lamp immediately when the
diagnostic runs and fails. A default value for the aftertreatment diesel particulate filter inlet temperature reading will
be used and active regeneration of the diesel particulate filter will be disabled. The ECM will turn off the MIL lamp
immediately after the diagnostic runs and passes.
• When Monitored:
Ignition ON
• Set Condition:
signal voltage is greater than a calibrated voltage for more than a calibrated time.
Possible Causes
FAILED SENSOR
(K186) EXHAUST GAS TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO GROUND
(K900) SENSOR GROUND CIRCUIT SHORTED TO GROUND
(K186) EXHAUST GAS TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND
CIRCUIT
ECM
DIAGNOSIS AND TESTING) .
Diagnostic Test
Disconnect the Exhaust Gas Temperature Sensor 1/2.
NOTE: The sensor's resistance value increases with decreasing temperature @ 50° C (122° F) resistance
ranges from 82k to 137k ohms.
Is the resistance between 82k and 300k ohms at ambient temperature?
Yes »Go To 2
PROCEDURE)
2. (K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND
CIRCUIT
Measure the resistance between the (K186) Exhaust Temperature 1/2 Signal circuit and (K900) Sensor ground cir~
cuit at the ECM harness connector. .
Yes »Go To 5
No »Go To 3
3. (K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the Exhaust Temperature Sensor 1/2.
Measure the resistance between the (K186) Exhaust Temperature 1/2 Signal circuit and ground from the sensor
harness connector.
Is the resistance greater than 100 Ohms?
Yes »Go To 4
No »Repair the short to ground in the (K1S6) Exhaust Temperature 1/2 Signal circuit.
DURE)
4. SENSOR GROUND CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K900) Sensor ground circuit in the sensor harness connector.
Is the resistance greater than 100 Ohms?
Yes »Go To
No »Repair the short to ground in the (K900) Sensor ground circuit.
DURE)
5. EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure resistance from (K1SB) Exhaust Temperature 1/2 SIGNAL circuit to all other circuits at the ECM harness
connector.
Yes »Go to 6
No »Repair the short between the circuits.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE • STANDARD PROCE·
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9·2241
6. ECM
While monitoring the Exhaust Temperature Sensor 1/2 with scan tool, connect and disconnect the Exhaust Temper-
ature Sensor 1/2 harness connector.
Does the voltage go from low with the sensor connected to high with the sensor disconnected?
Yes »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 • ENGINE - DIAGNOSIS AND TEST-
ING)
Perform POWERTRAIN VERIFICATION TEST· 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P2033-EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH - BANK 1 SENSOR
2
. - - - - - . - - - - - - - . - - - - - - - . StOI

~~~
I I I I I I
K9CD K900 K900 K900 KQOO K900 K900
18 20 18 20 18 20 1B
0810G DBJOG DBIDG DBJDG DBJDG DBJDG DBJDG
I I
~
lEI lOR·
EIHAUst J IENSOR-
[E
TEl PERATURE 1/t
EIHAUST
TEIPERATURE t/2
1
[E
2 SElSOR· 1
EIHAUST
TEl PERATURE 1/3

~
I I
~~
1 1 I I
K1B5 KISS K312 KS12 K186 K186
20 20 18 20 18
BRILB BRiB BRJDG BRIDG BRIDB BRIDB
I I I I
~~
A ~ ActGa
-1--- -I5 6 11
I
KQOO K1S5 K312 K1S6
18 1B 18 18
DBIDG BRitS BRJOG BRJOR
291 C2
r SENsOR - -
20
EXHAuST -
1 C2
-
10 1
- - ExHAUsT - - - -
C2
-EXHAUST -
91 C2
lIODULE.
I GROUND TEMPERATURE TEMPERATURE 113 TEMPERATURE 112 I ~::~IIAEOL
SENSOR i SENSOR SENSOR
L _____________________ J
10 1
10 \1
10 21
40 JI
;0 ~\
60 5\
1 2
IODULE·
EIGIIE
SEIilIDR- SElSOR· IEIISDR· CONTROL C2
EIHAUST EIHAUST EIHAUST ".lL)
TEIPERATURE 1/1 TEIPERATURE 1/2 TEIPERATURE 1/3
('.7L) (G.lL) ,1.1L)
Theory of Operation
The Exhaust Temperature sensors are used by the Electronic Control Module (ECM) to monitor the engine exhaust
temperatures in the aftertreatment system. The Exhaust temperature sensors are thermistors and change resistance
based on the temperature being measured. The ECM provides a 5-volt reference voltage to the sensor. The ECM
monitors the change in signal voltage and converts this to a temperature value. When the exhaust gas temperature
is cold, the sensor or thermistor resistance is high. The ECM signal voltage only pulls down a small amount through
the sensor to ground. Therefore, the ECM senses a high signal voltage or low temperature. When the exhaust gas
temperature is hot, the sensor resistance is low. The signal voltage pulls down a large amount. Therefore, the ECM
senses a low signal voltage, or a high temperature. The ECM will set the fault if it detects that the diesel oxidation
catalyst inlet exhaust gas temperature sensor signal voltage is greater than a calibrated voltage for more than a
calibrated time. The ECM illuminates the MIL lamp immediately when the diagnostic runs and fails. A default value
for the aftertreatment diesel oxidation catalyst inlet temperature reading will be used and active regeneration of the
diesel particulate filter will be disabled. The ECM will turn off the MIL lamp immediately after the diagnostic runs and
passes.
• When Monitored:
Ignition ON
• Set Condition:
Possible Causes
FAILED SENSOR
(K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT OPEN
(K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO THE (F855) 5-VOLT SUPPLY CIRCUIT
(K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO BATTERY
ECM
Diagnostic Test
Yes »Go To 2
PROCEDURE)
2. (K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND
CIRCUIT
Measure the resistance between the (K186) Exhaust Temperature 1/2 Signal circuit and (K900) Sensor ground cir-
cuit at the ECM harness connector.
Yes »Go To 5
No »Go To 3
3. (K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT OPEN

Disconnect the Exhaust Gas Temperature Sensor 1/2
Measure the resistance of the (K186) Exhaust Gas Temperature 1/2 Signal circuit from the sensor harness connec-
tor to the ECM harness connector.
Yes »Go To 4
No »Repair the open sensor (K186) Exhaust Temperature 1/2 Signal circuit.
DURE)

Measure the resistance of the (K900) Sensor ground circuit between the sensor harness connector and the ECM
harness connector.
Yes »Go To
No »Repair the open (K900) Sensor ground circuit.
DURE)
5. (K186) EXHAUST TEMPERATURE 1/2 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure the resistance between the (K186) Exhaust Temperature 1/2 Signal circuit to all other circuits at the ECM
harness connector.
Is the reSistance more than 100 k ohms?
Yes »Go to 6
No »Repair the circuits that are shorted together.
Perform POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 .. ENGINE - STANDARD PROCE-
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 . 2245
6. ECM
While monitoring the Exhaust Temperature Sensor 1/2 with scan tool, use a jumper wire and connect the (K186)
Exhaust Temperature 1/2 Signal circuit to the (K900) Sensor ground circuit at the sensor connector.
Did the DTC for voltage high go inactive and the OTC for voltage low become active?
Yes »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST·
ING)
DURE)
P2080-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR
1
• - - - - - . - - - - - - - . - - - - - - - . SIal

~~~
I I I I I I
K900 K900 K900 K900 K900 K900 K900
18 20 18 20 18 20 18
DBIOG DBIDG DBIDG DBIDG 0BID G DBIDG DBIDG
I I I I I I
'------------v- '------------v- '------------v-
'1 1
[1]
[1]
SEIIOR· ,
EIHAUST
TEIIPERATURE t/1 8ENaOR·
EIHAUST
TEIIPERATURE 1/2
[1]
2 SENSOR·
EIHAUST
TEIIPERATURE 1/3
1 1
EXCEPT 1 I' EXCEPT EXCEPT
~~~
I I I I I I
K185 K185 1<372 1(372 K196 K186
20 18 20 18 20 18
BRA.B BRIlB BRIDG BRIt>G BRIDB BRIt>B
I I I I I I
'------------v- '------------v- '------------v-
1 1 1
.(
1---1-----1----1 5 6 11 c1at
K900 K185 K372 K186

18 18 18 18
DBIt>G BRJtB BRJDG BRIOR
r
29 1C2
SENSOR - -
20 1
C2
EXHAUST - - - -
10 1
ExHAuST-
C2
- - - -EXHAUST -
91 C2
lIiODULE.
I GROUND TEMPERATURE TEMPERATURE 1/3 TEMPERATURE 112 I E·O~IT·REOL

SENSOR 1 SENSOR SENSOR C II

L_____________________ J
10
20 11
30 21
40 31
50 41
60 51
1 2
1I0DULE,
EUIIE
SENIOR· SENSOR· SENSOR· CONTROL C2
EINAUlT EINAUST EINAUST II,lLl
TEIIPERATURE 1/1 TEIiPERlfURE 1/2 TEIIPERATURE 1/3
(I.n, (1·7L1 (1.7L,
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9·2247
Theory of Operation
The Exhaust Temperature sensors are used by the electronic control module (ECM) to monitor the engine exhaust
temperatures in the aftertreatment system. The Exhaust Temperature sensors are thermistors and change resis-
ECM monitors the voltage on the signal pin and converts this to a temperature value. This fault is set by the ECM
if it detects that the aftertreatment diesel oxidation catalyst inlet temperature sensor reading is not increasing with
engine operating temperature after engine startup. The ECM illuminates the MIL lamp immediately when the diag-
nostic runs and fails. The ECM will disable all aftertreatment regenerations. The ECM will turn off the MIL lamp
immediately after the diagnostic runs and passes .
• When Monitored:
Engine Running
• Set Condition:
The ECM detects that the aftertreatment diesel oxidation catalyst inlet temperature sensor reading is not
increasing with engine operating temperature after engine startup.
Possible Causes
EXHAUST TEMPERATURE SENSOR 1/1

WIRING HARNESS OR CONNECTION
Diagnostic Test
1. OTHER OTCS
With a scan tool read DTCs.
Do you have any other OTC for the Exhaust Temperature sensors?
DURE)
No »Go To 2

Remove the Exhaust Temperature Sensor 1/1 and reconnect the wiring to the sensor. Monitor the scan tool, while
heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
Does the reading from the sensor increase at least -15 0 C (5° F) on the scan tool?
Yes »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
No »Replace the Exhaust Temperature Sensor 1/1.
Perform POWERTRAIN VERIFICATION TEST 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P2084-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR
2
e-----e-------. -------e Ito.

~~~
I I I I I I
K900 K900 K900 K900 K90o- KQOO K900
18 20 18 20 18 20 18
DBIDG DBIDG DBIDG DBIDG DBiDG D8iDG DBiDG
I I
'---v-'
J
m SEISOR.
EXHAUST
TEIPERATURE 1/1
m IEISOR.
EXHAUST
TEIPERATURE t/2
1
m
2
SENSOR·
EIHAUSI 1
TEMPERATURE 1/3
EXCEPT EXCEPT
~ ~
I I I I
KISS K1S5 K372 Kl72 KISS K186
20 18 20 18 20 18
BRIl.B BRitS BRn:lG BRIOG BRJDB BRiDB
I I
'---v-'
51 ~
-1---- 1----11 6 11 CtGI
K900 KISS K372 KISS

18 18 18 18
DBIDG BRIlB 8RIDG BRIOR
r
291
SENSOR -
C2
-
20
EXHAuST -
1 C2
- - -
10 1 C2
EXHAUsT - - - - -EXHAUST -
91 C2
110DULE.
I GROUND TEMPERA TURE TEMPERATURE 113 TEMPERA TURE 112 I ~::~NREOL
L_____________________ J
10
20
00000
00000
-oo~~
oJgggBI 'I
3D
40
50
00000
00000 o ggggg Ii ;1
00000 00000 i i ' 4'
!O 00000 L00000):j: 51
IODULE·
EIIGINE
SElSOR· SElSOR· SENSOR· CONTROL C2
EXHAUST EIHAUSI EINAUST (1.1L)
TEMPERlTURE 11t TEl PERATURE '12 TEl PERATURE 1/3
.I.7L) 11.7L, (6.lL)
tUN".
DR - - - - - - - - - ENGINE * ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 .. 2249
For a complete wiring diagram Refer to Section 8W~
Theory of Operation
temperatures in the aftertreatment system. The Exhaust Temperature Sensors are thermistors and change resis·
if it detects that the aftertreatment diesel particulate filter inlet temperature sensor reading is not increasing with
nostic runs and fails. The ECM will disable desoot, deSOx and deNOx. The ECM will turn off the MIL lamp imme-
diately after the diagnostic runs and passes .
• When Monitored:
Engine Running
• Set Condition:
The ECM detects that the aftertreatment diesel particulate filter inlet temperature sensor reading is not increas-
ing with engine operating temperature after engine startup.
Possible Causes

Diagnostic Test
1. OTHER DTCS
Do you have any other DTC for the Exhaust Temperature Sensors?
DURE)
No »Go To 2
2. EXHAUST GAS TEMPERATURE SENSOR 1/2

Remove the Exhaust Temperature Sensor 1/2 and reconnect the wiring to the sensor. Monitor the scan tool, while
heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
Does the reading from the sensor increase at least -15 0 C (50 F) on the scan tool?
Yes »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
No »Replace the Exhaust Temperature sensor 1/2.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE~
DURE)
P2121-ACCELERATOR PEDAL POSITION SENSOR 1 PERFORMANCE
r- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1MODULE·
I I ENGIIiE
COIITROL
I
I
15VOLT APPSNO.2 APPSNO,2 APPSNO,1 APPSNQ.I 5VOlT
I_SUPPl~ _ _ _ _ ~A~ ____ ~TURN _ _ _ _ _RETUR~ _ _ ~IGNAl _ _ _ SUPPl'!..- J
26 01 2, O. 22 O. 28 01 35 C. 21 01
1
K854
t8
mo
18
VTIBR BRNT
I I
• S031 • S030
I I
K854 K29 K400 K167 K23 K852
18 18 18 18 16 20
VTIBR WTIBR BRNT BRIDG 8RIWT BRA.B
. 28L
I I23 T
K854
20
--1----1-- -1- -1- Jcm
' T
27
II H
K29
20
I' H
' T
29
K40D
2D
I
., U
32 T
K167
20
"
I 30
M
T
K23
2fl
"
I 31
H
K852
T
20
VTIBR WTIBR BRNT BRJYl SRIWT BRNT
61 51 41 31 21 11 SENSOR·
5VOLT APPS NO.2 APPSNO,2 APPS NO.1 APPS NO.1 5 VOLT
SUPPLY
ACCELERATOR
SUPPLY SIGNAL RETURN RETURN SIGNAL
PEDAL
,MIT POSITIOII
, . Arr
~ ~
10 /~'OOOO"; r-
00000 1
20 00000 00000 I~
30 00000 00000 11
40
50
00000
00000
0 00000
00000
31
41
60 00000 00000 51
-~
L-'
"
SEIIOR· MODULE·
ACCELERATOR EII1GIII1E
PEDAL COIITROL C2
POSITIOII l6·1L1
11.1.. 71

Theory of Operation
During this time the customer will be in a limp home mode. The ECM will turn off the MIL lamp after the diagnostic
• When Monitored:
While the engine is running
• Set Condition:
The ECM detected a conformance error between APPS 1 and APPS 2
Possible Causes
WIRING HARNESS OR CONNECTOR DAMAGED

APPS
ECM
Diagnostic Test
1. OTHER DTCS PRESENT
Using the scan tool, check for any additional APPS' fault codes
Do you have any additional APPS faults?
Yes »troubleshoot other DTCs first, Go To 2
No »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 • ENGINE -
2. APPS HARNESS
Verify that the APPS is connected.
Inspect the harness and the APPS connector.
Are any pins damaged?
Yes »Repair or replace the harness.
DURE)
No »Go To 3
3. APPS
Monitor the APPS 1 and APPS 2 voltage with the scan tool while depressing the accelerator pedal.
Is the voltage transition shown on the scan tool smooth while depressing the accelerator pedal and is
the voltage from APPS 1 twice as much as the voltage from APPS 2?
Yes »Go To 4
DURE)
4. (K23) APPS 1 SIGNAL CIRCUIT OPEN

Disconnect the APPS connector.
Measure the resistance of the (K23) APPS 1 Signal circuit between the APPS connector and the C2 ECM connec-
tor.
Yes »Go To 5
No »Repair the open in the (K23) APPS 1 Signal circuit.
DURE)

Measure the resistance of the (K852) 5-volt Supply circuit between the APPS connector and the ECM connector.
Yes »Go To 6
No »Repair the open in the 5~volt Supply circuit.
DURE)
6. (K23) APPS 1 SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the APPS 1 Signal circuit
at the sensor connector.
Yes »Go To 7
No »Repair the short to ground in the (K23) APPS 1 Signal cir-
cuit.
SENSOR-
ACCEL.ERATOR
PEDAL
POSITION 8190dSdb
7. (K23) APPS 1 SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (K23) APPS 1 Signal circuit and all other circuits in the ECM connector.
Is the resistance greater than 100 K ohms for any of the other circuits?
Yes »Go To 8
No »Repair the shorted (K23) APPS Signal circuit.
DURE)

Measure the resistance between the ground and the (K852) 5-volt Sup-
ply circuit at the sensor connector.
Yes »Go To 9
No »Repair the short to ground in the (K852) 5-volt Supply cir-
cuit.
Peliorm POWERTRAIN VERIFICATION TEST - 6.7L.
IENSOR·
ACCELERATOR
PEDAL
POernON 8190d902
9. (K852) 5-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (K852) 5-volt Supply circuit and all other circuits in ECM harness connector.
Is the resistance greater than 100 K ohms for each circuit?
Yes »Go To 10
No »Repair the short in the (K852) 5-volt Supply circuit.
DURE)
10. (K167) APPS 1 RETURN CIRCUIT OPEN

Measure the resistance of the (K167) APPS 1 Return circuit between the sensor connector and the ECM connector.
Yes »Go To 11
No »Repair the open in the (K167) APPS Return circuit.
Peliorm POWERTRAIN VERIFICATION TEST - 6.7L). (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
11. (K23) APPS 1 SIGNAL CIRCUIT SHORTED TO (K852) 5-VOLT SUPPLY CIRCUIT
Measure the resistance between the (K23) APPS 1 Signal circuit and
the (K852) 5-volt Supply circuit at the sensor harness connector
Yes »Go To 12
No »Repair the short between the (K23) APPS Signal circuit and
the (K852) 5-volt Supply circuit. Perform POWERTRAIN
VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STAN-
DARD PROCEDURE)
SENSOR·
ACCELERATOR
PEDAL
POSITION 8190d952
12. (K167) APPS 1 RETURN CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (K167) APPS 1 Return circuit at and all other circuits in the ECM connector.
Yes »Go To 13
No »Repair the short in the (K167) APPS Return circuit.
DURE)
13. (K29) APPS 2 SIGNAL CIRCUIT OPEN

Measure the resistance of the (K29) APPS 2 Signal circuit between the APPS connector and the ECM connector.
Yes »Go To 14
No »Repair the open in the (K29) APPS 2 Signal circuit.
DURE)

Measure the resistance of the (F854) 5-volt Supply circuit between the APPS connector and the ECM connector.
Yes »Go To 15
No »Repair the open in the (F854) 5-volt Supply circuit.
DURE)
15. (K29) APPS 2 SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K29) APPS 2 Signal
Yes »Go To 16
No »Repair the short to ground in the (K29) APPS 2 Signal cir·
cuit. 5
SENSOR·
ACCELERATOR
PEDAL
POSITION 6190d9f2
16. (K29) APPS 2 SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (K29) APPS 2 Signal circuit and aU other circuits in the ECM harness connec-
tor.
Yes »Go To 17
No »Repair the shorted (K29) APPS 2 Signal circuit.
DURE)

Measure the resistance between ground and the (F854) 5-volt Supply
Yes »Go To 18
No »Repair the short to ground in the (F854) 5-volt Supply cir~
cuit. 6
Perform POWERTRAIN VERIFICATION TEST). (Refer to 9
- ENGINE - STANDARD PROCEDURE)
SI!NSOR·
ACCELERATOR
PEDAL
P08~N 8190dgea
18. (F854) S-VOLT SUPPLY CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (F854) 5~volt Supply circuit and aU other circuits in the C2 ECM harness con-
nector.
Yes »Go To 19
No »Repair the shorted (F854) 5-volt Supply circuit.
DURE)
19. (K400) APPS 2 RETURN CIRCUIT OPEN

Measure the resistance of the (K400) APPS 2 Return circuit between the APPS connector and the C2 ECM con-
nector.
Yes »Go To 20
No »Repair the open in the (K400) APPS 2 Return circuit.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGINE M STANDARD PROCE-
DURE)
20. APPS 2 SIGNAL CIRCUIT SHORTED TO (F8S4) S-VOlT SUPPLY CIRCUIT

Measure the resistance between the (K29) APPS 2 Signal circuit and
the (F854) 5-volt Supply circuit in the APPS harness connector.
Yes »Go To 21
No »Repair the short between the (K29) APPS 2 Signal circuit
and the (F854) 5-volt Supply circuit. 6 5
leNSOR·
ACCELERATOR
PlDAL
POSthON 819Oda5d
21. APPS 2 RETURN CIRCUIT SHORTED TO OTHER CIRCUITS

Measure the resistance between the (K400) APPS 2 Return circuit and all other circuits in the ECM connector.
Yes »Go To 22
No »Repair the shorted (K400) APPS 2 Return circuit.
DURE)
22. ECM
Reconnect the APPS connector.
While monitoring with the scan tool, disconnect the sensor connector.
Did a APPS 1 and APPS 2 voltage too low DTC set?
Ves »Go To 23
DURE)
23. APPS
Reconnect the APPS connector.
Monitor the APPS 1 and APPS 2 voltage with the scan tool while depressing the accelerator pedal.
Is the voltage transition shown on the scan tool smooth while depressing the accelerator and is the
voltage from APPS 1 twice as much as the voltage from APPS 2?
Ves »Refer to the INTERMITIENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DURE)
9 - 2258 ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL - - - - - - - - - DR
P2122-ACCELERATOR PEDAL POSITION SENSOR 1 CIRCUIT LOW
,-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110DULE·
I I EIGII£
COITROI.
I 5 VOL T APPS NO.2 APPS NO, 2 APPS NO. , APP$ NO, 1 5 VOL T I
l_sUPPl~ _ _ _ _ SIGNA~ _ _ _ _ ~T~ _ _ _ _ _RETUR~ _ _ ~IG~L _ _ _ S~l~ J
"I c. 21 e2 "I c. " CI "C. 27 C,
KS54 K400
18 18
VTIBR 8RNT
I
• 103t •
I SD30
I
I
K854 K29 K400 K167 K23 KB52
18 18 18 18 18 20
VTJBR WTIBR BRNT BRIDG BRIWT BIM.B
,
I' "L
2JT
K854
20
VTIBR
I
II t -.:+---.:J .::+.: ri
K29
20
WTJBR
K400
20
BRNT
Kt67
BRIYL
20
K23
20
BRNH
K852
20
BRNT
C1H
61 51 41 31 21 11 SENSOR·
5 VOLT APPS NO.2 APPS NO, 2 APPS NO, 1 APPS NO.1 5VOL T
SIGNAL SUPPLY
ACCELERATOR
SUPPLY SIGNAL RETURN RETURN
PEDAL
, MIT POSITIOII
II AIT
10 1
20 11
30 ,1
40 Jl
50 41
60 51
SElSOR· MODULE·
ACCELERATOR EIGIIIE
PEDAL COITROL C2
POSITIOI (1.7LJ

Theory of Operation
• When Monitored:
With the ignition on and no other APPS No.1 DTCs present.
• Set Condition:
When the APP Sensor No.1 voltage is too low. Engine will additionally idle if the brake pedal is pressed or has
failed. Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds.
ETC light is flashing.
Possible Causes

(K852) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
(K23) APP SENSOR NO.1 SIGNAL CIRCUIT OPEN
(K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO GROUND
(K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO THE (K167) APP SENSOR NO.1 RETURN CIRCUIT
(K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO THE (K400) APP SENSOR NO.2 RETURN CIRCUIT
APP SENSOR
ECM
Diagnostic Test
1. APP SENSOR BELOW 0.25 OF A VOLT

NOTE: When this DTC is Active the engine speed, torque, and vehicle speed are limited to a Limp in mode.
With a scan tool, read the APP Sensor No.1 voltage.
Is the voltage below 0.25 of a volt?
Yes »Go To 2
No »Go To 11
2. (K852) 5-VOLT SUPPLY CIRCUIT

Disconnect the APP Sensor harness connector.
Measure the voltage on the (K852) 5-volt Supply circuit in the APP Sen-
Yes »Go To 3
No »Go To 8
SENSOR-
ACCB..ERATOR
PEDAL
P08ITlOIII 8190d8c6
3. ACCELERATOR PEDAL POSITION SENSOR

Connect a jumper wire between the (K852) 5-volt Supply circuit and the
(K23) APP Sensor No.1 Signal circuit in the Sensor harness connector.
With a scan tool, monitor the APP Sensor No.1 voltage.
Yes »Replace the APP Sensor Assembly per Service Information.
After installation is complete. use a scan tool and select the 2
ETC RELEARN function to relearn the APPS values.
No »Go To 4
NOTE: Remove the jumper wire before continuing. 6
SENSOR·
ACCELERATOR
PEDAL
POSITION 8190d8cd
4. (K23) APP SENSOR NO.1 SIGNAL CIRCUIT OPEN

Measure the resistance of the (K23) APP Sensor No.1 Signal circuit from the APP Sensor harness connector to the
C2 ECM harness connector.
Yes »Go To 5
No »Repair the open in the (K23) APP Sensor No.1 Signal circuit.
DURE)
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 2261
5. (K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K23) APP Sensor
No.1 Signal circuit in the APP Sensor harness connector.
Ves »Repair the short to ground in the (K23) APP Sensor No.1
Signal circuit.
No »Go To 6
SENSOR·
ACCI!LI!R.ATOR
PEDAL
POSITION 819Od8db
6. (K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO THE (K167) APP SENSOR NO.1 RETURN
CIRCUIT
Measure the resistance between the (K23) APP Sensor No.1 Signal cir-
cuit and the (K167) Sensor No.1 Return circuit at the APP Sensor har-
ness connector.
Ves »Repair the short between the (K167) APP Sensor No.1
Return circuit and the (K23) APP Sensor No.1 Signal circuit. 3 2
No »Go To 7
SENIOR-
ACCELERATOR
PEDAL
POSrnON 8190d8eO
7. (K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO THE (K400) APP SENSOR NO.2 RETURN
CIRCUIT
cuit and the (K400) Sensor No.2 Return circuit in the APP Sensor har-
ness connector.
Yes »Repair the short between the (K400) APP Sensor No.2
Return circuit and the (K23) APP Sensor No.1 Signal circuit. 4.
No »Go To 10
SI!NSOR.
ACCELERATOR
PEDAL.
PosmON B190d8f6

Measure the resistance of the (K852) 5-volt Supply circuit from the Sensor harness connector to the C2 ECM har-
ness connector.
Yes »Go To 9
No »Repair the open in the (K852) 5-volt Supply circuit.
DURE)

Measure the resistance between ground and the (K852) 5-volt Supply
circuit in the APP Sensor harness connector.
Yes »Repair the short to ground in the (K852) 5-volt Supply cir-
cuit.
Perform the POWERTRAIN VERIFICATION TEST - 6.7l.
No »Go To 10
EI
SENSOR.
ACCELERATOR
PEDAL.
POSI11ON 8190d902
DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL g .. 2263
10. ECM
Ground circuits.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PRO-
CEDURE)
No »Replace and program the Engine Control Module per Service Information.
CEDURE)
11 . APP SENSOR SWEEP

Slowly press the Accelerator pedal down.
Does voltage start at approximately 0.45 of a volt and go above 4.6 volts with a smooth transition?
Perform the POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 .. ENGINE - STANDARD PROCE-
DURE)
No »Replace the APP Sensor Assembly per Service Information. After installation is complete, use a scan
tool and select the ETC RELEARN function to relearn the APPS values.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE .. STANDARD PRO-
CEDURE»
P2123-ACCELERATOR PEDAL POSITION SENSOR 1 CIRCUIT HIGH
r- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 'IODULE.
I I ENGINE
COIl1TAOL
I
I SVOl T APPS NO, 2 APPS NO.2 APPS NO, 1 APPS NO, 1 5 VOLT I
I_SUPPl:'" _ _ _ _ SIGNA..!:.... _ _ _ _ _ RETURN _ '.:.,.. _ _ _RETUR~ _ _ ~IGNAl _ _ _ SUPPL:'" J
" C2 " C2 " CI " C2 35 C2 27 CI
K854 K400
18 18
VTIBR BRNT
I I
• 103' • 1030
I I
K~4 KH K400 K1fi7 K23 O~
18 18 18 18 18 20
VTI8R WTIBR BRNT BRIDG BRNt'l BRIlB
·"L----1----1----1---1--J
I I 23 T
KB54
"
' T 27
29
K29
"
' T
29
22
K400
I
.1 35
32 '(
K167
I
,
I' ~
30 T
K23
' TC".
I ' 28
31
K852
20 20 20 20 20 20
VTIBR WTIBR BRNT BRlYl BRM'T BRNT
61 51 41 31 21 11 SEIIISOR·
5 VOLT APPS NO.2 APPS NO, 2 APPS NO.1 APPS NO.1 5 VOLT
ACCELERATOR
SUPPl Y SIGNAL RETURN RETURN SIGNAL SUPPLY
PEDAL
, MfT POSITION
'I All
10 I
10 I'
JO 11
40 31
50 41
6Q ;1
IEII180A· 10DULE·
ACCELERATOA EII1GI III E
PEDAL CONTROL C2
POSITION ,1.1L1
ItlldJt

DR - - - - - - - - - ENGINE .. ELECTRICAL 'DIAGNOSTICS - 6.7L DIESEL 9 - 2265
Theory of Operation
electronic circuitry within the pedal assembly. The primary signal vades between 0 and 5 volts and the secondary
signal varies between 0 and 2.5 volts. The Engine Control Module uses the two Signals to validate throttle pedal
position to control engine fueling. The ECM illuminates the MIL lamp immediately atter the diagnostic runs and fails.
During this time the customer will be in a limp home mode. The ECM will turn off the MIL lamp atter the diagnostic
• When Monitored:
With· the ignition on and no other APPS No.1 DTCs present.
• Set Condition:
When APP Sensor No.1 voltage is too high. Engine will additionally idle if the brake pedal is pressed or has
failed. Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds.
ETC light is flashing.
Possible Causes
(K23) APP SENSOR 1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

(K23) APP SENSOR 1 SIGNAL SHORTED TO THE (K852) 5-VOLT SUPPLY CIRCUIT
(K23) APP SENSOR 1 SIGNAL SHORTED TO THE (F854) 5-VOLT SUPPLY CIRCUIT
(K167) APP SENSOR 1 RETURN CIRCUIT OPEN
APP SENSOR
ECM
Diagnostic Test
1. APPS NO.1 VOLTAGE ABOVE 4.8 VOLTS

Yes »Go To 2
No »Go To 8

With a scan tool, monitor the Accelerator Pedal Position Sensor voltage.
Yes »Go To 3
No »Replace the APP Sensor Assembly per Service Information. Atter installation is complete, use a scan
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
9 • 2266 ENGINE· ELECIRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. (K23) APP SENSOR NO.1 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

Disconnect the C2 ECM harness connectors.
Measure the voltage on the (K23) APP Sensor No.1 Signal circuit in the
APP Sensor harness connector.
2
Yes »Repair the short to battery voltage in the (K23) APP Sensor
No.1 Signal circuit.
Perform the POWERTRAIN VERIFICATION TEST· 6.7L.
No »Go To 4 6
SENSOR-
ACCELERATOR
PEDAL
POamON 8190d94e
4. (K23) APPS NO.1 SIGNAL CIRCUIT SHORTED TO THE (K852) 5-VOLT SUPPLY CIRCUIT
cuit and the (K852) 5-volt Supply circuit in the APP Sensor harness
connector.
Yes »Repair the short between the (K23) APP Sensor No.1 Sig- 2 1
nal ci rcuit and the (K852) 5-volt Supply circuit.
No »Go To 5
SENSOR-
ACCELERATOR
PEDAL
POSITION 819Od952
5. (K23) APPS NO.1 SIGNAL CIRCUIT SHORTED TO THE (F854) 5-VOLT SUPPLY CIRCUIT
cuit and the (F854) 5-volt Supply circuit in the APP Sensor harness con-
nector.
Yes »Repair the short between the (1<23) APP Sensor No.1 Sig-
nal circuit and the (F854) 5-volt Supply circuit. 6 2
Perform the POWERTRAIN VERIFICATION TEST .. 6.7L.
(Refer to 9 .. ENGINE - STANDARD PROCEDURE)
No »Go To 6
~NSOR.
ACCELERATOR
PEDAL
POSITION 8190d956
6. (K167) APP SENSOR NO.1 RETURN CIRCUIT OPEN

Measure the resistance of the (K167) APP Sensor No.1 Return circuit from the APP Sensor harness connector to
the C2 ECM harness connector.
Yes »Go To 7
No »Repair the open in the (K167) APP Sensor No.1 Return circuit.
DURE)
7. ECM
Ground circuits.
Perform the POWERTRAIN VERIFICATION TEST· 6.7L. (Refer to 9 .. ENGINE - STANDARD PROCE·
DURE)
Perform the POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
8. APP SENSOR NO.1 SWEEP

Slowly press the Accelerator Pedal down.
AND TESTING)
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
P2127-ACCELERATOR PEDAL POSITION SENSOR 2 CIRCUIT LOW
.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 'IODULE.
I ,EIIGIIIE
CONTROL
I 5 VOLT APPS NO.2 APPS NO.2 APPS NO, 1 APPS NO.1 5 VOL T I
I_SUPPl~ _ _ _ _ ~A~ _ _ _ _ ~T~ _ _ _ _ _RETUR~ _ _ -.!I~l _ _ _ SUPPl~ J
" ,C2 " el 12, C' 28 C' 3S C2 21 C2
KB54 K400
18 18
VTIBR BRNT
I I
• 1031
• S030
I I
K854 K29 K400 K167 K23 K852
18 18 18 18 18 20
VTIER WTIER BRNT BRiOG BRIWT BRn..B
·"L--- 1-- -1
•• 23 T
K854
2D
VTIBR
I
•• H
27 T
K29
WTIBR
20
II
•nT
29
K400
20
BRNT
.: J -.: ~t -.: ~
K167
20
BRNL
K23
20
BRM'T
KB52
20
BRNT
em
61 51 41 31 21 11
5 VOLT APPS NO, 2 APPS NO.2 APPS NO, j APPS NO.1 5 VOLT SEN80R·
SUPPl Y SIGNAL RETURN RETURN SIGNAL SUPPLY
ACCELERATOR
PEDAL
• MfT POIITloll
. , AfT
la l
10 II
.10 11
~o II
50 41
60 51
SEUoA· IODULE·
ACCELERATOR EIIGIIIE
PEDAL CONTROL 02
POSITION ,1.1L,

9 • 2270 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
• When Monitored:
• Set Condition:
When the APP Sensor No.2 voltage is too low. Engine will only idle if the Brake pedal is Pressed or has failed.
Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds. ETC light
is flashing.
Possible Causes

(K29) APP SENSOR 2 SIGNAL CIRCUIT OPEN
(K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO GROUND
(K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO THE (K167) APP SENSOR 1 RETURN CIRCUIT
(K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO THE (K400) APP SENSOR 2 RETURN CIRCUIT
APP SENSOR
ECM
Diagnostic Test
1. APP SENSOR BELOW 0.25 OF A VOLT

NOTE: Sensor No.2 is pulled low by the ECM as part of its system testing. This test happens a couple of
times a second. So you can expect to see voltages close to zero occasionally with a normal sensor.
Is the voltage consistently below 0.25 of a volt?
Yes »Go To 2
No »Go To 11
2. (F854) 5-VOLT SUPPLY CIRCUIT

Measure the voltage on the (F854) 5-volt Supply circuit in the APP Sen-
Is the voltage between 4.5 and 5.2 volts? 6
Yes »Go To 3
No »Go To 8
SENSOR·
ACCELERATOR
PEDAL
8190dge6

Connect a jumper wire between the (F854) 5-volt Supply circuit and the
(K29) APP Sensor 2 Signal circuit in the Sensor harness connector.
Is the voltage above 4.5 volts with the jumper wire installed?
Yes »Replace the APP Sensor Assembly per Service Information.
After installation is complete, use a scan tool and select the
ETC RELEARN function to relearn the APPS values.
No »Go To 4
NOTE: Remove the jumper wire before continuing. 6
SENSOR-
ACCILaAATOR
PEDAL
POsmON 819Od9fe
4. (K29) APP SENSOR 2 SIGNAL CIRCUIT OPEN

Measure the resistance of the (K29) APP Sensor 2 Signal circuit from the APP Sensor harness connector to the C2
Yes »Go To 5
No »Repair the open in the (K29) APP Sensor 2 Signal circuit.
DURE)
9 • 2272 ENGINE - ELECTRICAL DIAGNOSl"ICS - 6.7L DIESEL - - - - - - - - - DR
5. (K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K29) APP Sensor 2
Signal circuit in the APP Sensor harness connector.
Yes »Repair the short to ground in the (K29) APP Sensor 2 Sig-
nal circuit.
Perform the POWERTRAIN VERIFICATION TEST ~ 6.7L. 5
No »Go To 6
SENSOR·
ACCELI!RATOR
PEDAL
POSITION 819Od9f2
6. (K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO THE (K400) APP SENSOR 2 RETURN CIRCUIT
Measure the resistance between the (K29) APP Sensor 2 Signal circuit
and the (K400) Sensor 2 Return circuit in the APP Sensor harness con~
nector.
Yes »Repair the short between the (K400) APP Sensor 2 Return
circuit and the (K29) APP Sensor 2 Signal circuit. 5 4
No »Go To 7
SINSOR·
ACCELERATOR
PEDAL
POSITION 8190d9fa
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 2273
7. (K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO THE (K167) APP SENSOR 1 RETURN CIRCUIT
and the (K167) Sensor 1 Return circuit in the APP Sensor harness con-
nector.
Yes »Repair the short between the (K167) App Sensor 1 Return
circuit and the (K29) APP Sensor 2 Signal circuit.
No »Go To 10
SINSOR.
"CCE1.ERATOR
PEDAL
POSfTION 819Od9(6

Measure the resistance of the (F854) 5-volt Supply circuit from the Sensor harness connector to the C2 ECM har-
ness connector.
Yes »Go To 9
No »Repair the open in the (F854) 5-volt Supply circuit.
Perform POWERTAAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)

Measure the resistance between ground and the (F854) 5-volt Supply
circuit in the APP Sensor harness connector.
Yes »Repair the short to ground in the (F854) 5-volt Supply cir-
cuit.
No »Go To 10
SENSOR·
ACeELE~TOR
PEDAL
POSn1ON 8190dgea
10. ECM
Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to aU Power and
Ground circuits.
Periorm POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
Periorm POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
11 . APP SENSOR SWEEP

Slowly press the Accelerator pedal down.
Periorm the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE M DIAGNOSIS AND TESTING)
No »Replace the APP Sensor Assembly per Service Information. After installation is complete. use a scan
DURE)
P2128..ACCELERATOR PEDAL POSITION SENSOR 2 CIRCUIT HIGH
r- - - - - - - - - - - - - - - - - - - - - - -_ --:- - - - -, - - - 'IODULE-
f I EIIGIIIE
COITAOL
15VOLT APPSNO.2 APPSNO.2 APPSNO.l APPSNO.l 5 VOLT I
I_SUPPL~ _ _ _ _ SIGN~ _ _ _ _ ~TURN _ _ _ _ _RE.!!:Rt~ _ _ ~IG~L _ _ _ S~L~ 1
26 02 21 C2 22 02 26 .2 "02 27.2
1
K854
18
K400
18
1
VTIBR BRNT
•
I 1031 I
• 8030
I I
K854 K29 K400 K167 K2l K852
18 18 18 18 18 20
VTIBR WTJBR BRNT BRJ1lG BRNH BRILB
· 2.LT
I I 23
K854
20
---1-- 1 -1 --l--J.llo
' T 27
I I 29
K29
20
I 29
II 22
K400
20
T I
I ' 35
32 T
K167
20
' T '
I ' 34
30
K23
2D
I 31
II 28
K852
20
T
VTIBR WTIBR BRNT BRIYL BRJWT 8RNT
81 51 41 31 21 11
SENSOR-
5 VOLT APPS NO, 2 APPS NO.2 APPS NO.1 APPS NO.1 5VOLT
RETURN RETURN SIGNAL SUPPLY
ACCELERATOR
SUPPLY SIGNAL
PEDAL
I MIT POSll10111
I' AIT
10 I
lO II
30 21
40 31
50 41
SO 51
IEISOR· 10DULE·
ACCELERATOR EIGIIE
PEDAL CONTROL C2
POSITIOII II.lLl
"t.db

9 - 2276 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
• When Monitored:
• Set Condition:
When APP Sensor No.2 voltage is too high. Idle is additionally forced any time the brake is applied or failed.
Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds. ETC light
is flashing.
Possible Causes
(K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

(K29) APP SENSOR 2 SIGNAL SHORTED TO THE (F854) 5-VOLT SUPPLY CIRCUIT
(K29) APP SENSOR 2 SIGNAL SHORTED TO THE (K852) 5-VOLT SUPPLY CIRCUIT
(K400) APP SENSOR 2 RETURN CIRCUIT OPEN
APP SENSOR
ECM
Diagnostic Test
1. APPS NO.2 VOLTAGE ABOVE 3.0 VOLTS

NOTE: Diagnose any 5-Volt Supply DTCs before continuing.
Yes »Go To 2
No »Go To 8

Yes »Go To 3
CEDURE)
3. (K29) APP SENSOR 2 SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

Measure the voltage on the (K29) APP Sensor 2 Signal circuit in the
APP Sensor harness connector.
Is the voltage above 0 volts? 5
Yes »Repair the short to battery voltage in the (K29) APP Sensor
2 Signal circuit.
No » Go To 4 6
SENSOR·
ACCELERATOR
PEDAL
POernON 819Oda59
4. (K29) APPS 2 SIGNAL CIRCUIT SHORTED TO THE (F854) 5-VOLT SUPPLY CIRCUIT
and the (F854) 5-volt Supply circuit in the APP Sensor harness connec-
tor.
Yes »Repair the short between the (K29) APP Sensor 2 Signal 6 5
circuit and the (F854) 5-volt Supply circuit.
No »Go To 5
e
SENSOR·
ACCEL..ERATOR
PBDAL
POIITION 819Oda5d
5. (K29) APPS 2 SIGNAL CIRCUIT SHORTED TO THE (K852) 5·VOLT SUPPLY CIRCUIT
and the (K852) 5-volt Supply circuit in the APP Sensor harness connec-
tor.
Yes »Repair the short between the (K29) APP Sensor 2 Signal
circuit and the (K852) 5-volt Supply circuit.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L
No »Go To 6
SENSOR.
ACCELERATOR
PEDAL
POSmoN 819Oda83
6. (K400) APP SENSOR 2 RETURN CIRCUIT OPEN

Measure the resistance of the (K400) APP Sensor 2 Return circuit from the APP Sensor harness connector to the
Yes »Go To 7
No »Repair the open in the (K400) APP Sensor 2 Return circuit.
Perform the POWERTRAIN VERIFICATION TEST 6.7L. (Refer to 9 - ENGINE - STANDARD PRO·
CEDURE)
7. ECM
Ground circuits.
CEDURE)
8. APP SENSOR NO.2 SWEEP

Slowly press the Accelerator Pedal down.
Yes »Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 ~ ENGINE - DIAGNOSIS
AND TESTING)
Perform the POWERTRAIN VERIFICATION TEST - 6.lL. (Refer to 9 - ENGINE ~ STANDARD PRO-
CEDURE)
9 .. 2280 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
P2141-EGR AIRFLOW THROTTLE CONTROL CIRCUIT LOW
Theory of Operation
The EGR Airflow Throttle is a smart device that is commanded by the ECM through a PWM signal. This is a com-
pletely modulated device. The ECM will light the MIL lamp immediately after this diagnostic runs and fails. The ECM
will turn off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
Ignition on .
• Set Condition:
Status line feedback voltage is outside of a calibratable range.
Possible Causes
12 VOLT SUPPLY SHORTED TO GROUND

12 VOLT SUPPLY SHORTED TO 5-VOLTS
EGR AIRFLOW CONTROL VALVE RETURN LINE SHORTED TO VOLTAGE
EGR AIRFLOW CONTROL VALVE STATUS LINE OPEN
EGR AIRFLOW CONTROL VALVE STATUS LINE SHORTED TO GROUND
EGR AIRFLOW CONTROL VALVE
ECM
Diagnostic Test
1. DTC STATUS
Is P2141 active?
Yes »Go To 2
ING)
2. 12 VOLT SUPPLY CIRCUIT AND THE RETURN CIRCUIT

Using a voltmeter, measure the voltage on the EGR Airflow Control Valve engine harness connector from the power
supply circuit to the return circuit.
Is the measured voltage equal to battery voltage?
Yes »Go To 5
No »Go To 3
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 .. 2281
3. 12 VOLT SUPPLY SHORTED LOW

Reconnect the EGR Airflow Control Valve harness connector.
Are there any Mass Airflow or Turbocharger faults?
Yes »Repair power supply issue from the Smart Power Relay
No »Go To 4
4. RETURN CIRCUIT SHORTED HIGH

Measure the resistance between the return circuit in the EGR Airflow Control Valve connector to the return circuit in
Yes »Repair the open harness from 10 position crossover connector to EGR Airflow Control Valve
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE .. STANDARD PROCEDURE)
No »Repair/replace engine harness
5. EGR AIRFLOW CONTROL VALVE STATUS LINE OPEN

Measure the resistance between the status circuit in the EGR Airflow Control Valve connector to the status circuit in
the C 1 ECM harness connector.
Ves »Go To 6
No »Repair the open status circuit in the harness.
6. EGR AIRFLOW CONTROL VALVE STATUS LINE SHORTED TO GROUND

Measure the resistance between the EGR Airflow Control Valve status circuit at the ECM engine harness connector
and ground.
Is the resistance greater than 100 kohms?
Yes »Go To 7
No »Repair the short circuit to ground
Perform POWERTRAIN VERIFICATION TEST. (Refer to 9 .. ENGINE .. STANDARD PROCEDURE)
7. EGR AIRFLOW CONTROL VALVE

Yes »Replace EGR Airflow Control Valve.
No »Replace ECM.
DR ENGINE· ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 - 2283
P2142-EGR AIRFLOW THROTTLE CONTROL CIRCUIT HIGH
Theory of Operation
The EGR Airflow Throttle is a smart device that is commanded by the ECM through a PWM signal. This is a com-
pletely modulated device. The ECM will light the MIL lamp immediately after this diagnostic runs and fails. The ECM
will turn off the MIL lamp after the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
Ignition on .
• Set Condition:
Status line feedback voltage is outside of a calibratable range.
Possible Causes
EGR AIRFLOW CONTROL VALVE RETURN LINE OPEN

EGR AIRFLOW CONTROL VALVE STATUS LINE SHORTED TO VOLTAGE
AIRTHROTILE
ECM
Diagnostic Test
1.. DTC STATUS

Is P2142 active?
Yes »Go To 2
ING)
2. EGR AIRFLOW CONTROL VALVE RETURN LINE OPEN

Measure the resistance between the return circuit in the EGR Airflow Control Valve connector to the return circuit in
Ves »Go To 3
No »Repair the open return circuit in the harness.
3. EGR AIRFLOW CONTROL VALVE STATUS LINE SHORTED

Measure the resistance between the EGR Airflow Control Valve status circuit at the ECM engine harness connector
and ground.
Is the resistance greater than 100 kohms?
Yes »Go To 4
No »Repair the short circuit to ground
4. EGR AIRFLOW CONTROL VALVE

Yes »Replace EGR Airflow Control Valve.
No »Replace ECM.
P2227-BAROMETERIC PRESSURE SENSOR RATIONALITY
Theory of Operation
The barometric pressure sensor is used to measure exhaust gas pressure in the intake manifold. The Electronic
Control Module (ECM) provides a 5-volt supply to the barometric pressure sensor on the sensor supply circuit. The
ECM also provides a ground on the sensor return circuit. The barometric pressure sensor provides a signal to the
ECM on the barometric pressure sensor signal circuit. This sensor signal voltage changes based on the environ-
mental pressure. There are two parts to this fault code, a key on check and a rationality check. At key ON, the
readings for the boost pressure. exhaust gas pressure, and barometric pressure are compared. This fault code
occurs if the barometric pressure reading is different from the other two. This diagnostic is run 5 seconds after key
on. During normal engine operation the rationality check verifies the pressure reading is below the barometric pres-
sure value at one mile below sea level. If the sensor is reading an unreasonable value for a calibrated period of
time then an error is recorded. The key-on portion of the rationality will light the MIL immediately after the diagnostic
runs and fails. The rationality portion has to fail in two consecutive drive cycles for the MIL to become illuminated.
During this time the ECM uses an estimated barometric pressure. The ECM turns off the MIL when the diagnostic
• When Monitored:
• Set Condition:
The ECM does not read a change in value from the sensor over time.
Possible Causes
INLET TEMPERATURE/PRESSURE SENSOR
Diagnostic Test
1. INLET TEMPERATURE/PRESSURE SENSOR

Wait 5 seconds after ignition is turned ON, using the scan tool, check DTCs
Is P2227 stored?
Yes »Go to 2
No »Replace the Inlet Temperature/Pressure Sensor.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE STANDARD PROCE·
DURE)
• INTERMITTENT CONDITION
Start the engine and let it idle for 1 minute. With the scan tool, monitor the ambient air pressure reading.
Does the value fluctuate slightly, indicating the sensor is not stuck?
No »Replace the barometric pressure sensor.
PROCEDURE)
P2228-BAROMETRIC PRESSURE CIRCUIT LOW
r-----.
I 1I0DULE.
I BOOST EIGIIE
1 PRESSURE I CONTROL
1 SENSOR 1
..... ..!:.GNAl _ ..J
1STC' r- - - -SElSOR.
K31 1 ITEIPERATUREI
18 I PRESIURE-
BR I II LET
-
11
BOOST - - - - - SEIISOR·
I
I AIR
INLET
I
1
1 1TEIIPERATURE}
PRESSURE I
1
PRESSURE
SENSOR 1PRESSURE.... , I_~E~_J
1 SIGNAL I
1 1
SENSOR 5 VOLT 1
1 GROUND SUPPLY
K916 F855
18 18 K618
BRJOR PKfY'L 18
BRfY'l
•
!
S044
I
• S173
I I
KSld F855
is 18
BRIOR PKfY'L
"le.SENSOR
20 e.
r------------------, ,,1..
5 VOLT INLET IIIIODULE·
I GROUND SUPPl V AIR I EIGIIE
1 PRESSURE I COITROL
L_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___ 1
SENSE
10 ,
10 II
30 II
40 11
50 41
60 :1
TEll PERATU REI

PRESSUAE·
lAP 1I0DULE·
(1.7L) EIIGIIIE
CONTROL C1
[1.1L)
.1IJ....

• When Monitored:
• Set Condition:
Possible Causes
OTHER DTCS PRESENT

(K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND CIRCUIT
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO THE (K916) SENSOR GROUND CIRCUIT
(K616) (K616) INLET AIR PRESSURE SIGNAL CIRCUIT OPEN
(K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test

Do you have multiple DTCs?
DURE)
No »Go To 2
2. SENSOR VOLTAGE
Disconnect the Inlet Temperature/Pressure Sensor harness connector.
Measure the voltage between the (F855) 5-volt supply circuit and (K916) Sensor ground circuit of the sensor har-
ness connector.
Yes »Go To 3
No »Go To 5

While monitoring scan tool, use a jumper wire to connect the (F855) 5-volt supply circuit to the (K616) Inlet Air
Does the scan tool show a pressure sensor out of range high DTC?
Yes »Replace the Inlet Temperature/Pressure Sensor.
DURE)
No »Go To 4
4. (K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
Measure the resistance between the (K616) Inlet Air Pressure Signal circuit and (K916) Sensor ground circuit in the
Inlet Temperature/Pressure Sensor harness connector.
Yes »Go To 5
No »Repair or replace wiring harness.
DURE)
5. 5-VOLT SUPPLY CIRCUIT SHORTED 'TO THE (K916) SENSOR GROUND CIRCUIT
Measure the resistance between the (F855) 5-volt supply 'circuit and (K916) Sensor ground circuit in the Inlet Tem-
perature/Pressure Sensor harness connector.
Yes »Go To 6
No »Repair the short or replace the harness.
DURE)
6. (K616) INLET AIR PRESSURE SIGNAL CIRCUIT OPEN

Measure the resistance of the (K616) Inlet Air Pressure Signal circuit from the C1 ECM harness connector and the
Sensor harness connector.
Yes »Go To 7
DURE)

Measure the resistance of the (F855) 5-volt Supply circuit from the Inlet Temperature/Pressure Sensor harness con-
nector and the C1 ECM harness connector.
Yes »Go To 8
No »Repair or replace the Engine harness.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE· STANDARD PROCE·
DURE)
8. (K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the the (K616) Inlet Air Pressure Signal circuit in the Inlet Temperature/
Pressure Sensor harness connector.
Yes »Go To 9
No »Repair the short to ground in the (K616) Inlet Air Pressure Signal circuit.
DURE)
9. (F855) 5·VOLT SUPPLY CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (F855) 5-volt Supply circuit in the Inlet Temperature/Pressure Sen-
Yes »Go To 10
No »Repair the short to ground (F855) 5-volt Supply circuit shorted to ground or replace the wire harness.
CEDURE)
10. ECM
Install the ECM harness connector.
While monitoring scan tool, use a jumper wire to connect the (F855) 5-volt supply circuit with the (K616) Inlet Air
Does the scan tool show a pressure sensor out of range high DTe?
DURE)
9 - 2290 ENGINE· ELECTRICAL DIAGNOSTICS" 6.7L DIESEL - - - - - - - - - DR
P2229-BAROMETRIC PRESSURE CIRCUIT HIGH
r-----.
1 IODULE·
I BOOST EIGINE
I SENSOR I
' - ..2.!,GNAL _ ..J
19 ret r- - - -SENSOR.
K31 I I TEMPERATURE/
18 I PRESSURE·
8R I IILET
-
11
BOOST - - - - - SElSOR·
I
I
INLET
AIR
I
I
I
1
I
PRESSURE
SENSOR
I TEl PERATURE/
1PRESSURE·IAP _
I
PRESSURE
-=E~_J
1'"
I SIGNAL 1
I SENSOR 5 VOL T I
I GROUND SUPPLY I
--------
4j 21
K91S F855
K616
19 18
PKlYl 18
BRIOR
BRlYl
I
• 8044
I
• 8173
I I
K916 F855
18 18
BR/OR PKlYl
et .J
3,let 20- et
r------------------,
SENSOR 5 VOL T INLET MODULE·
I GROUND SUPPLY AIR I ENGIIE
l ___________________ 1 SENSE
.~
rl r-,
~
10 If~'ooo~ 00000 I
1
la
la
40 II ggggg 0
00000
00000
00000
00000
II
21
31
50
60 l 00000
00000
~
00000
00000
~I
51
SENSOA· ~ \-J
TEIPERATUAEJ
PREISURE·
MAP MODULE·
11.7L) ENGIIE
CONTROL C,
".lLl
1t1.,.11

DR - - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 • 2291
Theory of Operation
The ECM provides a S-volt supply to the inlet air pressure/temperature combination sensor on the sensor supply
circuit. The Inlet Temperature/Pressure Sensor provides a signal to the ECM on the inlet ambient air pressure sen-
sor signal circuit. This sensor signal voltage changes based on the pressure of the atmosphere. The ECM will detect
a low signal voltage when the vehicle is operating at high altitudes. The ECM will detect a high signal voltage when
the vehicle is operating at sea level altitudes. The inlet air pressure/temperature sensor is located on the air filter
box lid after the air filter. The ECM will illuminate a MIL lamp immediately after the diagnostic runs and fails. During
this time the ECM will use a default value for inlet air pressure. The customer may experience an engine power
derate. The ECM will turn off the MIL after the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
• Set Condition:
Possible Causes
OTHER DTCS PRESENT

(K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO VOLTAGE
(F8S5) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY
ECM
Diagnostic Test
Do you have multiple DTCs?
DURE)
No »Go To 2
2. CHECKING (F855) 5-VOLT SUPPLY CIRCUIT AND THE (K916) SENSOR GROUND CIRCUIT
Disconnect the Inlet Temperature/Pressure Sensor harness connector.
Measure the voltage between the (F855) 5-volt supply circuit and (K916) Sensor ground circuit of the Inlet Temper-
ature/Pressure Sensor harness connector.
Yes »Go To 3
No »Go To 4

While monitoring scan tool, use a jumper wire to connect the (K916) Sensor ground circuit to the (K616) Inlet Air
Pressure Signal circuit at the Inlet Temperature/Pressure Sensor harness connector.
Does the scan tool show a P2228 Barometric Pressure Sensor Low DTC.
Yes »Replace the Inlet Temperature/Pressure Sensor.
DURE)
No »Go To 4
4. (K616) INLET TEMPERATURE/PRESSURE SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage on the (K616) Inlet Air Pressure Signal circuit at the Inlet Temperature/Pressure Sensor har-
ness connector.
Yes »Go To 5
No »Repair or replace short to voltage.
DURE)
5. 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE

Measure the voltage on the (F855) 5-volt supply circuit at the sensor harness connector.
Yes »Go To 6
No »Repair the short to voltage or replace the harness.
DURE)
6. (K616) INLET AIR PRESSURE SIGNAL CIRCUIT SHORTED TO THE (F855) 5-VOLT SUPPLY
Measure the resistance between the (K616) Inlet Air Pressure Signal circuit and the (F855) 5-volt supply circuit of
the Inlet Temperature/Pressure Sensor harness connector.
Yes »Go To 7
DURE)

Measure the resistance of the (K916) Sensor ground circuit from the Inlet Temperature/Pressure Sensor harness
connector to the C1 ECM harness connector.
Ves »Go To 8
No »Repair or replace the Engine harness.
DURE)
8. ECM
Install the ECM harness connector.
While monitoring scan tool, use a jumper wire to connect the (K916) Sensor ground circuit with the (K616) Inlet Air
Pressure Signal circuit at the Inlet Temperature/Pressure Sensor harness connector.
Did DTC P0107 set?
Yes »Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
DURE)
DURE)
9 - 2294 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7l DIESEL DR
P2262 ..TURBOCHARGER BOOST PRESSURE NOT DETECTED - MECHANICAL
Theory of Operation
The variable geometry turbocharger (VGT) is electronically activated by the Electronic turbo actuator. The Electronic
turbo actuator is a smart device and receives information via the J1939 datalink from the ECM. The Electronic turbo
actuator performs its own diagnostics and reports failures back to the ECM using the J1939 datalink. The ECM then
decodes the error message and converts it to a fault code. The ECM lights the MIL lamp immediately after the
diagnostic runs and fails. The ECM will turn off the MIL lamp immediately after this diagnostic runs and passes in
4 consecutive drive cycles.
• When Monitored:
Ignition on.
• Set Condition:
The VGT sliding nozzle is slow to move or is unable to move to the fully closed position at initial key-on. The
physical limits of the VGT sliding nozzle have been found to be greater than or less than 1000/0.
Possible Causes

TURBOCHARGER
Diagnostic Test
1. INTERMITTENT CONNECTION
Turn ignition off.
Disconnect the Electronic Turbo actuator harness connector.
Are any pins or damage done to the connector?
Yes »Repair/replace harness.
DURE)
No »Go To 2
2. ELECTRONIC TURBO ACTUATOR
NOTE: It is important to drain engine coolant before Electronic Turbo Actuator removal.
Remove the Electronic Turbo Actuator from the turbocharger.
lnspect Electronic Turbo Actuator for a broken drive gear on the Electronic Turbo Actuator.
Is the VGT actuator drive gear broken/damaged?
Yes »Replace the Electronic Turbo Actuator
DURE)
No »Go To 3
3. TURBOCHARGER
Inspect the sector gear on the turbocharger for damage or broken teeth.
Move the sector gear lever on the turbocharger bearing housing up and down from stop to stop.
Check for smooth movement between the stops.
NOTE: The actuator lever must move evenly and crisply as it is moved.
Does the nozzle slide evenly from stop to stop and are the gear teeth undamaged?
Yes »Replace the Electronic Turbo Actuator
DURE)
No »Replace the turbocharger assembly.
DURE).
P2266-WATER IN FUEL SENSOR CIRCLIIT LOW
• • S045
I
K914
18
BRlWT
11 ....
[I) GA.
WATER
IN FUEL
21
G123 K914
18 18
VTIlG 8RlWT
341c1 471c1
r- - - WATER - - - - - - - SENS'CiR - ---, MODULE·
I IN FUEl GROUND I EIIGINE
I SENSOR I CONTROL
SIGNAL
1 I
1 _______________ J
n
"
2
~1 10
20
JO
40
SO
so
Irni~~~
0
~oooo
00000
00000
00000
00000
00000
00000
00000
00000
00000
I
l'
2<
1~
J'
5<
SENSOR· rr-----d ~
WATER -rr " --.- " -0- ----
III FUEL
(1.1L,
MODULE·
ENGIIiE
CDNTROL C.
,1·1L1
Itunu

DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS -' 6.7L DIESEL 9 - 2297
Theory of Operation
The water in fuel sensor is attached to the fuel filter. The Powertrain Control Module (ECM) provides a 5-volt ref-
erence signal to the water in fuel sensor. When the water collected in the fuel filter covers the sensor probes. the
water in fuel sensor then pulls the 5-volt reference voltage to ground indicating high water accLimulation in the fuel
filter. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. The ECM turns off the MIL
lamp af1er the diagnostic runs and passes in 4 consecutive drive cyples .
• When Monitored: . .
Ignition on .
• Set Condition:
Low voltage detected at the WrF signal circuit at the ECM.
Possible Causes
WATER IN FUEL SENSOR

(G123) WIF SIGNAL CIRCUIT SHORTED TO GROUND
(G123) WIF SIGNAL CIRCUIT SHORTED TO THE (K914) SENSOR GROUND CIRCUIT
ECM
Diagnostic Test
1. WATER IN FUEL SENSOR

Disconnect the Water in Fuel Sensor harness connector.
Measure the voltage between the (G123) Water in Fuel Signal circuit and the (K914) Sensor ground circuit of the
WIF Sensor harness connector.
Ves »Replace the Water in Fuel Sensor.
DURE)
No »Go To 2
2. WIF SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT

Measure the resistance between the (G123) WIF Signal circuit and the (K914) Sensor ground circuit of the sensor
harness connector.
Yes »Repair the short between the (G123) WIF Signal circuit and the (K914) Sensor ground circuit.
DURE)
No »Go To 3
3. (G123) WIF SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (G123) WIF Signal circuit at the sensor harness connector.
Yes »Repair the short to ground in the (G123) WIF Signal circuit.
DURE)
No »Go To 4
4. ECM
Measure the resistance between the (G123) WIF Signal circuit and the (K914) Sensor ground circuit of the sensor
connector.
DURE)
No »Test Complete.
P2267-WATER IN FUEL SENSOR CIRCUIT HIGH
. - - - - - - - - - • 10..
I
Kg14
18
BRNIT
11
m
2T
llllORO
WATER
II FUEL
G123
18 IS
VTA,G BRtWT
,,1 Ci
,.. - -WATER - - - - - - -
"l.i
S"ENSOR - ..., MODULE·
I IN fUEl GROUND I EIGIIE
I SENSOR I COITROL
SIGNAL
I I
1_______________ 1
,--, ,...,
10
20
oooo~ 00000 r
11
00000 00000
30 00000 00000 21
40
50
00000
00000
0 00000
00000
11
41
£0 00000 00000 51
IEIIOR· ~ ...I
.ATER '-J '-'
II FUEL
(l.lL,
MODULE·
EIIIIE
COITROL Ct
CI.lL,

Theory of Operation
The water-in-fuel sensor is attached to the bottom of the fuel filter. The ECM provides a 5-volt reference signal to
the water-in-fuel sensor. When the water collected in the fuel filter covers the sensor probes, the water in fuel sen-
sor then pulls the 5-volt reference voltage to ground indicating high water accumulation in the fuel filter. The ECM
illuminates the MIL lamp immediately after the diagnostic runs and fails. During this time water in fuel may cause
white smoke, loss of power or hard starting. The MIL lamp will turn once the water is drained from the filter.
• When Monitored:
Ignition on .
• Set Condition:
High voltage detected at the WIF signal circuit at the ECM.
Possible Causes
(G123) WIF SIGNAL CIRCUIT SHORTED TO VOLTAGE

(G123) WIF SIGNAL CIRCUIT OPEN
WATER IN FUEL SENSOR
ECM
Diagnostic Test
1 . ACTIVE DTC
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION Diagnostic procedure. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
2. WATER IN FUEL SENSOR

Disconnect the Water in Fuel Sensor.
Using a scan tool monitor the Water in Fuel Sensor voltage.
Connect a jumper wire between the (G123) WIF Signal circuit and the (K914) Sensor ground circuit.
Did the voltage display 5.0 volts with the connector disconnected and drop close to 0 volts when the
jumper wire was installed?
Yes »Replace the Water in Fuel Sensor.
DURE)
No »Go To 3
3. (G123) WATER IN FUEL SENSOR SHORTED TO VOLTAGE

Measure the voltage on the (G123) WIF Signal circuit at the Water in Fuel Sensor harness connector.
Is there any voltage present?
Yes »Repair the short to voltage on the (G123) WIF Signal circuit.
DURE)
No »Go To 4
4. (G123) WIF SIGNAL CIRCUIT OPEN

Measure the resistance on the (G123) WIF Signal circuit from the Water in Fuel Sensor harness connector to the
Is the resistance greater than 5.0 ohms?
Yes »Repair the excessive resistance on the (G123) WIF Signal circuit.
DURE)
No »Go To 5

Measure the resistance on the (K914) Sensor ground circuit from the Water in Fuel Sensor harness connector to the
Is the resistance greater than 5.0 ohms?
Yes »Repair the excessive resistance on the (K914) Sensor ground circuit.
Perform POWERTRAIN VERIFICATION TEST - B.7L. (Refer to 9 - ENGINE· STANDARD PROCE-
DURE)
No »Go To 6
6. ECM
While monitoring with scan tool, use a jumper wire and connect the (G123) WIF Signal circuit to the (K914) Sensor
ground circuit at the sensor connector.
Perform POWERTRAIN VERIFICATION TEST - B.lL. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
9 - 2302 ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
P2269-WATER IN FUEL CONDITION
• - - - - - - - - • SI4I
I
K914
18
BRlWT
11 SElSOR·
WATER
II FUEL
21
G12l K914
18 18
vaG ~mT
r - -
3.101
WATER - - - - - - -
,JC1
SENSOR - -, MODULE·
I I~HUEL GROUND I ENGINE
I SENSOR I CONTROL
SIGNAL
I I
I _______________ J
10 1
20 11
30 k'
40 31
50 41
SO 51
SEUOR·
W'TER
II FUEL
".U)
MODULE·
ENGINE
CONTROL C1
(1.7L1
IIII"U

Theory of Operation
The water in fuel sensor is attached to the fuel filter. The Powertrain Control Module (ECM) provides a 5-volt ref-
erence signal to the water in fuel sensor. When the water collected in the fuel filter covers the sensor probes, the
water in fuel sensor then pulls the 5-volt reference voltage to ground indicating high water accumulation in the fuel
filter. The ECM illuminates the MIL lamp immediately after the diagnostic runs and fails. The ECM turns off the MIL
• When Monitored:
Ignition on .
• Set Condition:
Low voltage detected at the WIF signal circuit at the ECM.
Possible Causes
IWATER IN FUEL
ECM
Diagnostic Test

Do you have any additional water in fuel DTCs?
Ves »Repair other Water in fuel sensor DTC's first.
DURE)
No »Go To 2
2. WATER IN FUEL
Using the service publications as a guide, drain the water in fuel separator.
Did the DTC become inactive after draining the water in fuel separator?
Yes »Clear DTC, repair complete.
DURE)
No »Go To 3
3. ECM
Disconnect the WI F sensor harness connector.
Using the scan tool, monitor for DTC's while connecting a jumper wire between the (G123) signal circuit of the water
in fuel sensor and battery voltage.
Did the water in fuel light go out?
Yes »Refer to the INTERMITIENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
PROCEDURE)
P2299-BRAKE PEDAL POSITION I ACCELERATOR PEDAL POSITION
INCOMPATIBLE
Theory of Operation
This diagnostic tests for a stuck throttle or throttle position sensor. The algorithm only runs when detected throttle
position is above 8% and maintains a position within 20/0 for more than two seconds (there is a longer time duration
if under 100% throttle). If the brake pedal is pushed during that time, the diagnostic will fai1. This fault will not occur
if the brake pedal is applied first and then the throttle pedal is engaged. If this diagnostic runs and fails the ECM will
light a momentary ETC lamp. The ETC lamp will only be active when the condition exists. While the error is active
the customer will likely experience a throttle derate. The throttle position must be below 8% with both brake
switches off in order for this error to reset.
• When Monitored:
Engine on, throttle position maintained above 8% with less than a 2% deviation in two seconds .
• Set Condition:
Brake pedal is depressed during the monitored condi~ions,
Possible Causes
TWO FOOTED DRIVING (AUTOMATIC) OR THREE FOOTED DRIVING (MANUAL)

ACCELERATOR PEDAL POSITION SENSOR
BRAKE SWITCH STUCK
ECM
Diagnostic Test
1 . OTHER DTCS
Are there DTCs for the pedal position sensors or brake switch present?
Ves »Repair other DTC's first
No »Go To 2
2. PEDAL POSITION SENSOR OR BRAKE SWITCH

Start engine. Monitor reported value on the tool. Monitor brake position on the scan tool.
Use the scan tool to monitor accelerator position.
Move throttle through a range of positions.
Also depress the brake pedal.
Monitor the brake position on the scan tool.
Does the reported accelerator position and brake position match actual position?
Ves »Go To 3
No »Troubleshoot pedal pOSition sensor or brake switch.
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l DIESEL g .. 2305
3. ECM
Interview owner and ask if the ETC lamp turned on while they were driving "two footed" (using the right foot for
throttle and left for brake)
Is the owner a two footed driver?
Yes »Explain to the driver that the diagnostic is trying to detect a stuck throttle or throttle position sensor. The
lamp they experienced is momentary and will go away when the two footed driver condition is gone.
Repair complete
DURE)
9 • 2306 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL DR
P242B-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR

3 .. DIESEL
e-----e - - - - - - - e - - - - - - - e 8101

~~~
I I I I I I
KQOO K90Q KQOfl mo K90fl KQOO K9DO
16 20 18 20 18 20 18
DBI1)G DBiDG DBI1)G DBI1)G DBIDG 0811)G DBI1)G
I I I I
'----v----" '----v----"
21
m IENSOR.
EIHAUST
TEIPERATURE 1/t
m IENSOR.
EIHAUST
TEIIPERATURE 1/2
SENSOR·
EXHAUST
TEMPERATURE ,,3
11
~
I I
~~
I I I I
KI8S K1SS K372 K372 KISS K186
20 18 20 18 20 18
BRil.8 BRA.B BRIDG BRID G BRIDB BRIDB
I I I I
'----v----" '----v----"
~ ~ etl.
1-- -I
6 11
K900 K185 K372 KISS

18 t8 18 18
DBIDG BRILB BRIDG BRIOR
2Q 1 C2 20 1C2 10 1 C2 91 C2
r SENSOR - - EXHAuST - - - - ExHAUST- - - - -EXHAUST - lIiODULE.
I GROUNQ TEMPERATURE TEMPERATURE 1/3 TEMPERATURE 1/2 I EIIGIIE
SENSOR I SENSOR SENSOR CONTROL
I SIGNAL SIGNAl SIGNAL I
L--- __________________ J
10 1
20 II
lQ 21
40 31
50 41
gO 51
1 2
10DULE·
ENGIIE
SENSOR· SfNSOA· SENSOR· CONTROL C2
EXHAUST EIHAUST EIHAUST (l.lLl
TEMPERATURE 1/1 TEMPERATURE t/2 TEMPERATURE 1/3
,S.lL) ('.lL) (6.fLl
'''''''ll
For a complete wiring diagram Refer to, Section 8W.
Theory of Operation
if it detects that the aftertreatment diesel particulate filter outlet temperature sensor reading is not increasing with
nostic runs and fails. Regeneration of the aftertreatment diesel particulate filter will be disabled. The ECM will turn
off the MIL lamp immediately after the diagnostic runs and passes .
• When Monitored:
Engine Running
• Set Condition:
The ECM detects that the Exhaust Temperature Sensor reading is not increasing with engine operating tem-
perature after engine startup.
Possible Causes

Diagnostic Test
1. OTHER DTCS
Do you have any other DTC for the Exhaust Gas Temperature sensors?
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 .. ENGINE .. STANDARD PROCE-
DURE)
No »Go To 2

Remove the Exhaust Temperature Sensor 1/3 and reconnect the harness connector to the sensor. Monitor the scan
tool, while heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
Does the reading from the sensor increase at least -15 0 C (50 F) on the scan tool?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 .. ENGINE -
No »Replace the Exhaust Temperature Sensor 1/3
Perform POWERTRAIN VERIFICATION TEST .. 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
9 - 2308 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L D I E S E L - - - - - - - - - - DR
P242C-EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW· BANK 1 SENSOR 3
e-----e-------e-------e 1101
~~~
I I I I I I
K900 mo K900 KOOO K900 K900 K900
18 20 18 20 18 20 18
DBJ1)G DBIDG DBJ1)G DBn:lG DBIDG DBIUG DBIOS
m IENSOA.
EIHAUST
TEIPERATU RE 1/1
m IEIiSOR.
ElHAUST
TEIIPERATURE 1/2
1
m
2
SENSOR·
EXHAUST
1
TEIPERITUAE 1/3

~
I I
~~
1 I I I
K185 K185 K372 K372 KI86 K186
20 18 20 18 20 18
BRJlB BRJtB BRIDG BRIDG BRIDB BRIDB
I I
'--v--"
A A
1----1
6 11 OtOl
K90D KISS K372 KISS

18 1B 18 18
DBIDG 8RILB BRIDG BRIOR
291c2 20102 lolc2 y1c2

r S"ENSOR - - EXHAuST - - - - ExHMT- - - - -EXHAUST - 1IODULE.
I GROUND TEMPERATURE TEMPERATURE 113 TEMPERATURE 112 IEIGIIE
SENSOR 1 SENSOR SENSOR CONTROL
L_____________________ J
10
20 'I
30 21
40 31
50 41
60 51
IDDULE·
EIGIIE
IEIIOR· SElSOR· 8EII8DR· COITROL C2
EIHAUST EIHAUST EIHAUST (S.7L)
TEMPERATURE 1/1 TEMPEAATURE 1/2 TEIPERATURE 1/3
(s,n, 1I,7L) ,1.lL)
.....,u.
Theory of Operation
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will set the fault code if it detects
that the Exhaust Temperature Sensor 1/1 Signal voltage is less than a calibrated voltage for longer than a calibrated
period. The ECM illuminates the MIL lamp immediately when the diagnostic runs and fails. A default value for the
Exhaust Temperature Sensor 1/1 reading will be used and active regeneration of the diesel particulate filter will be
disabled. The ECM will turn off the MIL lamp immediately after the diagnostic runs and passes .
• When Monitored:
Ignition ON
• Set Condition:
Possible Causes
FAILED SENSOR
(K372) EXHAUST GAS TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR GROUND
CIRCUIT
(K372) EXHAUST GAS TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test
Yes »Go To 2
PROCEDURE)
9· 2310 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - DR
2. (K372) EXHAUST GAS TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO THE (K900) SENSOR
GROUND CIRCUIT
Measure the resistance between the (K372) Exhaust Gas Temperature 1/3 Signal circuit and the (K900) Sensor
ground circuit at the ECM harness connector.
Yes »Go To 5
No »Go To 3
3. (K372) EXHAUST GAS TEMPERATURE 113 SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the Exhaust Gas Temperature Sensor 1/3.
Measure the resistance between ground and the (K372) Exhaust Gas Temperature 1/3 Signal circuit.
Is the resistance below 100 Ohms?
Yes »Repair the short to ground in the (K372) Exhaust Gas Temperature 1/3 Signal circuit.
DURE)
No »Go To 4

Measure the resistance of the (K900) Sensor ground circuit between the sensor harness connector and the ECM
harness connector.
Yes »Go To
No »Repair the open in the (K900) Sensor ground circuit.
DURE)
5. (K372) EXHAUST GAS TEMPERATURE 113 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
Measure resistance between the (K372) Exhaust Gas Temperature 1/3 Signal circuit and other circuits at the ECM
harness connector.
Ves »Go to 6
Perform POWERTRA1N VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
6. ECM
While monitoring the Exhaust Gas Temperature Sensor 1/3 with scan tool, use a jumper wire and connect the
(K372) Exhaust Gas Temperature 1/3 Signal circuit and the (K900) Sensor ground circuit at the sensor connector.
Did the DTC for voltage high go inactive and the DTC for voltage low become active?
AND TESTING)
DURE)
9 - 2312 ENGINE .' ELECTRICAL DIAGNDS'nCS .. 6.7L DIESEL - - - - - - - - - DR
P242D-EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH - BANK 1 SENSOR
3
e -----e -------e-------e 510.

~'~~
I I I I I I
K900 K900 K900 Kg 00 K900 K900 K900
18 23 18 20 18 20 18
DBIOS DBIDG OBIDG 08IDG D8IDG D8iDG DBIDG
I I
'-y---J
m 8EII80Ra
EIHAUST
TEl PERATURE 1/1
m IEIISOR.
EIHAUST
TEIPERATURE 1/2
1
m
2
SElSOR.
EIHAUST 1
TEIPERATURE tJ3

~~~
I I I I I I
K185 K185 Kl12 K312 K1S6 KISS
20 18 20 1B 20 18
BRtS BRll.B BRIDG BRIDG BRIDS BRIDB
I I I I
'-y---J '-y---J
J.. 1
4
1---1-----1 5 6 CtGI
K900 KISS K1e6

18 18 lB 18
DBIDG BRitS BRIDG BR/OR
29lc2 2olc2 101C! glC2

r SENSOR - - EXHAuST - - - - ExHAUsT - - - -EXHAUST - lIODUlE.
I GROUND TEMPERATURE TEMPERATURE 113 TEMPERATURE 1/2 I :::~NREOL
I I
L____________ SIGNAL SIGNAL
_______ J SIGNAL
I
II
?I
11
~I
51
MODULE·
EIGINE
SEIIOR· SElSOR· IEISOR· CONTROL C2
EIHAUST EXHAUST EIH1UST (S.UI
TEMPERATURE 1/1 TEIPERATURE 1/2 TEIPERATURE 1/3
(a,fLl (I.nl (I.U,
Theory of Operation
The Exhaust Temperature Sensors are used by the Electronic Control Module (ECM) to monitor the engine exhaust
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will set the fault if it detects that
the diesel oxidation catalyst inlet exhaust gas temperature sensor signal voltage is greater than a calibrated voltage
for more than a calibrated time. The ECM illuminates the MIL lamp immediately when the diagnostic runs and fails.
A default value for the Exhaust Temperature Sensor 1/1 reading will be used and active regeneration of the diesel
particulate filter will be disabled. The ECM will turn off the MIL lamp immediately after the diagnostic runs and
passes .
• When Monitored:
Ignition ON
• Set Condition:
The ECM will set the fault if it detects that the Exhaust Temperature Sensor Signal voltage is greater than a
calibrated voltage for more than a calibrated time.
Possible Causes
FAILED SENSOR
(K372) EXHAUST TEMPERATURE 1/3 SIGNAL CIRCUIT OPEN
(K372) EXHAUST TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO V<?LTAGE
(K372) EXHAUST TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS
ECM
Diagnostic Test
Is the resistance between 82k and aOOk ohms at ambient temperature?
Yes »Go To 2
PROCEDURE)
9·2314 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
2. EXHAUST TEMPERATURE SENSOR 1/3 CIRCUIT CHECK

Measure the resistance between the (K372) Exhaust Temperature 1/3 Signal circuit and (K900) Sensor ground cir-
cuit at the ECM harness connector.
Yes »Go To 5
No »Go To 3
3. (K372) EXHAUST TEMPERATURE 1/3 SIGNAL CIRCUIT OPEN

Disconnect the Exhaust Temperature Sensor 1/3
Measure the resistance of the (K372) Exhaust Temperature 1/3 Signal circuit between the sensor harness connector
and the ECM harness connector.
Yes »Go To 4
No »Repair the open in the (K372) Exhaust Temperature 1/3 Signal circuit.
DURE)

Measure the resistance of the (K900) Sensor ground circuit between the Exhaust Temperature 1/3 Sensor harness
connector and the ECM harness connector.
Yes »Go To
No »Repair the open in the (K900) Sensor ground circuit.
DURE)
5. (K372) EXHAUST TEMPERATURE 1/3 SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure resistance between the (K372) Exhaust Temperature 1/3 Signal circuit and all other circuits at the ECM
harness connector.
Yes »Go to 6
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 • ENGINE· STANDARD PROCE-
DURE)
6. ECM
While monitoring the Exhaust Temperature Sensor 1/3 with scan tool, use a jumper wire and connect the (K372)
Exhaust Temperature 1/3 Signal circuit to the (K900) Sensor ground at the sensor connector. .
Did the DTC for voltage high go Inactive and the DTC for voltage low become active?
Yes »Refer to the INTERMITTENT CONDITION A DIESEL Symptom. (Refer to 9 - ENGINE· DIAGNOSIS
AND TESTING)
DURE)
P242F-DIESEL PARTICULATE FILTER RESTRICTION - ASH ACCUMULATION
Theory of Operation
The engine aftertreatment system monitors the soot load in the aftertreatment diesel particulate filter. Under normal
operating conditions, the aftertreatment diesel particulate filter is self-cleaning, where soot is converted to ash.
Under light load operating conditions, the driver may be notified via the vehicle's EVIC message center that it may
be necessary to modify the vehicles driving routine in order to allow the aftertreatment diesel particulate filter system
to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the
engine and set a DTC and MIL lamp, requiring service. The soot load in the aftertreatment diesel particulate filter is
estimated using the Exhaust Pressure sensor and the calculated soot output of the engine. This fault code can be
triggered if the application is not operating at a duty cycle high enough to actively regenerate the aftertreatment
diesel particulate filter. This fault code indicates that the exhaust temperatures exiting the turbocharger are not high
enough to actively regenerate the soot that is trapped in the aftertreatment diesel particulate filter. It may be nec-
essary to increase the duty cycle of the application in order to prevent plugging of the aftertreatment diesel partic-
ulate filter. This fault will be triggered if the electronic control module (ECM) detects that the soot load of the
aftertreatment diesel particulate filter has surpassed the most severe level threshold. The aftertreatment diesel par-
ticulate filter needs to be replaced, do not regenerate this filter. The ECM will illuminate the MIL lamp immediately
when the diagnostic runs and fails. The driver will be notified via the vehicle's EVIC Message Center (CATALYST
FULL: SERVICE REaD). The ECM will also initiate a derate of engine power output in an effort to protect the vehi-
cle aftertreatment system. The ECM will turn off the MIL lamp immediately after the soot load in the aftertreatment
diesel particulate filter has dropped below the severe level threshold (this should be accomplished through replacing
the aftertreatment diesel particulate filter) and the DTC has been cleared .
• When Monitored:
• Set Condition:
The ECM detects that the soot load of the aftertreatment diesel particulate filter has surpassed the most
severe level threshold. The aftertreatment diesel particulate filter requires replacement.
Possible Causes
PROGRESSIVE DAMAGE TO THE AFTERTREATMENT SYSTEM FROM AN ENGINE FAILURE, INCLUDING

BUT NOT LIMITED TO EXCESSIVE FUEL, OIL OR COOLANT IN THE AFTERTREATMENT SYSTEM MAY
CONTRIBUTE TO A HIGH PRESSURE RELATED FAULT.
AFTERTREATMENT DIESEL PARTICULATE FILTER COULD BE PLUGGED WITH ACCUMULATED ASH.
OPERATING IN LIGHT LOAD CONDITIONS THAT PREVENT EXHAUST TEMPERATURES FROM BEING HIGH
ENOUGH TO ACTIVELY REGENERATE THE AFTERTREATMENT PARTICULATE FILTER.
TEMPERATURE SENSOR(S) FAILED IN-RANGE LOW
Diag nostic Test
1. OTHER DTCS
Are any other Misfire or Exhaust Gas Temperature/Pressure Sensor DTCs Active?
No »Go To 2
Potential causes include a stuck open exhaust gas recirculation valve or a variable geometry turbocharger actuator
that is not moving correctly.
Yes »Replace the failed base engine component causing the high black smoke levels. Replace the aftertreat-
ment diesel particulate filter.
DURE)
No »Go To 3
3. CYLINDER MISFIRE
Start the engine.
DURE)
No »Go To 4

With the scan tool check the temperature values of the Exhaust Gas Temperature Sensors.
Are the Exhaust temperature sensors reading within 6 degrees C of each other?
Yes »Go To 5
DURE)
ENGINE
DURE)
No »Go To 6

Yes »Replace the aftertreatment diesel particulate filter.
Reset the Regenerative filter timers. Located under miscellaneous functions.
DURE)
AND TESTING)
P244A-DIESEL PARTICULLATE FILTER DIFFERENTIAL PRESSURE TOO LOW
Theory of Operation
The engine aftertreatment system monitors the soot load in the aftertreatment diesel particulate filter. The ECM
monitors for the presence of the aftertreatment particulate filter. This diagnostic checks to make sure that the after-
treatment particulate trap is present and functioning correctly. The ECM monitors the presence of the aftertreatment
diesel particulate filter via interpretation of data received from the Exhaust Pressure Sensors, which monitors pres-
sure differential across the aftertreatment diesel particulate filter. The ECM will set the fault if It detects that the
aftertreatment diesel particulate filter is not present in the aftertreatmenVexhaust system. The ECM will illuminate
the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp immediately after
the diagnostic runs and passes.
This diagnostic runs when the engine is running, but not during active regeneration of the aftertreatment par-
ticulate filter.
• Set Condition:
The ECM will set the fault if it detects that the aftertreatment diesel particulate filter is not present in the after-
treatment/exhaust system.
Possible Causes
AFTERTREATMENT DIESEL PARTICULATE FILTER HAS BEEN REMOVED FROM THE VEHICLE
AFTERTREATMENT DIESEL PARTICULATE FILTER IS CRACKED OR BROKEN
AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL TUBES ARE BROKEN, LOOSE OF HAVE
BEEN TAMPERED WITH
AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL TUBES ARE REVERSED
EXHAUST SYSTEM LEAK
AFTERTREATMENT EXHAUST PRESSURE SENSOR FAILED IN-RANGE
Diagnostic Test
1. OTHER DTCS
Are any Misfire or Exhaust Temperature/Pressure Sensor DTCs Active?
Yes »Repair all other DTCs before continuing.
No »Go To 2
2. EXHAUST PRESSURE SENSOR TUBES

Inspect the Exhaust Pressure Sensor tubes for the following:
Leaks or cracks in the differential pressure tubes.
Loose fittings differential pressure tubes.
Missing or broken differential pressure sensor tubes.
Plugged or Reversed differential pressure sensor tubes.
Exhaust Pressure Sensor tubes are in good condition and installed properly?
Yes »Go To 3
No »Repair of replace the Exhaust Pressure Sensor tubes.
Go To 4
9 .. 2320 ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR

Inspect the aftertreatment diesel particulate filter. Inspect for evidence of tampering or removal of the diesel partic-
ulate.
Tampering or removal of the aftertreatment system has been detected?
Yes »Instan the correct aftertreatment system for the vehicle.
Go To 4
No »Go To 4
4. P244A INACTIVE
Check for active fault codes.
Is fault code P244A inactive?
Yes »Repair complete. Erase DTC's.
DURE)
No »Go To 1
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS· B.7l DIESEL 9 • 2321
P244D-EXHAUST TEMPERATURE TOO HIGH FOR PARTICULATE FILTER
REGENERATION-BANK 1
e-----e-------e------e It••

~~~
I I I I I I
K9DO K900 K9DO K900 K900 K900 GOO
18 20 18 20 18 20 18
OBKlG OBKlG DB41G OB41G DS/OG DB41G DBIDG
I I I I
~ ~
.1
m ,1 lll ..R•
IIN'UIT
TIIPlRI1URI111
m
..
lll . .RO
IINAUIT
nl'IUTURI 1/1
1
m
2
lEI lOR·
IINAUIT 1
1EI'IRATURE 1/1
EXCEPT ! Y EXCEPT EXCEPT

~~~
I I I I I I
K185 K185 1(372 1(372 K18S K186
20 18 28 18 20 18
BRA.B BRlB BRKlG BRKlG BRIDB 8RK18
I I I I I I
~~~
• l l
r---i-----i--- -r0tll
l 5 6 11
KI80 1(185 K312 K186

18 f8 18 18
DBKlG BRA.B BR41G BRIOR
29 1 01 20 101 10 1 Ct 9 101
r SENsOR - - EXHAUST - - - - exHAUsT- - - - -EXHAUST - 110Duu.
I GROUND TEMPERATURE
SENSOR 1
TEMPERATURE 113
SENSOR
TEMPERATURE In
SENSOR COITRDL
,1••.1.
1
L_____________________ J SIGNAL SIGNAL SIGNAl'
10 00000 00000 I
20 00000 00000 11
30
ggggg 0 00000 ~I
!I
~~ 00000
00000
00000 41
14 00000 00000 51
I 2
IODULE·
EI ••I.
I.IIOR· I •• SOR· IEI.OR· OOITROLOI
EINIUIT IIHIUIT IIHIUIT ,1.lLI
TE.PlRlTUR.t/1 nl'lUIURI t/l TI.'IRlTUR.I/3
II.nl CI,lL, II,U,
For a complete wiring diagram Refer to Section 8W ..
Theory of Operation
ECM monitors the voltage on the signal pin and converts this to a temperature value. When the exhaust gas tem-
Therefore, the ECM senses a low signal voltage, or a high temperature. The ECM will illuminate the MIL lamp
immediately when the diagnostic runs and fails. Active regeneration of the aftertreatment particulate filter will be
disabled. This DTC fault is latched when set and can only be cleared by a scan tool.
• When Monitored:
• Set Condition:
The ECM detects that the Exhaust Temperature is greater than a calibrated temperature for a calibrated period
of time.
Possible Causes
EXCESSIVE FUEL ENTERING THE AFTERTREATMENT/EXHAUST SYSTEM

EXHAUST TEMPERATURE SENSOR 1/3 FAILED IN-RANGE
EXCESSIVE ENGINE OIL BEING INTRODUCED INTO THE AFTERTREATMENT SYSTEM FROM THE ENGINE
Diagnostic Test
1. FUEL INJECTOR
Are any fuel injector DTCs Active?
Yes »Repair any fuel injector DTCs before continuing.
DURE)
No »Go To 2
2. CYLINDER MISFIRE
Start the engine.
DURE)
No »Go To 3
3. EXHAUST TEMPERATURE SENSOR 113

Engine off for 5 minutes.
Check the temperature values for the Exhaust Temperature Sensor 1/1 and Exhaust Temperature Sensor 113.
Are the values of the Exhaust Temperature Sensor 1/1 and Exhaust Temperature Sensor 1/3 reading
within 6° C (42.8° F) of each other?
Yes »Go To 4
No »Replace the Exhaust Temperature Sensor 1/3. Inspect the aftertreatment system for possible damage.
DURE)
ENGINE
DURE)
No »Go To 5

Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE·
DURE)
AND TESTING)
9 - 2324 ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - - DR
P2453 .. DIESEL PARTICULATE FILTER PRESSURE SENSOR A CIRCUIT
PERFORMANCE
I - - - - - - - -, IIODULE·
EIGIlIE
I APPS NO.2 5VOLT I CONTROL
L _ RETUR~ _ ~UPPLY _ ~
221 C2 26 C2
K40fl KS54
1
18 18
BRNT VTIBR
I I
- S030 -S031
I I
mo K854
18 18
BRNT VTJBR
3L- ~CtO.
Y
K400 K854
18
BRNT VTJBR
31
B
SENSOR.
EXH1UST
PRESSURE t/2
1 2'(
K182
18
t
BRNH
2 Ci0e
K1B2
18
BRJWT
r - 341c2 -
E~UST lIiODULE.
ENGINE
I I
PRESSURE 112 CONTROL
SENSOR
I I
SIGNAL
L ____ J
10 1
20 11
~o 11
40 JI
50 ~1
60 01
SENSOR·
ElH1UST IIODULE·
PRESSURE 1/2 EIGINE
(6.7L1 CONTROL C2
(s.7L)
.t ......
Theory of Operation
The ECM provides a 5-volt supply to the aftertreatment diesel particulate filter differential pressure sensor on the
sensor supply circuit. The ECM also supplies a ground on the sensor return circuit. The aftertreatment differential
pressure sensor provides a signal to the ECM. This sensor signal voltage changes based on the differential pres-
sure across the aftertreatment diesel particulate filter. The ECM detects that the aftertreatment differential pressure
reading is higher than a calibrated threshold when the ignition switch is on and the engine is not running. The ECM
also detects that the aftertreatment differential pressure reading does not increase while the vehicle is driving/mov-
ing. The ECM illuminates the MIL lamp immediately when the diagnostic runs and fails. A default value is used for
the aftertreatment differential pressur~ reading when the fault is active. The ECM will turn off the MIL lamp imme-
diately after the diagnostic runs and passes in four consecutive drive cycles or the DTC has been cleared by a scan
tool
• When Monitored:
When the key is turned on .
• Set Condition:
The circuit voltage to the ECM is greater than a calibrated threshold, or the delta pressure value is less than
a calibrated threshold in comparison to the initial key-on value for a calibrated distance traveled.
Possible Causes
AFTERTREATMENT DIESEL PARTICULATE FILTER IS CRACKED OR BROKEN

(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO GROUND
AFTERTREATMENT DIESEL PARTICULATE FILTER EXHAUST TUBES ARE BROKEN,
AFTERTREATMENT DIESEL PARTICULATE FILTER EXHAUST TUBES ARE REVERSED
EXHAUST SYSTEM LEAK
EXHAUST PRESSURE 1/2 SENSOR FAILED IN-RANGE
Diagnostic Test
1. OTHER DTCS
Is DTC P2454 or 2455 Active?
No »Go To 2
2. AFTERTREATMENT SYSTEM LEAKS

Inspect the aftertreatment system for leaks.
Are leaks found?
DURE)
No »Go To 3
3. AfTERTREATMENT EXHAUST PRESSURE SENSOR LINES

Inspect the Exhaust Pressure Sensor tubes.
Are leaks or blockages found or tubes swapped?
DURE)
No »Go To 4
4. (K182) EXHAUST PRESSURE SENSOR 112 SIGNAL CIRCUIT SHORTED TO GROUND

Disconnect the Exhaust Pressure Sensor 1/2 Sensor.
Measure the resistance between the (K182) Exhaust Pressure Sensor 1/2 Signal circuit and ground in the Sensor
harness connector.
Yes »Repair the short to ground in the (K182) Exhaust Pressure Sensor 1/2 Signal circuit.
DURE)
No »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 - ENGINE -
DR - - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL 9 .. 2327
P2454-DIESEL PARTICULATE FILTER PRESSURE SENSOR A CIRCUIT LOW
,- - - - - - - IIi0DULE.
EIIGIIiE
I APPS NO.2 5VOl T I CONTROL
L _R~R~ _ ~U~Y_..J
C2 26iC2
22i
K400 K854
18 18
BRNT VTJ8R
I I
e 803G eS03f
I I
K400 K854
18 18
BRNT VTIBR
3 L- - 9'1J
'I
Cto.
K400 K854
18 18
BRNT VTJ8R
31 IIIIOR.
E 21
1T
EIHAUST
PRESSURE 1/2
'--------' K182
18
BRAVT
2 t Cto.
K182
18
BRIWT
341C2
r- EXHAUST - lIiODULE.
ElGIIiE
I PRESSURE lf2 I CONTROL
SENSOR
I SIGNAL I
L ____ J
a
-<=t
10 t'~[OOO~ ~oooo"" I
20 00000 00000 11
1 30 00000 00000 21
3 40
SO
00000
00000
0 00000
00000
31
41
eo 00000 00000 51
.A
LJ
~
~
\ J I
IEIIOR.
EXHAUST IIODULE·
PRESIURE 1/2 EIIGINE
(s.n, COIITROL C2
IS.n,

9 - 2328 ENGINE - ELECTRICAL D~AGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
The ECM provides a 5-volt supply to the Exhaust Pressure Sensor on the sensor supply circuit. The ECM also
supplies a ground on the sensor return circuit. The Exhaust Pressure Sensor provide a signal to the ECM on the
Exhaust Pressure sensor signal circuit. This sensor signal voltage changes based on the differential pressure across
the aftertreatment diesel particulate filter. he ECM will set the fault if it detects that the Exhaust Pressure Signal
voltage is less than O.2-volt for more than 1 second. The ECM will illuminate the MIL lamp immediately when the
diagnostic runs and fails. A default value is used for the Exhaust Pressure reading. Active aftertreatment regener-
ation will be disabled. The ECM will turn off the MIL lamp immediately after the diagnostic runs and passes .
• When Monitored:
The diagnostic runs continuously when the Igniton is in the ON position .
• Set Condition:
The ECM detects that the aftertreatment diesel particulate filter differential pressure signal voltage is less than
0.2 volt for more than 1 second.
Possible Causes
(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT OPEN

(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO GROUND
(K854) 5-VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND
EXHAUST PRESSURE SENSOR 1/2
Diagnostic Test
1. EXHAUST PRESSURE SENSOR 112

Visually inspect the Exhaust Pressure Sensor 1/2 and harness.
Disconnect Exhaust Pressure Sensor 112 harness connector.
Measure the resistance of the Exhaust Pressure Sensor 1/2.
Yes »Go To 2
No »Replace the Exhaust Pressure Sensor 112.
DURE)
2. P2454 INACTIVE
Reconnect Exhaust Pressure Sensor 1/2 harness connector.
Is the P2454 inactive?
DURE) "
No »Go To 3
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS • 6.7l DIESEL 9 .. 2329
3. (K182) EXHAUST PRESSURE SENSOR 112 SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between the engine ground and the sensor (K182) Exhaust Pressure Sensor 1/2 Signal
Yes »Go To 4
No »Repair the short to ground in the (K182) Exhaust Pressure Sensor 1/2 Signal circuit.
DURE)
4. (K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO OTHER CIRCUIT IN
HARNESS
Measure the resistance between the (K182) Exhaust Pressure Sensor 1/2 Signal circuit and all other circuits in the
Yes »Go To 5
DURE)
5. ECM
Reconnect the ECM harness connector C2.
Disconnect (K182) Exhaust Pressure Sensor 1/2 harness connector.
Did the DTe for low voltage go inactive and the DTC for high voltage become active?
DURE)
9 • 2330 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
P2455-DIESEL PARTICULATE FILTER PRESSURE SENSOR A CIRCUIT HIGH
I - - - - - - - IIiODULE.
EIGIIE
I APPS NO.2 HOl T I COITROL
L _ R~R~ _ 2 UPPl Y_ -.J
221 C2 26 C2
K400
1
K954
18 1S
BRNT VTffiR
I I
• 1030 .SD31
I I
K400 K854
18 18
BRNT VTffiR
3 L- - J
\ 9\
CtDI
K400 KB54
18 18
BRNT VTffiR
31
IEIIOR.
B 21
1T
EIHAUST
PRESIUAE 1/2
'---------' K182
18
BRAVT
2 t CtDe
K1S2
18
BRIWT
341c2
r- EXHAU-;; - lIlODULE.
EIGIIE
I PRESSURE 1/2 I COITROL
SENSOR
I SIGNAL I
L ____ J
"
eJ
~
10
20
00000
00000
~
00000
1
II
30 00000 00000 21
1 3 40
sa
00000
00000
0 00000
00000
31
41
00 00000 00000 51
~
L.J L.J
.)
SE.'OR·
EIHAUST IIODULE·
PRESSURE t/2 EIGIIE
(I.U) COITROL C2
'I.U)

DR - - - - - - - - - ENGINE " ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 - 2331
Theory of Operation
The ECM provides a 5-volt supply to the Exhaust Pressure Sensor 1/2 on the sensor supply circuit. The ECM also
supplies a ground on the sensor return circuit. The Exhaust Pressure Sensor provides a signal to the ECM on the
Exhaust Pressure Sensor 1/2 Signal circuit. This sensor signal voltage changes based on the differential pressure
across the aftertreatment diesel particulate filter. The ECM detects that the Exhaust Pressure Sensor 1/2 signal
voltage is greater than a calibratable voltage for more than a calibratable duration. The ECM illuminates the MIL
lamp immediately when the diagnostic runs and fails. A default value is used for the aftertreatment diesel particulate
filter differential pressure reading. Active aftertreatment regeneration will be disabled. The ECM will turn off the MIL
lamp immediately after the diagnostic runs and passes .
• When Monitored:
Key ON
• Set Condition:
The ECM detects that the Exhaust Pressure Sensor 1/2 Signal voltage is greater than CaUbratable voltage for
more than a calibratable duration.
Possible Causes
(K400) APPS RETURN CIRCUIT OPEN

(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT OPEN
(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO THE (K854) 5-VOLT SUPPLY
CIRCUIT
(K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM
Diagnostic Test
1. EXHAUST PRESSURE SENSOR 1/2
Visually inspect the Exhaust Pressure Sensor 1/2 and harness.
Disconnect the Exhaust Pressure Sensor 1/2 harness connector.
Measure the resistance of the Exhaust Pressure Sensor 1/2.
Yes »Go To 2
No »Replace the Exhaust Pressure Sensor 1/2.
Perlorm POWERTRAIN VERIFICATION TEST - B.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
2. P2455 INACTIVE
Reconnect Exhaust Pressure Sensor 1/2 harness connector.
Ignition on, engine not running. .
Is the P2455 inactive?
Yes »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 - ENGINE -
No »Go To 3
3. (K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage on the (K182) Exhaust Pressure Sensor 1/2 Signal circuit at the sensor connector.
Is there any voltage present?
Ves »Repair the short to voltage on the (K182) Exhaust Pressure Sensor 1/2 Signal circuit.
DURE)
No »Go To 4
4. (K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT OPEN

Measure the resistance of the (K182) Exhaust Pressure Sensor 1/2 Signal circuit from the ECM harness connector
to the Exhaust Pressure Sensor 112 harness connector.
Ves »Repair the excessive resistance in the (K182) Exhaust Pressure Sensor 1/2 Signal circuit.
DURE)
No »Go To 5
5. (K400) APPS RETURN CIRCUIT OPEN

Measure the resistance of the (K400) APPS Return circuit from the C2 ECM harness connector to the Exhaust
Pressure Sensor 1/2 harness connector.
Yes »Repair the excessive resistance in the (K400) APPS Return circuit.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ,- ENGINE - STANDARD PROCE-
DURE)
No »Go To 6
6. (K182) EXHAUST PRESSURE SENSOR 1/2 SIGNAL CIRCUIT SHORTED TO THE (K854) 5-VOLT SUPPLY
CIRCUIT
Measure the resistance between the (K182) Exhaust Pressure Sensor 1/2 Signal circuit and the (K854) 5-volt Sup-
ply circuit at the Exhaust Pressure Sensor 1/2 harness connector.
Yes »Repair the short between the (K182) Exhaust Pressure Sensor 1/2 Signal circuit and the (K854) 5-volt
Supply circuit.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE· STANDARD PROCE·
DURE)
No »Go To 7
7. ECM
Leave the Exhaust Pressure Sensor 1/2 harness connector disconnected.
Using a jumper wire, connect the (K182) Exhaust Pressure Sensor 1/2 Signar circuit to the (K400) APPS Return
circuit in the sensor harness connector.
Did the DTC for (P2455) high voltage go inactive and the DTC for (P2454) low voltage become active?
DURE)
9 • 2334 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7l DIESEL - - - - - - - - - DR
P2457-EXHAUST GAS RECIRCULATION COOLING SYSTEM PERFORMANCE
Theory of Operation
This test will fail if the EGR Temperature is greater than a calibrated threshold for a calibrated period of time. This
monitor protects the system from a failed EGR Cooler.
• When Monitored:
Engine running.
'!' "\",
• Set Condition:
Exhaust gas recirculation temperature sensor is reading higher than a calibrated value for more than a caU-
bratable period of time.
Possible Causes
COOLANT TEMP DTCS

EGR VALVE DTCS
ENGINE OR FUEL MODIFICATIONS THAT EXCEED OEM SPECIFICATIONS
FUEL SYSTEM DTCS
EGR COOLER FOULING
Diagnostic Test
1. OTHER DTC'S
Are there any coolant temperature, fuel system or EGR valve DTC's?
Yes »Repair other DTC's first
DURE)
No »Go To 2
2 . EGR COOLER
Remove the exhaust gas inlet and outlet to the EGR cooler.
Check the cooler for excessive blockages on the inlet and outlet orifices.
Is there exhaust gas fouling of the EGR cooler?
Yes »Replace the EGR cooler.
DURE)
No »Go To 3
3. ENGINE OR FUEL MODIFICATIONS THAT EXCEED OEM SPECIFICATIONS

Inspect vehicle/engine for signs of Engine or Fuel modifications that exceed OEM specifications.
Are there signs the customer installed an modification kit that exceed OEM specifications?
Ves »Return vehicle to customer. Explain that modifying the engine hardware/software may cause the engine
to run outside of its normal operating limits.
P245A-EGR COOLER BYPASS CONTROL CIRCUIT IOPEN
- - - - - - - 1RELAT·
I I SIIRT
I POWER
I SMART I
POWER I
I RElAY I
l ____ ~EED _
4'(
F348
16
PKIOR
"
, 261t42 C130
F348
16
PKIOR
10 t
F348
C112
16
PKIOR
I
• 1040
I
F348
16
PKfOR
3J
SMART
VALYE·EGR
POWER EGR COOLER
RELAY EGR BYPASS 1"&81
BYPASS VALVE ACTUATOR ,1.JL/DHIDt)
FEED
K972
18
DBrrN
I
• S050
I
K671 K610 K972
18 18 18
BRIDB BRItB DBrrN
171 C1 91 C1 331 Ct
I EGR - - - EGR - - AcTUATOR 'IODUlE.
EIGIIE
I BYPASS I BYPASS GROUND COITROl
STATUS VALVE
I I SIGNAL , MIT
L __________ -.J " AIT
n n
~,
II ~
//
10 1
20
/00000"" rooooo' 11
00000 00000
30 00000 00000 21
40 00000 (.) 00000 JI
'i0 00000 00000 41
00000 00000
60
,-, '-'
~ ~
'-'
./
51
IIODULE· VAlVE·EGR RELAT·

EIGlIIE COOLER .IART
CONTROL C1 1"&88 POWER
(1·7L1 II.JL DH/Dt) (1.7l DIEIEL)
lin ...

Theory of Operation
The EGR Cooler bypass valve is used to bypass the EGR cooler when the engine is in an active regeneration
mode. This is to prevent EGR cooler fouling. There are two portions to this diagnostic. At key on the ECM drives the
control line low and then high and monitors the correct status response. Throughout engine operation looks for
status response voltage to be within 5-8 volts. The EGR Cooler Bypass vQ.lve will send a signal between 1.0 and
1.7 volts. When this occurs the ECM logs a fault. The second portion of this diagnostic monitors Exhaust Gas Recir-
culation temperature. If the EGR Cooler Bypass valve was in bypass mode incorrectly, the exhaust gas recirculation
temperatures would exceed a temperature limit; this condition will also trigger the fault. The ECM will light a MIL
lamp immediately after this diagnostic runs and fails. The ECM will turn off the MIL lamp after the diagnostic passes
• When Monitored:
Key on
• Set Condition: ,
Voltage detected at status line is between 1.0 volt and 1.7 volts for more thar(150 seconds consecutively.
Possible Causes
(F348) SMART POWER RELAY COIL FEED SHORTED TO BATTERY

(F348) SMART POWER RELAY COIL FEED OPEN CIRCUIT
EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR ERRORS
COOLANT SYSTEM
EGR COOLER
(K671) STATUS CIRCUIT SHORTED TO GROUND
(K671) STATUS CIRCUIT SHORTED TO 5-VOLT SOURCE
ACTUATOR FAILURE
Diagnostic Test
1. OTHER DTC'S
Are there faults present for the VGT, EGR Airflow Control Valve or Mass Airflow sensor?
Yes »Repair the open or short to ground in (F348) Smart Power Relay Coil Feed circuit.
DURE)
No »Go To 2
2. OTHER DTC'S
Are there any faults present for the Exhaust Gas Recirculation Temperature sensor or EGR Alflow Control
Valve Circuit errors?
Yes »Troubleshoot those DTC's first.
No »Go To 3
3. P245A ACTIVE
Is P245A Active?
Yes »Go To 4
Go To 7
Refer to the INTERMITIENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
4. COOLANT SYSTEM
Check coolant system for correct coolant concentration, correct fluid level and any signs of contamination.
Does coolant system check okay?
Yes »Go To 5
No »Repair coolant system issue.
DURE)
5. EGR COOLER
Remove EGR cooler.
Inspect for excessive cooler fouling/debris.
Inspect aftertreatment system damage.
Is EGR Cooler Fouled, or aftertreatment system damaged?
Yes »Clean EGR Cooler per service manual or replace if necessary or repair or replace aftertreatment sys-
tem.
Go To 7
No »Go To 6
DR - - - - - - - - - ENGINE • ELECTRICAl' DIAGNOSTICS • 6.7L DIESEL 9 .. 2339
6. (K671) EGR COOLER BYPASS STATUS CIRCUIT OPEN

Measure the resistance between the (K671) status circuit in the EGR
Cooler Bypass Valve harness connector with the (K671) status circuit in
the ECM harness connector.
Yes »Replace the EGR Bypass valve.
Go To 7 4
No »Repair the open circuit or high resistance.
Go To 7
VALVE.eGR
COOLER
10
20 11
30 21
40 31
50 'Ii
liII 51
MODULE-
ENGINE
CONTROlC1
(8.7l)
81bc48b4
7. EXHAUST GAS RECIRULATION (EGR) TEMPERATURE SENSOR

Remove the EGR temperature sensor and check for soot on the sensor.
Is there soot on the sensor?
Yes »Wipe off sensor using brake cleaner or contact cleaner, allow to dry and re-install.
DURE)
No »Reinstall, repair complete.
DURE)
" '
P245C-EGR COOLER BYPASS CONTROL CIRCUIT LOW
- - - - - - - 1REL"·
I IIIART
I POWER
I SMART I
POWER I
I RELAY I
l ____ -lE~_
41
F348
16
PKIOR
, 261f
. , 42 Otao
F348
16
PKJOR
10 t 0112
f348
16
PKIOR
I
• 8148
I
f348
16
PKIOR
31 VALVE-EAR
SMART
POWER EGR COOLER
EGR BYPASS ITPASS
RELAY
FEED BYPASS VALVE ACTUATOR (1.7l/DMID"
K972
18
DBITN
I
• S050
I
K671 K670 K972
18 18 18
BRIDB BRILB OBfTN
171 01 91 Ct 331 Ct
r EaR - - - EaR - - AcTUATOR -, IIODUlE·
ElailE
I BYPASS BYPASS GROUND I COlnOl
STATUS VALVE
I SIGNAL I
L __________ .-J
, MfT
I I AfT
r1 r1
10
'l. 'I 0,'
00000 "00000
20 00000 00000 11
)0 00000 00000 21
40
sa
00000
00000
0 00000
00000
31
41
sa 00000 00000 51
~
~
I....J L...I
MODULE- VALVE·EGA RELAY·

ElailE COOLER SIART
COITROL Ct BTPASS POWER
II.n, (I.n IH/D1I ,t.lL D.ESEL)
.n••••

Theory of Operation
The EGR Cooler Bypass valve is used to bypass the EGR cooler when the engine is in an active regeneration
mode. This is to prevent EGR cooler fouling. At key on the ECM drives the control line low and then high and
5-8 volts. The signal line is the command from the ECM to the bypass valve. If this line is shorted high the bypass
valve be unable to bypass the cooler. EGR orifice temperatures will unexpectedly low. This is a high side driver. The
ECM turns on the MIL lamp immediately after this diagnostic runs and fails. The MIL lamp is turned off once the
diagnostic runs and passes in four consecutive drive cycles.
• When Monitored:
Keyon .
• Set Condition:
EGR Cooler Bypass signal line voltage is above a calibrated threshold.
Possible Causes

(K670) SIGNAL CIRCUIT SHORTED TO HIGH SOURCE
INTERNAL VALVE FAILURE
ECM
Diagnostic Test
1. P245C ACTIVE
Ignition on , engine not running.
Is DTC P245C active?
Yes »Go To 2
Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
2. (K670) EGR COOLER BYPASS SIGNAL CIRCUIT OPEN

Measure the resistance between the signal circuit in the (K670) EGR
Cooler Bypass Valve connector with the (K670) signal circuit in the
4
Yes »Go To 3
No »Repair the open circuit or high resistance.
Perform POWERTRAIN VERIFICATION TEST - 6.7L VALVE-EQR 2
to
20 11
30 21
..0 ;'1
50 41
eo 51
MODULE.
ENGINE
CONTROL C1
(6.7L)
81bc5c5c
3. P245C ACTIVE
Is P245C active?
Yes »Go To 4
4. ECM
Use a jumper wire to connect the (K670) EGR bypass signal circuit to
ground.
Did P245C go inactive?
Yes »Replace the EGR Bypass Valve.
No » Replace ECM.
Replace and program the Engine Control Module (Refer to VALVE-EGR
9 - ENGINE - STANDARD PROCEDURE) COOLER
8YPASS
(6.7LDtW1)
81bc5c61
9 ·2344 ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
P245D-EGR COOLER BYPASS CONTROL CIRCUIT HIGH
- - - - - - -lREU'.
I ISM'RT
I POWER
I SMART I
POWER I
I RELAY I
l ____ ~E~_
~ l' '
FJ4a
16
PK/OR
, 261t 01"
, . 42
F348
16
PK/OR
to t cUt
F348
16
PKIOR
I
• S040
I
F348
16
PK/OR
3J VALIE-E.R
SMART
EGR COOLER
POWER
EGR BYPASS ITPAIS
RELAY
BYPASS VALVE ACTUATOR ,6.1L/DHJDt)
FEED
K972
18
DBITN
I
• S050
I
K671 K670 K972
18 18 lB
BRIDB BRItB D8nN
111 C1 9101 331 C1

r EGR - - - EGR - - AcTUATOR -, MODULE.
EIGINE
I BYPASS BYPASS GROUND I CONTROL
STATUS VALVE
I SIGNAL I
L __________ -.J "
• MIT
AIT
n n
'l: ~
10
OOOOO~ "00000 11
10 00000 00000
)~
00000 00000 21
4a 00000 <0> 00000 II
50 00000 00000 41
60 00000 00000 5~
~
'/
" '-'
MODULE·
EttGINE
.......
YALVE-EGR
COOLER
RELAY·
SIIART
CONTROL Oi BYPASS POWER
(6.7L) ,1.1L DH/D1, ,1.1L DIESEL)

Theory of Operation
The signal line is the command from the ECM to the bypass valve. If this line is shorted high the bypass valve be
bypassing the cooler. EGR orifice temperatures will increase. This is a high side driver. There is no action taken if
this fault goes active .
• When Monitored:
Key on
• Set Condition:
When EGR Cooler Bypass valve is in cooter bypass mode and signal line is higher than a calibrated threshold.
Possible Causes

(K670) SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
ECM
1. P245D ACTIVE
With the scan tool. read DTC's.
Yes »Go To 2
Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 • ENGINE· DIAGNOSIS
AND TESTING) ,
2. (K670) SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT

Disconnect the EGA Cooler Bypass valve harness connector.
Measure the resistance between the (K670) EGR Cooler Bypass Valve
signal circuit in the engine harness C1 ECM connector and all other cir· 9
cuits in the ECM connector.
Yes »Go To 3
No »Repair the short circuit. 10
2Q 11
Perform POWERTRAIN VERIFICATION TEST - 6.7L. 30 21
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L)
81bc5c69
9 - 2346 ENGINE - ELEC-rRICAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR
3. P245D ACTIVE
Is P245D active?
Ves »Go To 4
4. ECM
Use a jumper wire to connect the (K670) EGR bypass signal circuit to 2
12-volts.
With the scan tool, read OTC's.
Did P245D go inactive?
Ves »Replace the EGR Bypass Valve.
No » Replace ECM. BAnERY·

Replace and program the Engine Control Module (Refer to POSITIVI!!
VALVE-EGR
(DIESEL LEFT BATTeRY)
9 - ENGINE - STANDARD PROCEDURE) COOLER
BYPASS
(8.7L DHlD1)
81bc5c74
P2463-DIESEL PARTICULATE FILTER - SOOT ACCUMULATION
Theory of Operation
The engine aftertreatment system monitors the soot load in the aftertreatment diesel particulate filter. Under normal
operating conditions the aftertreatment diesel particulate filter is self-cleaning, where soot is converted to ash. Under
light load operating conditions, the driver may be notified via the vehicle's EVIC message center that it may be
necessary to modify the vehicle's driving routine/duty-cycle in order to allow the aftertreatment diesel particulate filter
system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate
and set a fault, requiring service. The soot load in the aftertreatment diesel particulate filter is estimated using the
Exhaust Pressure Sensors and the calculated soot output of the engine. This fault code can be triggered if the
application is not operating at a duty cycle high enough to actively regenerate the aftertreatment diesel particulate
filter. This fault code indicates that the exhaust temperatures exiting the turbocharger are not high enough to actively
regenerate the soot that is trapped in the aftertreatment diesel particulate filter. It may be necessary to increase the
duty cycle of the application in order to prevent excessive soot accumulation and plugging of the aftertreatment
diesel particulate filter. The ECM will set this fault if it detects that the aftertreatment diesel particulate filter is
plugged or that the differential pressure across the diesel particulate filter is above the calibrated moderately severe
threshold limit. The ECM will illuminates the MIL lamp immediately when the diagnostic runs and fails. The driver will
be notified via the vehicle's EVIC Message Center. The ECM will also derate engine power output in an effort to
protect the vehicle aftertreatment system. The ECM will turn off the MIL lamp immediately after the soot load has
dropped below the Moderately Severe Level Threshold .
• When Monitored:
• Set Condition:
The ECM will set this fault if it detects that the soot load in the diesel particulate filter is above the moderately
severe level threshold limit.
Possible Causes
DIESEL PARTICULATE FILTER PLUGGED

EXHAUST TEMPERATURES NOT HIGH ENOUGH TO ACTIVELY REGENERATE THE AFTERTREATMENT
PARTICULATE FILTER.
DAMAGE TO THE AFTERTREATMENT SYSTEM FROM AN ENGINE FAILURE
EXHAUST TEMPERATURE SENSORS FAILED IN-RANGE LOW
EXHAUST PRESSURE SENSOR FAILED IN-RANGE HIGH
Diagnostic Test

Potential causes include a stuck open exhaust gas recirculation valve or a variable geometry turbocharger actuator
that is not moving correctly, faulty fueling or oil intrusion into the aftertreatmentlexhaust system.
Yes »Replace the failed base engine component causing the high black smoke levels. Replace the aftertreat-
ment diesel particulate filter.
DURE)
No »Go To 2
2. CYLINDER MISFIRE
Start the engine.
DURE)
No »Go To 3

With the scan tool check the temperature values of the Exhaust Temperature sensors.
Are the Exhaust temperature sensors reading within 6 degrees C of each other?
Yes »Go To 4
DURE)
ENGINE
DURE)
No »Go To 5
5. REGENERATION OF AFTERTREATMENT
Technician should drive vehicle per service information in response to level of EVIC Message Center Notification to
facilitate Active Regeneration of the Aftertreatment Particulate Filter.
After the Active Regeneration of the Aftertreatment Particulate Filter, Clear DTC with Service Tool Is
DTC P1451 still Active?
Yes »Go To 6
No »Repair completed, inform Owner of vehicle duty cycle requirements
DURE)
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9 - 2349

DURE)
AND TESTING)
P250a.. CHARGING SYSTEM OUTPUT LOW
I - - - - - - GENERATOR
GEN I
I GEN FIELD I
I ...!ENSE _ _ CONTROL .J
'I 'I
A804 K20
lS 18
RO BR/GY
28 C1 40 C1
1- ~N- - - GEN - - -'IODULE.
ENGINE
I SENSE FIELD ICOIIIROL
I CONTROL I
L ________ -.J
10
20
I 00000
00000
00000
00000
I
II
30 00000 0 00000 11
40 .~OOOOO 00000 I Jl
SO 00000 00000 41
60 00000 00000. 51
.----:;t 'h;--r:?J
IODULE·
ENGINE
CONTROL C1
GENERATOR
(I.n)
.hUU.

Theory of Operation
alternator to charge is 14. 75~volt. The ECM then receives feedback from the alternator on the voltage level it is
• When Monitored:
• Set Condition:
The battery voltage exceeds target voltage by more than a calibrated value.
Possible Causes
GENERATOR
(K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND
ECM
Diagnostic Test
1. ACTIVE DTC
Is DTC P065A active?
Yes »Go To 2
No »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 ~ ENGrNE ~
2. GENERATOR
Disconnect the Generator field harness connector.
Measure the resistance between the generator field terminals at the generator.
Yes »Go To 3
No »Replace the generator.
DURE)
3. (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND

Measure the resistance of the (K20) Generator Field Control circuit between the generator and battery negative.
Is the resistance greater than 100 ohms?
Yes »Go To 4
No »Repair the short to ground in the (K20) Generator Field Control circuit shorted to ground.
PROCEDURE)
9 • 2352 ENGINE· ELECTRICAL DIAGNOSTICS • &.7L DIESEL - - - - - - - - - DR
4. ECM
Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery
negative circuits of the ECM harness connector.
Compare the voltage reading from the vottmeter with that of the scan tool.
Perform POWERTRAIN VERIFICATION TEST - 6.7l. (Refer to 9 • ENGINE - STANDARD PROCE-
DURE).
DR ENGINE • ELECTRICAL. DIAGNOSTICS • 6.7L DIESEL 9 - 2353
P2504-CHARGING SYSTEM OUTPUT HIGH
r - - - - GEN- I
-IIIIU'O.
I GEN FIELD I
I ~N~ _ _ C~TR~ .J
2i 'i
AU' K20
18 18
RD BRJGY
r--------
28
GEN
et 40
GEN
ef
-'.OIULI-
11111.
I SENSE FiElD I e.I'I.L
I CONTROL I
L ________ ...l
~ ~
'Oooo~ 00000 I
00000 00000 II
00000 00000
00000
00000
0 00000
00000
II41
00000 00000· 51
1...1
-
• •ULI·
alill
I.I..AIOI OOlf.'Let
1t.'L)
"......
9 - 2354 ENGINE - ELECTRICAt DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
alternator to charge is 14.75-volt. The ECM then receives feedback from the alternator on the voltage level it is
• When Monitored:
• Set Condition:
Battery voltage is less than 11.5 volts for more than 8 seconds. Battery voltage must exceed 12 volts for more
than 5 seconds for fault to become inactive.
Possible Causes
DIRTY OR LOOSE CONNECTIONS

ADD-ON OR ACCESSORY WIRES AT BATTERY TERMINAL
HIGH RESISTANCE IN THE B+ CIRCUIT
HIGH RESISTANCE IN THE B+ CROSS OVER CABLE
HIGH RESISTANCE IN THE GROUND CIRCUIT
GENERATOR
ECM
Diagnostic Test
1. ACTIVE DTC
Is DTC P065A active
Yes »Go To 2
2. DIRTY OR LOOSE CONNECTIONS

Visually inspect the positive and negative connections at the battery.
Visually inspect the battery negative connections at the engine block.
Yes »Go To 3
No »Clean and/or tighten the connections.
DURE)
3. ADD-ON OR ACCESSORY WIRES AT BATTERY TERMINAL

Check for add-on or accessory wiring at positive (+) terminal of the battery.
Are there any damaged wires at ·the battery?
Yes »Remove defective or miss wired add-on or accessory wiring from battery.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (R~fer to 9 • ENGINE - STANDARD PROCE-
DURE)
No »Go To 4
4. HIGH RESISTANCE IN THE B+ CIRCUIT

Measure the voltage between the B+ post of the generator and the B+ post of the battery while the engine is run-
ning.
Is the voltage above .4 volts?
Ves »Repair the high resistance in the B+ circuit from battery to the generator.
DURE)
No »Go To 5
5. HIGH RESISTANCE IN THE B+ CROSS OVER CABLE

Measure the voltage between the B+ post of the generator and the B+ post of the right side battery to the left side
battery while the engine is running.
Ves »Repair the high resistance in the B+ cross over cable from right side battery to left side battery.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 ~ ENGINE - STANDARD PROCE-
DURE)
No »Go To 6
6. HIGH RESISTANCE IN THE GROUND CIRCUIT

Measure the voltage between the generator case and the B- post of the battery.
Yes »Repair the high resistance in the ground circuit.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 ~ ENGINE ~ STANDARD PROCE-
DURE)
No »Go To 7
7. GENERATOR
Disconnect the Generator field hamess connector.
Measure the resistance between the generator field terminals at the generator.
Yes »Go To 8
No »Replace the generator.
PROCEDURE)
8. ECM
Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery
negative circuits of the ECM harness connector.
Compare the voltage reading from the voltmeter with that of the scan tool.
No »RepJace and program the ECM in accordance with the Service Information.
DURE)
P2509-ECM/PCM POWER INPUT SIGNAL INTERMITTENT
Iun AD
-
F
-IIiODULE.
I
I
@ FUSE
TOTALLY
I INTEGRATED
I POWER
I 42 I
30A I
L_l ___ J
11'C3
A209
10
RD
,l . .
A209
10
RD
I
e - - e - - e ItS!
A209
I A209
I A209
I
16 16 16
RD RD RD
r- 1 49
FUSED -
C2 50 1
FUSED- -
C2 60 1
FUSED- -
C2
- - - - - - - - - lMODULE.
B(t)
L _ _ _ _ _ _ _ _ _ _ ~ROUND_
B(t) B(t)
~ROUN~ _ GROUI!.. J EIIIGIIIIE
COIIITAOL
47, C2 481' C2 57, C2
Z902 Z902 Z902
16 16 16
BK BK BK
I I I
e • e 11 ••
I
Z902
10
BK
I
.a. G114
40
50
j! fg!,
lu~
g~mIlii ,. ~~ggigg
,,00000
ggggg j
Y" 00000
00000
I', ::
J'
4'
60 OO:00'.!J 51
IIODULE·
EIIGINE
COIIITROL C2
(l.lL)
It.Mdl

Theory of Operation
The ECM receives a constant voltage from the batteries through the unswitched battery wires that are connected
directly to the positive (+) battery post. The ECM receives switched battery input through the vehicle Ignition Switch
wire when the vehicle is turned on. The ECM will illuminate the MIL lamp immediately after the diagnostic runs and
fails. During the time the customer may experience some performance effects such as engine dying or hard starting.
Fault information, trip information could be inaccurate. The ECM will turn off the MIL lamp after the diagnostic runs
• When Monitored:
Continuous - key on or key off .
• Set Condition:
Loss of voltage detected at the ECM for a calibrated amount of time. Supply voltage to the PCM fell below 6.2
volts momentarily or the ECM was not allowed to power down correctly (retain battery voltage for 30 seconds
after key off).
Possible Causes
POOR CONNECTIONS AT THE BATTERIES

LOW BATTERY VOLTAGE
OPEN FUSED B+ TO ECM
OPEN GROUND CIRCUIT
BATTERY + SHORTED TO OTHER CIRCUITS
RETURN CIRCUIT SHORTED
BATTERY + SHORTED TO GROUND
Diagnostic Test
1. POOR CONNECTIONS AT THE BATTERIES

Visually inspect the wiring at the battery for damaged wires, or corrosion.
Are the connections tight and free of corrosion?
Yes »Go To 2
No »Repair the poor connections at the batteries.
DURE).
2. LOW BATTERY VOLTAGE

Measure the voltage between the positive and negative posts of the batteries.
Is the battery voltages both above 12 volts?
Yes »Go To 3
No »Recharge or replace the battery (s).
DURE).
3. OPEN FUSED B+ TO ECM

Measure the resistance between the positive battery post and the ECM supply circuits.
Yes »Go To 4
No »Repair the open tused B+ circuit to ECM.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Reter to 9 - ENGINE - STANDARD PROCE-
DURE).
4. OPEN GROUND CIRCUIT

Measure the resistance between the negative battery post and the ECM ground circuits.
Yes »Go To 5
No »Repair the open ground circuit.
DURE).
5. BATTERY + SHORTED TO OTHER CIRCUITS

Measure the resistance between the ECM supply circuits and all other circuits in the ECM harness connector,
except other supply circuits.
Yes »Go To 6
No »Repair the battery circuit short to other circuits in engine harness.
DURE).
6. RETURN CIRCUIT SHORTED

Measure the resistance between the ECM return circuits and all other circuits in the ECM harness connector, except
other return circuits.
Ves »Go To 7
DURE).
7. BATTERY + SHORTED TO GROUND

Measure the resistance between the ECM B+ supply circuits and ground.
No »Repair Battery + shorted to ground.
DURE).
9 .. 2360 ENGINE .. ELECTRICAL DIAGNOSl"ICS - 6.7L DIESEL - - - - - - - - - - DR
P254C-PTO SPEED SELECTOR SENSOR CIRCUIT LOW
Theory of Operation
The remote accelerator pedal position sensor varies the signal voltage to the ECM
as the remote accelerator pedal is depressed and released. Low signal voltage is
received by the ECM when the remote accelerator lever is a 00/0. A high signal
voltage is received by the ECM when the remote accelerator is at 1000/0. The
remote accelerator pedal position circuit contains a remote accelerator pedal
position 5-volt supply, remote accelerator pedal position return and remote
accelerator pedal signal. When the ECM senses a signal voltage lower than the
normal operating range of the sensor, this fault is set. NOTE. The remote
accelerator pedal or lever location varies with each original equipment
manufacturer (OEM). Refer to the OEM troubleshooting and repair manual. The
ECM will light the MIL lamp immediately after this diagnostic runs and fails. The
ECM will turn off the MIL lamp after the diagnostic runs and passes in 4
• When Monitored:
Key on .
• Set Condition:
The ECM detects that the remote accelerator pedal signal voltage is less than 0.1 volts for more than 1 sec-
ond.
Possible Causes
REMOTE ACCELERATOR PEDAL OR LEVER POSITION (K128) SIGNAL SHORTED TO ENGINE GROUND OR
(K400) RETURN CIRCUIT IN THE HARNESS OR SENSOR
REMOTE ACCELERATOR PEDAL OR LEVER POSITION SENSOR
OPEN CIRCUIT IN THE REMOTE ACCELERATOR (K128) SIGNAL, (K854) 5-VOLT SUPPLY OR (K400)
RETURN WIRE IN THE HARNESS OR CONNECTORS
ECM
Diagnostic Test
1. OTHER DTC'S
Are there any sensor supply fault codes?
No »Go To 2
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 .. 2361
2. P254C ACTIVE
Is P254C active?
Ves »Go To 3
AND TESTING)
3. OPEN CIRCUIT
Disconnect the remote accelerator pedal or lever position sensor from the harness.
Measure the voltage from the accelerator pedal or lever position (K854) 5-volt supply circuit to the accelerator pedal
or lever position (K400) return circuit at the sensor harness connector.
Is the measured voltage between 4.75 and 5.25 volts?
Ves »Go To 4
No »Go To 6
4. P254D ACTIVE
While monitoring the scan tool jumper between the accelerator pedal or lever position (K854) 5-voft supply circuit
and the accelerator pedal or lever position (K128) signal circuit at the sensor harness connector.
Is DTC P254D active and DTC P254C inactive?
Ves »Go To 5
No »Go To 6
5. P254C ACTIVE
Reconnect the remote accelerator pedal or lever position sensor from the harness.
Is DTC P254C active?
Ves »Replace the remote accelerator pedal or lever.
DURE)
No »
Repair complete. The removal and installation of the connector corrected the failure.
6. (K854) 5..VOLT SUPPLY CIRCUIT OPEN

the ignition off.
Measure the resistance between the C2 ECM harness connector (K854) 5-volt supply circuit and the remote accel-
erator pedal or lever harness connector (K854) 5-volt supply circuit.
Yes »Go To 7
No »Repair the open (K854) 5-volt supply circuit.
DURE)

Measure the resistance between the C2 ECM harness connector (K128) signal circuit and the remote accelerator
pedal or lever harness connector (K128) signal circuit.
Yes »Go To 8
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 .. ENGINE .. STANDARD PROCE·
DURE)
8. (K128) SIGNAL CIRCUIT SHORT TO OTHER CIRCUIT

Measure the resistance between the (K128) signal circuit in the C2 ECM harness connector and all other circuits in
Yes »Go To 9
No »Repair the (K128) signal circuit shorted to another circuit.
DURE)
9. (K1 SIGNAL CIRCUIT SHORT TO GROUND

Measure the resistance between the (K128) signal circuit in the C2 ECM harness connector and ground.
Yes »Go To 10
No »Repair the (K128) signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 .. ENGINE - STANDARD PROCE-
DURE)
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 .. 2363
10. ECM
Is DTC 254C stored?
Yes »Repair complete. The removal and installation of the connector corrected the failure.
No »Replace and program the Engine Control Module per the Service Information.
DURE)
P254D-PTO SPEED SELECTOR SENSOR CIRCUIT HIGH
Theory of Operation
The remote accelerator pedal position sensor varies the signal voltage to the ECM
as the remote accelerator pedal is depressed and released. Low signal voltage is
received by the ECM when the remote accelerator lever is a 00/0. A high signal
voltage is received by the ECM when the remote accelerator is at 100% • The
remote accelerator pedal position circuit contains a remote accelerator pedal
position 5-volt supply, remote accelerator pedal position return and remote
accelerator pedal signal. When the ECM senses a signal voltage lower than the
normal operating range of the sensor, this fault is set. NOTE. The remote
accelerator pedal or lever location varies with each original equipment
manufacturer (OEM). Refer to the OEM troubleshooting and repair manual. The
ECM will light the MIL lamp immediately after this diagnostic runs and fails. The
ECM will turn off the MIL lamp after the diagnostic runs and passes in 4
• When Monitored:
Key on .
• Set Condition:
The ECM detects that the remote accelerator pedal signal voltage is greater than 4.5 volts for more than 1
second.
Possible Causes
(K128) SIGNAL CIRCUIT SHORTED TO BATTERY OR 5-VOLT SUPPLY

(K400) RETURN CIRCUIT IN THE HARNESS OR CONNECTORS
(K854) 5-VOLT SUPPLY SHORTED TO BATTERY
REMOTE ACCLERATOR PEDAL OR LEVER POSITION SENSOR
ECM
Diagnostic Test
1 . OTH ER DTC'S
Are there any sensor supply fault codes?
No »Go To 2
2. P254D ACTIVE
Is P254D active?
Yes »Go To 3
No »Refer to the INTERMITIENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
3. OPEN CIRCUIT
Measure the voltage from the accelerator pedal or lever position (K854) 5-volt supply circuit to the accelerator pedal
or lever position (K400) return circuit at the sensor harness connector.
Is the measured voltage between 4.75 and 5.25 volts?
Yes »Go To 4
No »Go To 6
4. P254C ACTIVE
Is P245C active and P245D inactive?
Yes »Go To 5
No »Go To 6
5 . P254D ACTIVE
Yes »Replace the remote accelerator pedal or lever.
DURE)
No »
Repair complete. The removal and installation of the connector corrected the failure.
9 -. 2366 ENGINE - ELECTRJCAL DIAGNOSTICS - 6.7L DIESEL - - - - - - - - - DR

Measure the resistance between the C2 ECM harness connector (K400) return circuit and the remote accelerator
pedal or lever harness connector (K400) reeturn circuit.
Yes »Go To 7
DURE)
7. (K400) RETURN CIRCUIT SHORT TO OTHER CIRCUIT

Measure the resistance between the (K400) return circuit in the C2 ECM harness connector and all other circuits in
Yes »Go To 8
No »Repair the (K400) return circuit shorted to another circuit.
DURE)
8. ECM
Is OTC 2540 stored?
Yes »Repair complete. The removal and installation of the connector corrected the failure.
No »Replace and program the Engine Control Module per the Service Information.
DURE)
P2579-TURBOCHARGER SPEED SENSOR CIRCUIT PERFORMANCE
IIATT AI
r -f " - I 10DULE·
TOTALLY
I
I
@ FUSE
I_UIUUD
I POWER
I 42 I
I lOA I
l_l __ J
SENSOR·
T~ TURBO
SPEED
TURBO
SPEED
TURIO
IPEED
SENSOR SENSOR
A209 GROUND
SIGNAL
10 ACTUATOR·vaT
j
RO VaT vaT (t.UI
VGT HIGH LOW POWER
ACTUATOR DATA DATA RElAY
2 0130 GROUND LINK LINK FEED
21 3T 41
A209 K540 K541 K972 0130 0131 F348
10 18 18 18 18 18 16
RD BRroy BRNT DBlrN BRNT WTIlG PKIOR
I
I
e---e---.ltl.
I I
1
TO
A209 A21l9 A209 OTHER
la 16 16 MODULES
RO RD RD
491 CI 501 C2 60101 42 C1 43 01 II CI 38 Ct 3g 01

I fuSED - fuSED - FUSED - TURBO - - TURBO- - - VGT - - - VOT - - - VGT - , IODULE·
8(+) B(t) Bit} I Ela.NE SPEED SPEED ACTUATOR ACTUATOR ACTUATOR
I I COITROL SENSOR SENSOR GROUND HIGH lOW
I DATA SIGNAL GROUND DATA
I LINK I LINK
- - - - - - - - - - - - - - - - - - - - - - ____ -_1
ACTUATOR·'IT SElSOR·
'I.U)
,I.U,
TURBO SPEED
~ ~ n
/' " ~
10
/00006 ~ooo,~" 1 10
00000 '00000
20 00000 00000 11 20 00000 00000 II
)0 00000 00000 21 00000 00000 11
40
00000
00000
0 00000
00000 31
3D
4D
00000
00000
0 00000
00000 31
sa 00000 00000 so 00000 00000
ia \ . .A \.. ~1
51 SO '- ~
41
5t
'-' -= ~ ~
IODULE· IODULE·
EIIIIE EIlIIIE
COITROL Cf CONTROL C2
CI.UI (1.1L)
11124...

9 • 2368 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - - DR
Theory of Operation
speed reading. The ECM will light the MIL lamp immediately after this diagnostic runs and fails. The MIL lamp will
turn off once the diagnostic runs and passes in four consecutive drive cycles.
• When Monitored:
Engine running, turbo speed estimate is greater than a calibrated threshold
• Set Condition:
The ECM calculates an estimated turbo speed. The fault is activated when the difference of speed from the
Turbo Speed Sensor and the turbo speed estimate is greater than a calibrated value. The fault is also acti-
vated if the turbo speed sensor reading goes above a calibrated limit.
Possible Causes
ECM GROUNDS
(K540) TURBO SPEED SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS
(K540) TURBO SPEED SIGNAL CIRCUIT SHORTED TO GROUND
(K540) TURBO SPEED SIGNAL CIRCUIT OPEN
(A209) FUSED B+ CIRCUIT
Diagnostic Test
1. DTC ACTIVE
Use the accelerator pedal to accelerate the engine speed to a high idle (100%) and hold the engine speed at high
idle for at least 20 seconds
Does P2579 come active?
Yes »Go To 2

Turn Ignition off.
Disconnect the Turbocharger Speed Sensor harness connector.
Measure the resistance of the Turbo Speed Sensor by probing (K540) Turbo Speed Signal circuit and the (K541)
Turbo Speed Sensor ground circuit at the turbocharger speed sensor.
Yes »Go To 3
No »Replace the turbocharger speed sensor.
DURE).
3. (K541) TURBO SPEED SENSOR GROUND CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K541) Turbo Speed Sensor ground circuit in the sensor harness
connector.
Is the resistance greater than lOOk ohms?
Yes »Go To 4
No »Repair the short to ground in the (K541) Turbo Speed Sensor ground circuit.
DURE).
4. TURBO SPEED SENSOR CIRCUIT CHECK

Reconnect the turbocharger speed sensor harness connector.
Measure the resistance between the (K540) Turbo Speed Signal circuit
and (K541) Turbo Speed Sensor ground circuit at the ECM harness
connector.
43 42
turbocharger speed sensor. The turbocharger speed sensor resis-
tance was read in step 2.
Is the resistance within 10 ohms of sensor resistance?
10
20 11
Yes »Go To 5 30 21
No »There is high resistance or an open circuit in the engine '"'

eo
31
41
harness. Otherwise there is a low resistance (short) across eo 51
the sensor circuits. Repair/replace engine harness.

Perform POWERTRAIN VERIFICATION TEST - 6.7L. MODULE-
(Refer to 9 - ENGINE - STANDARD PROCEDURE). - ENGIIE
CONTROLC1
(1.7L)
81a64a43
5. (K540) TURBO SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the (K540) Turbo Speed
Signal circuit at the ECM harness connector.
42
Yes »Go To 6
No »There is a short to ground in the (K540) Turbo Speed Sig-
nal circuit.
(Refer to 9 - ENGINE - STANDARD PROCEDURE). 20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(6.7L) B1a64a4a
9 - 2370 ENGINE· ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL - - - - - - - - - DR
6. (K540) TURBO SPEED SENSOR SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS

all other circuits in the ECM harness connector except the turbocharger
speed (K541) Turbo Speed Sensor ground circuit.
42
Ves »Go To 7
No »There is a short between circuits of the ECM harness.
Repair or replace the engine harness.
(Refer to 9 - ENGINE - STANDARD PROCEDURE). 10
20 11
30 21
40 31
50 41
60 51
MODULE·
ENGINE
CONTROLC1
(8.7L) 818648ge
7. ECM
Start the engine.
Use the accelerator pedal to accelerate the engine speed to a high idle (1000/0) and hold the engine speed at high
Does DTC P2579 become active during engine operation?
Ves »Replace the ECM.
DURE).
No »The problem may exist in the turbocharger speed sensor circuit or it may exist with other vehicle elec-
tronic components. The problem may have been corrected when the harness connections were re-con-
nected. Be certain that the ECM and chassis grounds are in good condition.
Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 - ENGINE -
DR - - - - - - - - - ENGINE· ELECTRICAL, DIAGNOSTICS - 6.7L DIESEL 9 . 2371
P2580-TURBOCHARGER SPEED SENSOR CIRCUIT LOW
I"n At
r
l
-FI -IIODUlE.
TOU"'
I @ FUSE
IIITEGRATED
ItPOWER
I 42 I
I 30A I
I_I __ J
'r
A209
10
TlSRBO
SPEED
SENSOR
SIGNAL
TURBO
SPEED
SENSOR
GROUND
lEI lOR·
TUllO
SPEED
...-----------------------,ICIUllO.·VIT
RO VGT VGT (S.lLl
,1
VGT HIGH LOW POWER
cu. 21 ACTUATOR DATA OA,TA RELAV
'1 GROUND LINK LINK FEED
r
A20Q K540 K541
21
K972
3
0130
1 4T
0131 F348
lD 18 18 18 18 18 16
RD BRIGY SRNT DBITN BRNT WTltG PKIOR
j
• - - - . - - - . It65
I I I
1
TO
16 16 16 MODULES
RO RO RD
49102 501c2 601c2 42 Cf 43 C1 3301 38 Ct 3901

;- fuSED - fuSED - fuSED - -TURBO - - TURBO- - - VGT - - - VGT - - - VGT - , IODUlE-
I B(+) B(t) B(+) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR I :::~~~L
SENSOR SENSOR GROUNQ HIGH lOW t
I DATA DATA SIGNAL GROUND
-
I - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-_ _ _ _ -_ _ JI
ICTUllOl·Yen lEI lOR·

".U) . TURIO SPEED
CI.U,
n ,..,
10
roooo~ ~oooo"'" 1 10 f
10 00000 00000 11 10 II
30 00000 00000 21 10 11
40
00000
00000
0 00000
00000 31 40 31
~o
00000 00000 41 10 41
60 ~ 51 60 11
'-' '-'
10DULE· IODULE·
EIGIIE EIIGINE
CONTROL ct CONTROL C2
(I.JL) (e.lLl .,114...

9 • 2372 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
Theory of Operation
speed reading. If this fault becomes active the ECM will light the MIL light immediately. During this time the ECM
uses an estimated turbocharger speed. An engine power derate may be experienced. The ECM turns off the MIL
when the diagnostic runs and passes in 4 consecutive drive cycles .
• When Monitored:
When the key is on and the ECM detects a valid turbocharger speed .
• Set Condition:
ECM detects turbocharger speed detected is less than a calibration limit for a calibratable amount of time.
Possible Causes
ECM GROUNDS
(K540) TURBO SPEED SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS
(K540) TURBO SPEED SIGNAL CIRCUIT SHORTED TO GROUND
(K540) TURBO SPEED SIGNAL CIRCUIT OPEN
(A209) FUSED B+ CIRCUIT
Diagnostic Test
1. OTHER DTCS
Are any DTCs present for inlet air pressure or boost pressure?
Yes »Troubleshoot other DTCs first
No »Go To 2
Does P-2580 come active?
Yes »Go To 3
DR - - - - - - - - - ENGINE ·'-ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 - 2373

Turn Ignition off.
Disconnect the Turbocharger Speed Sensor harness connector.
Measure the resistance of the Turbo Speed Sensor by probing (K540) Turbo Speed Signal cir-
cuit and the (K541) Turbo Speed Sensor ground circuit at the turbocharger speed sensor.
Is the resistance between 600 and 1600 ohms? 81ca58fe
Yes »Go To 4
No »Replace the turbocharger speed sensor.
DURE).
4. (K541) TURBO SPEED SENSOR GROUND CIRCUIT SHORTED TO GROUND

Disconnect the ECM C1 harness connector.
Sensor ground circuit in the sensor harness connector. 2
Yes »Go To 5
No »Repair the short to ground in the (K541) Turbo Speed Sen-
sor ground circuit.
Perform POWERTRAIN VERIFICATION' TEST - 6.7L.
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
SENSOR-
TURBO SPEED
(8.7L)
81ca5926
5. TURBO SPEED SENSOR CIRCUIT CHECK

Reconnect the turbocharger speed sensor harness connector.
and (K541) Turbo Speed Sensor ground circuit at the ECM harness
connector.
turbocharger speed sensor. The turbocharger speed sensor resis- 43 42
tance was read In step 2.
Is the resistance within 10 ohms of sensor resistance?
Yes »Go To 6
No »There is high resistance or an open circuit in the engine
11
harness. Otherwise there is a tow resistance (short) across 21
the sensor circuits. Repair/replace engine harness. 31
41
(Refer to 9 - ENGINE - STANDARD PROCEDURE).

MODULE·
ENGItE
CONTROLC1
(I.7L)
81864&43
6. (K540) SPEED SENSOR SIGNAL SHORTED TO GROUND

Signal circuit at the ECM harness connector.
42
Yes »Go To 7
No » There is a short to ground in the (K540) Turbo Speed Sig-
nal circuit.
(Refer to 9 - ENGINE - STANDARD PROCEDURE). 20 11
30 21
40 31
60 41
eo 51
MODULE·
ENGINE
CONTROLC1
(6.7L) 81a64a4a
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNO,STICS - 6.7L DIESEL 9 .. 2375
7. (K540) TURBO SPEED SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS

all other circuits in the ECM harness connector except the turbocharger
speed (K541) Turbo Speed Sensor ground circuit.
42
Yes »Go To 8
No »There is a short between circuits of the ECM harness.
Repair or replace the engine harness.
(Refer to 9 - ENGINE - STANDARD PROCEDURE). 10
20 11
30 21
40 31
50 41
eo 51
MODULE·
ENGINE
CONTROL C1
(8.7L) 81a64age
8. ECM
Start the engine.
Does DTC P2580 come active during engine operation?
Yes »Replace the ECM
DURE).
No »The problem may exist in the turbocharger speed sensor circuit or it may exist with other vehicle elec-
tronic components. The problem may have been corrected when the harness connections were re-en-
gaged. Be certain that the ECM and chassis grounds are in good condition.
Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure. (Refer to 9 - ENGINE -
P2609-INTAKE AIR HEATER SYSTEM PERFORMANCE
+ IITTEAY·
IUlllIlAY
A19
4
RDIYL
r - - - - - ~ - - - - I MODULE·
I EICINE
• 1199 I ICDITRDL
I INTAKE AIR I
I INTAKE AIR HEATER I
HEA TER RElAY
I RELAY CONTROL I
L ~ONTR~ _ _ _ ~ETUR~ _ ..J
FUSIBLE
LINK
551' C2 39 I' C2
A19 K174 K974
10 18 18
RDlYl BRlYl BRJBK
19 1-
I' - - - - --l 38
Ct31
K174
18
BRlYl
951
j: t- - - - - - - - - - - -BI··~..r:.~~AlR
. .·
30
i
81'( 86
1
Klt74
A58
4 1B
BK BRJEK
A
mHEATEA.
lIJ IUUIAIR
3D
87 10
20 'I
30 21
40 31
86 50 41
fiO 51
8rA
RELlY· MODULE·
INTAKE &IR ENGIIE
HEllER CONTROL C2
(DIESEL, (S.7L)

DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7L DIESEL g .. 2377
Theory of Operation
elements. The ECM wi/I light the MIL lamp when the diagnostic runs and fails in two consecutive drive cycles. The
ECM ~iII turn off the MIL lamp when the diagnostic runs and passes in 4 consecutive drive cycles.
• When Monitored:
First 15 seconds of engine operation.
• Set Condition:
The ECM does not detect a voltage drop on the intake air heater circuit.
Possible Causes
INTAKE AIR HEATER OPEN
INTAKE AIR HEATER GROUND OPEN
OPEN BATTERY CABLE FROM INTAKE AIR HEATER RELAY
BATTERY CABLE OPEN
Diagnostic Test
1. INTAKE AIR HEATER OPEN
Measure the resistance between the intake air heater supply and ground terminal.
Yes »Go To 2
No »Replace the open Intake Air Heater.
DURE)
2. INTAKE AIR HEATER GROUND OPEN

Measure the resistance of the intake air heater ground circuit between the intake air heater terminal and the intake
manifold cover ground connection.
Yes »Go To 3
No »Repair the open Intake Air heater ground.
DURE)
3. OPEN BATTERY CABLE FROM INTAKE AIR HEATER RELAY

Measure the resistance of the battery cable between the intake air heater and the intake air heater relay.
Yes »Go To 4
No »Repair The open or high resistance battery cable from the intake heater relay to heater.
PROCEDURE)
4. BATTERY CABLE OPEN

Measure the resistance of the battery cable between the battery and the intake air heater relay for the relay.
Yes »Go To 5
No »Replace the battery cable from the battery to the Intake Air Heater Relay.
DURE)

Disconnect the intake air heater relay signal wire.
Connect a jumper wire from the signal terminal of the intake air heater relay to battery positive.
Did the relay click when 12 volts was applied?
Yes »Refer to the INTERMITIENT CONDITION - DIESEL Symptom (Diagnostic Procedure). (Refer to 9 -
No »Replace Intake Air Heater Relay.
DURE)
P268C-CYLINDER 1 INJECTOR DATA INCOMPATIBLE
Theory of Operation
Each injector has a six digit alphanumeric correction code. The correction code is printed on the intake side of the
injector and is used to identify the injector calibration. This code must be entered into the ECM using a scan tool.
• When Monitored:
Ignition on .
• Set Condition:
The Checksum calculation for the injector correction code failed.
Possible Causes
INCORRECT INJECTOR CODE ENTERED FOR THAT CYLINDER'

Always perform the Pre-Diagnostic Troubleshooting ,procedure before proceeding. (Refer to 9 - ENGINE -
1. INCORRECT INJECTOR CODE ENTERED

Using the a scan tool view injector correction codes.
NOTE: See service information for the location of the alphanumeric code on the injector.
Do the six digits entered into the ECM match the alphanumeric code on the injector?
Yes »Repair Complete
No »Read the six digit alphanumeric code on the injector and enter into the ECM using the scan tool. Key off
and wait approximately 30 seconds. Key on, the fault should become stored if entered correctly.
DURE)
9 .. 2380 ENGINE .. ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
P268D-CYLINDER 2 INJECTOR DATA INCOMPATIBLE
Theory of Operation
injector and is used to identify the injector caUbration. This code must be entered into the ECM using a scan tool.
• When Monitored:
Ignition on .
• Set Condition:
Possible Causes
INCORRECT INJECTOR CODE ENTERED FOR THAT CYLINDER

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE ..

and wait approximately 30 seconds. Key on, the fault should move to stored if entered correctly.
DURE)
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS - 6.7l DIESEL 9·2381
P268E-CYLINDER 3 INJECTOR DATA INCOMPATIBLE
Theory of Operation
Ignition on .
• Set Condition:
Possible Causes


Ves »Repair Complete
DURE)
P268F-CYLINDER 4 INJECTOR DATA INCOMPATIBLE
Theory of Operation
• When Monitored:
Ignition on .
• Set Condition:
The Checksum calculation for the injector correction code faUed.
Possible Causes

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE ..

DURE)
P2690-CYLINDER 5 INJECTOR DATA INCOMPATIBLE
Theory of Operation
• When Monitored:
Ignition on .
• Set Condition:
Possible Causes


NOTE: See service information for t,he location of the alphanumeric code on the injector.
DURE)
P2691-CYLINDER 6 INJECTOR DATA INCOMPATIBLE
Theory of Operation
• When Monitored:
Ignition on.
• Set Condition:
The Checksum calculation for the injector correction code faUed.
Possible Causes


NOTE: See service infonnatlon for the location of the alphanumeric code on the injector.
Do the six digits entered into the ECM match the alphanumeric code on the Injector?
Perform POWERTRAIN· VERIFICATION TEST - 6.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
P2AOO-02 SENSOR 1/1 CIRCUIT PERFORMANCE
IIAn AI
I L-. - - - - -IIODUU.
- - - - - - - - - - - - - - - - - 'IODILI.
I I B~-
(+)
_
l ELECTRONICS
I'OTALLY
1.'I!'RA1I!D I 1 11 • 111
I I FUSED IGNITION I I POWII I DIAGNOSTIC DIAGNOSTIC COI'ROL
I I SWITCH OUTPUT ! I I PORT lOW PORT HIGH I
I___
L {RUN-STAR2!... .J I _ DATA~ _ _ ~A~IN~ _G~N~ _G~N~ _G~N~ J
1"_____ _ 51 CI 31 CI 47) CI Y
48 CI 57) CI
20lca 1902 1902 1902
16 16 16
F960 BK BK BK
20
PKltG
• ------.Inl . - - - . - - - . Ii ••
I I !
F960 F960 0132 0133 1902
20 20 18 18 10
PKA.G PKA.G . WT WT/OR BK
~
I
,.... - - - "'IODULI.
A41 1
r cn,
.... 1it
I FUSED IGNITION I
AlTI-LOCI F960
SWITCH OUTPUT llAllI 18
I {RUN-START) I(,wnl PKA.G
'- - - - ....... 10 .J.,- - - - - - - B v Ct ••
y 7'( I
FNO 0132 D133
20 20 20
PKA.G WT WTIOR
9A 3..1.. llA
FUSED IGNITION DIAGNOSTIC DIAGNOSTIC 10DULI·
OIUI.OR
(RUN-STARl) DATA LINK DATA LinK 11.'lL .IIULI
02111 02111 02111 02112 0211'.1 02112

02111 HEATER HEATER PUMPCHl 02112 HEATER HEATER PUMP CELt
GROUND CURRfNT RETURN RETURN SUPPLY TRIM SIGNAL PUMP RETURN RETURN SUPPLY TRIM SIGNAL
lOT 7T 14 T 16T IT 15 T 6T 5'( 12T

8
1
21 13T 4T
1902 K89 K902 K79 K99 Kl03 K41 K734 K904 K80 K299 K733 K141
20 20 211 20 20 20 20 20 20 20 20 20 20
BK BRlLG BRItlG BR4.B BRA.G BRn..B DMB BR'()G DBIDG BRITN BRIWT BR DBlYl
"t. 11
1902
20
BK J J J .1
02112
CURRENT
02112
RETURN
021/2
HEATER
02 If.!
HEATER
.1 .1
02112
PUMP CELl
02112
SIGNAL
1.1'.1·
On1111}2
I
.ltM
PUMP CONTROL
RETURN
CONTROL
SUPPLV
CURRENT
TRIM
II.n DI!lI!LI
r---02-111---0-2-11-1--02-111--0-2-111--0-2-1f1-~O~21~f1"'" 111l0R·
PUMP RETURN HEATER HEATER PUMP CELL SIGNAL Olnll i/t
CURRENT CONTROL CONlROl CURRENT ('.n DIIIIL)
RETURN SUPPLY TRIM
1902
10
BK
I
... 1114
ItMMeI
• - - - - - . - - - - - - - . - - - - - - - . StOt

~~~
I I I I I I
K900 Kg DO K900 K900 K900 K900 KQOa
18 20 18 20 18 20 18
OBIDG DBIDG DBIDG DBIDG DBIDG DBII) G OBIDG
I I
'-----v--"
8EISOR·
EIHAUST J SEUOA.
[B
TEIPERATURE 1/1
EIHAUST
TEIPERATURE 112
[B
2 SEIIOR·
EIHAUST
TEMPERATURE t~
1 1
eXCEPT 1 Y EXCEPT EXCEPT
~~~
I I 1 I I I
K1SS K1SS K372 K372 Kl86 K1S6
20 18 20 18 20 18
BRAB BRAB BRJ1JG BRIDG BRIDB BRIDB
j I I I
'-----v--" '-----v--"
.51 1 1 ctoa
1---1-----, 6 11
I
K900 K185 K372 K18S
18 18 18 18
DBIDG BRA.8 BRIDG BRIOR
r
291 C2
SENSOR - -
20
EXHAuST -
1 C2
- - -
10
ExHAUST-
1 C2
- - -
91
-EXHAUST -
C2
lMODULE.
I GROUNO I
TEMPERATURE TEMPERATURE 1/3 TEMPERATURE 112 ENIITNREOL
SENSOR 1
COl SENSOR SENSOR
I SIGNAL SIGNAl SIGNAL I
L _____________________ J
n n
10 roooo~ 00000 1
20 00000 00000 11
10 00000 00000 21
40
50
00000
00000
0 00000
00000 .511
31
60 00000 00000
~
'-' ~
10DULE·
EIIIIIIE
IENSOR· SENSOR· SENSOR· CONTROL C2
EIHAUST EIHAUST EXHAUST {1.lL,
TEIPERATURE 1/t TEMPERATURE 1/1 TEIPERATURE 1/J
(l.lL) (1·7L1 ,1.1L1
..........
Theory of Operation
system. This diagnostic checks to make sure that the 02 content matches the expected 02 content for the engine
operating conditions. The ECM will set the fault if it detects that the actual 02 measurement does not match the
expected value. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will
turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles .
• When Monitored:
• Set Condition:
The ECM will set the fault if it detects that the actual 02 measurement does not match the expected value.
Possible Causes
UNDETECTED OVER OR UNDER FUELING OR AIR HANDLING ISSUES

EXHAUST SYSTEM LEAK
EGR SYSTEM LEAK
02 SENSOR 1/1 FAILED IN-RANGE
MASS AIR FLOW SENSOR FAILURE
ENGINE MISFIRE
1. OXYGEN SENSOR
Disconnect the Oxygen Sensor harness connector.
Yes »Go To 2 3
2 6
4
SENSOR.
OXYGEN 111
(B.7L DIESEL)
(COMPONENT SIDE)
81b400ab
2. SHORTED EXHAUST TEMPERATURE SENSOR 1/1 (K185) SIGNAL CIRCUIT TO (K900) RETURN CIRCUIT
Reconnect the Oxygen sensor.

Measure resistance of the Temperature sensor 1/1 (K185) signal and
(K900) return circuits at the ECM harness connector.
temperature.
Is the resistance 3.2 +1- 0.8 ohms at ambient temperature?
Yes »Go To 5 10
No » Go To 3 20 11
30 21
40 31
SO 41
MODULE-
ENGINE
CONTROLC2
(6.7L) 81bd335d
3. EXHAUST TEMPERATURE SENSOR 1/1 (K185) SIGNAL CIRCUIT OPEN

Disconnect the Exhaust Temperature Sensor 1/1 harness connector.
Measure the resistance of the Exhaust Temperature sensor 111 (K185)
signal circuit between the sensor harness connector and the ECM har-
ness
Yes » Go To 4
No » Repair the open sensor Signal circuit. 2
Perform POWERTRAIN VERIFICATION TEST . 6.7L.

20
SENSOR·
EXHA.UST
TEMPERATURE 111
(6.1L)
10
20 11
30 21
40 31
50 41
MODULE·
ENGINE
CONTROLC2
(6.7L) 81bd3362
4. EXHAUST TEMPERATURE SENSOR 1/1 (K900) RETURN CIRCUIT OPEN

Measure the resistance of the sensor (K900) Return circuit between the
Yes »Go To 5
No »Repair the open Return circuit.
Perform POWERTRAIN VERIFICATION TEST - B.7L
2.
29
SENSOR·
EXHAUST
TEMPERATURE 1/1
(II.7L)
10
2() 11
30 21
40 31
50 41
MODULE·
ENGINE
CONTROLC2
(6.7L) 81bd33Sf
5. EXHAUST TEMPERATURE SENSOR 1/1 (K185) SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
Measure resistance from (K185) signal circuit to all other circuits at the
Perform POWERTRAIN VERIFICATION TEST - B.7L 20
10
20 11
30 21
40 31
50 41
MODULE-
ENGINE
CONTROLC2
(8.7L) 81bd3373
P2A01-02 SENSOR 1/2 CIRCUIT PERFORMANCE
II,nu
L-. - - - - - IIDDULI!.
I
c-:....
(+)
_ l ELECTRONICS
I TDTlLL'
IITEQRITI!D I
- - - - - - - - - - - - - - - - - , I.DULI!·
I I! IQ III!
B
I I FUSED IGNITION I I POWI!R I DIAGNOSTIC DIAGNOSTIC COITROL
L (RU~START) ..J I _ DATA LINK _ _ ~ATALlN~ _GROUN~ _GROUN~ _G~N~ J
I __-_T_-____ _ 51 C2 31 C2 47 '( CI 48 '( C2 57 '( C2
20 IC~ Z902 Z902 Z902
16 16 16
F960 BK BK BK
20
PKAG
------.Ins .---.---.IU4
I I
F960 D132 D133 Z902
20 18 18 10
PKA.G WT WTIOR BK
r- -
I
'----v----"
- -
32
FUSED IG~TION
SW!TCH OUTPUT
J.
I
....., IODULI!.
UTI.LOCI
IUII!I
I
.41 t
Fgeo
.m
I
.a..H4
18
I (RUN-START) ('WILl I PKA-G
'-------'
10 J.,- - -- - - - 8 v CUI
y 7y I
FgeD 0132 D133
20 20 20
PKA.G WT WTlOR
9,1.. 3A llA
IODUU·
SWITCH OUTPUT PORT lOW PORT HIGH 0211!."R
(RUN-START) DATA LINK DATA LINK
II.n DII!II!L,
021/1 02111 02111 02 In 02112 021/2

lOT 7T 14, 16T IT 15 T 6T 5T 12T BT 2T 13 T 4T

Z902 KB9 K902 K79 K99 Kl03 K41 K734 K90 .. K8D K299 K73J KI4t
20 20 20 20 20 20 20 20 20 20 20 20 20
BK BRIlG BRlDG BRA.B BRIlG BRILB DBILB 8Rl)G DBllG
"t.
BRITN BRIWT BR DBIVL
11
Z902
20
BK J J J .I .I .I
02112
CURRENT
021n
RETURN
02112
HEATER
021f2
HEATER
021n
PUMP CEll
021n
SIGNAL
II!IIOII·
onll!. tl2
I
• It ...
PUMP CONTROL
RETURN
CONTROL CURRENT
TRIM
II.7L DII!II!L)
SUPPLY
02111 02 til 021/1 02111 02111 02111 II!IIOR·

PUMP RETURN HEA TER HE~ TER PUMP CELL SIGNAL onal!. 1/1
CURRENT CONTROL CONTROL CURRENT 'I.n DII!II!LI
RETURN SUPPLY TRIM
Z902
10
BK
I
... Ct14
• - - - - - . - - - - - - - . - - - - - - - . 1101
I EXCEPT I EXCE~T I EXCEPT

~~~
I I I I I I
1<900 K900 K900 1<900 1(900 K900 mo
18 20 18 20 18 20 18
DBIDG DBIDG DBIDG DBIDG DBlDG DBJOG OB,uG
I I I I I I
~~~
21 8EIII80R' 21
[I] ElHAUST
TEMPERATURE 1/1
[I]
SElSOR·
EIHAUIT
TEMPERITURE 1/2
[I]
2
SEIII80R·
EIHAUIT
TEIPERATURE '/0
11
~
I I
~~
I I I I
K185 K185 K172 K372 K186 K186
20 18 20 18 20 18
BRn. B BRILB BRIDG BRID G BRIDS BRIDS
I I I I I I
~~~
1 A
4
1---1-----1----1 5 .,l 6 11 CtOI
K900 K185 K372 K186

18 18 18 18
DBIDG BRItB BR,uG BRiaR
291 C2 20 1 C2 10 1 C2 91 C2
r SENsOR -
GROUND
- EXHAuST - - - -
TEMPERATURE
ExHAUST-
TEMPERATURE 113
- - - -EXHAUST -
TEMPERATURE 112
lMODULE.
I EIIIGIIilE
I SENSOR 1 SENSOR SENSOR CONTROL
L_____________________ J
10 ,
20 11
JO 21
40 )1
50 41
60 51
MODULE·
ENGINE
SEUOR· SENIOR· 8EN80R· CONTROL C2
EINAUIT EINIUST EIUUST (1.7L)
TEMPERATURE 1/1 TEMPERATURE 1/2 TEMPERATURE 1/3
(1.7L) (I.JL) (1·7L1
IfdfU.

Theory of Operation
system. This diagnostic checks to make sure that the 02 content matches the expected 02 content for the engine
operating conditions. The ECM will set the fault if it detects that the actual 02 measurement does not match the
expected value. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will
turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles.
• When Monitored:
• Set Condition:
The ECM will set the fault if it detects that the actual 02 measurement does not match the expected value.
Possible Causes
UNDETECTED OVER OR UNDER FUELING OR AIR HANDLING ISSUES

EXHAUST SYSTEM LEAK
EGR SYSTEM LEAK
02 SENSOR 1/2 FAILED IN-RANGE
MASS AIR FLOW SENSOR FAILURE
ENGINE MISFIRE
1. OXYGEN SENSOR 1/2

Disconnect the Oxygen Sensor1/2 harness connector.
heater supply and (KBO) 02 heater return circuits.
Yes »Go To 2 3
2 6
.4
SENSOR.
OXYGEN 111
(6.1L DIESEL)
(COMPONENT SIDE)
81b400ab
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.7l DIESEL 9 • 2393
2. SHORTED EXHAUST TEMPERATURE SENSOR 112 (K186) SIGNAL CIRCUIT TO (K900) RETURN CIRCUIT
Reconnect the Oxygen sensor.

Measure resistance of the Temperature sensor 1/2 (K186) signal and
(K900) return circuits at the ECM harness connector.
temperature.
Ves »Go To 5 1Q
No »Go To 3 20 11
30 21
40 31
50 41
MODULE·
ENGINE
CONTROLC2
(6.7L) 81bd350b
3. EXHAUST TEMPERATURE SENSOR 1/2 (K186) SIGNAL CIRCUIT OPEN

Discormect the Exhaust Temperatu re Sensor 1/2 harness connector.
Measure the resistance of the Exhaust Temperature sensor 1/2 (K186)
signal circuit between the sensor harness connector and the ECM har-
ness
Yes »Go To 4
No »Repair the open sensor -Signal circuit. ,2
Perform POWERTRAIN VERIFICATION TEST - 6'.7L.

SENSOR-
EXHAUST
10
20 11
30 21
40 31
50 41
MODULE-
ENGINE
CONTROLC2
(6.7L) 81bd3515
4. EXHAUST TEMPERATURE SENSOR 112 (K900) RETURN CIRCUIT OPEN

Measure the resistance of the Exhaust Temperature Sensor 1/2 (K900)
Return circuit between the sensor harness connector and the ECM har-
ness connector. 2

Yes »Go To 5
No » Repair the open Return circuit.
29
10
2() 11
30 21
40 31
SO 41
MODULE-
ENGINE
CONTROLC2
(6.7L) 81bd351c
5. EXHAUST TEMPERATURE SENSOR 1/2 (K186) SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
Measure resistance of the Exhaust Temperature Sensor 1/2 (K186) sig-
nal circuit to all other circuits at the ECM harness connector.
9
Perform POWERTRAIN VERIFICATION TEST - S.7L.
(Refer to 9 - ENGINE - STANDARD PROCEDURE) I
No » Repair the circuits that are shorted together.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. 1""'1 1""'1
(Refer to 9 - ENGINE - STANDARD PROCEDURE) /: v .:\

10
o~ 000" 00000
20 00000 00000 11
00000 00000
30
40
00000
00000
0 00000
00000
21
31
50
00000 00000 41
A ~
~
" L...I 1.....1
MODULE·
ENGINE
CONTROLC2
(6.7L) 81bd3530
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS - 6.7L DIESEL 9 ~ 2395
U0001-CAN C BUS
• When Monitored:
Ignition run time is greater than 1 second. Battery voltage between 9 and 16 volts. Engine run time greater
than 3 seconds .
• Set Condition:
The ECM loses communication over the CAN C Bus circuit. The circuit is continuously monitored. One Trip
fault.
Possible Causes
CAN C BUS OPEN OR SHORTED CONDITION
PCM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 • ENGINE •
Refer to 8 • ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diagnostic
procedures and for further possible causes.
Diagnostic Test
1. ACTIVE DTC
With a scan tool, read FCM (TIPM) DTCs.
Yes »Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diag-
nostic procedures and for further possible causes.
No »Refer to the INTERMITTENT CONDITION - DtESEL Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST - S.7L (Refer to 9 - ENGINE - STANDARD PROCE-
DURE)
U0101-LOST COMMUNICATION WITH TCM
• When Monitored:
than 3 seconds .
• Set Condition:
The PCM doesn't receive a Bus Message from the Transmission Control Module for 7 consecutive seconds.
One trip failure. The circuit is continuously monitored. Two Trip fault.
Possible Causes
PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT CHECK

BUS FAILURE OPEN OR SHORTED CONDITION
PCI BUS UNABLE TO COMMUNICATE WITH THE SCAN TOOL
PCM
Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diagnostic
Diagnostic Test
1. ACTIVE DTC
Start the engine.
NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, because this fault is
set after two failed trips.
Is the DTC Active or Pending at this time?
Ves »Go To 2
AND TESTING)
2. PCM FUSED IGNITION SWITCH OUTPUT CIRCUIT

Disconnect the C1 PCM harness connector.
With a 12-volt test light connected to ground probe the (F202), (F1). and (T751) Fused Ignition Switch Output circuit.
Perform the above check with the Ignition key in the off lock position, Ignition on, engine not running position, and
during cranking.
Wiggle the related wire harness while probing the special tool with the test light to try to interrupt the circuit.
Ves »Go To 3
No »Repair the excessive resistance in the (F202), (F1), and (T751) Fused Ignition Switch (Off, Run, Start)
circuit. Inspect the related fuse, if the fuse is open check the circuit for a short to ground.
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
3. PCI BUS UNABLE TO COMMUNICATE WITH THE SCAN TOOL

NOTE: Determine which modules this vehicle is equipped with before beginning.
NOTE: When attempting to communicate with any of the modules on this vehicle, the scan tool will display
1 of 2 different communication errors: a NO RESPONSE message or a BUS +/- SIGNALS OPEN MESSAGE.
Use the scan tool, attempt to communicate with the remaining control modules.
Was the scan tool able to communicate with one or more of the Modules?
Ves »Replace and program the Powertrain Control Module.
PCM/ECM PROGRAMMING - DIESEL (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No »Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diag-
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9 - ENGINE - STANDARD PROCE·
DURE)
9 • 2398 ENGINE· ELECTRICAL DIAGNOSTICS· - 6.7L DIESEL DR
U010C-LOST COMMUNICATION WITH TURBOCHARGER/SUPERCHARGER

CONTROL MODULE
I
I
-I -I
18ATT AD
r ~ IODULE·
TOTALLY
~
IINTEGUTED
I FUSE
I POWER
I I 42 I
I lOA I
I_I __ J
'r
A209
RD
10
TURBO
SPEED
SENSOR
SIGNAL
TURBO
SPEED
SENSOR
GROUND
SElSOR·
TURBO
SPEED
VGT
ACTUATOR·YGT
(I,ll)
VGT
,t
VGT HIGH LOW POWER
'1
ACTUATOR DATA DATA RElAV
Cta GROUND LINK LINK FEED
21 3T 41
A20S K540 K541 K912 om 0131 FHa
10 18 18 18 18 18 16
RD BRJGY BRNT DBfTN BRNT WTIlG PK/OR
I
I
e---e---e
I I
StiS 1
TO
16 16 16 MODULES
RD flO RD
491 501 601 Ct C2 C2 42 C1 43 C1 33 Ct 38 Ct 39 C1

----------------------------,
I FUSED FUSED FUSED TURBO TURBO VGT VGT VGT IODULE·
B(t) 8(+) B(+) SPEED SPEED ACTUATOR ACTUATOR ACTUATOR I EICUIIE
I SENSOR SENSOR GROUND HIGH lOW I CONTROL
I____________________________ LINK LINK
1I
ACTUATOR·vaT SElSOR·
(S.7L, TURIO SPEED
(1.7L)
,....,
-=
II
10
20
~oo~ 1'00000'
II
00000 00000
00000 00000
11
31
30
40
00000
00000
0 00000
00000
21
11
41 50 00000 00000 41
51 60 ~ 11
~
MODULE· MODULE·
EllaillE EIIIGIIE
COITROL Ct CONTROL C2
CI·7L1 II.U)
Theory of Operation
smart device that receives information via the J1939 datalink from the primary engine electronic control module
(ECM). The VGT actuator performs its own diagnostics and reports failures back to the primary engine ECM using
the J1939 datalink.
• When Monitored:
Ignition on .
• Set Condition:
The ECM does not receive a message from the VGT actuator in a calibrated amount of time.
Possible Causes
J1939 DATALINK
POWER SUPPLY TO VGT ACTUATOR OPEN
POWER SUPPLY TO VGT ACTUATOR SHORTED TO GROUND
SIGNAL CIRCUIT FROM VGT ACTUATOR OPEN
INTERMITTENT COMMUNICATION BETWEEN THE VGT ACTUATOR AND THE ECM ON THE J1939 DATALINK
ECM
Diagnostic Test
1. OTHER DTC'S
Are there low voltage errors for the Mass Airflow sensor or EGR Airflow Controller?
Yes »Repair the Smart Power Relay power supply.
CEDURE)
No »Go To 2
2. U010C ACTIVE

Yes »Go To 3
No »Refer to the INTERMITTENT CONDITION - DIESEL Symptom. (Refer to 9 - ENGINE· DIAGNOSIS
AND TESTING)
9·2400 ENGINE - ELECTRICAL DIAGNOSTICS - 6. 7L DIESEL - - - - - - - - - DR
3. POWER SUPPLY TO VGT ACTUATOR OPEN

Disconnect the VGT actuator harness connector.
Measure the voltage between the VGT actuator power SUPPLY circuit
and the VGT actuator RETURN circuit at the VGT actuator harness 2
connector.
NOTE: Check the voltage at key-on and while cranking the engine.
Is the voltage greater than 11.0 volts?
4
Yes »Go To 4
No »Repair/Replace the Smart Power Relay harness.
ACruATOR-
Perform POWERTRAIN VERIFICATION TEST VER - 6.7L. I!LI!CTRONIC
TURBO
(8.7L)
81b38324
4. J1939 DATALINK OPEN

Disconnect the C1 ECM harness connector
[ ] ...
Measure the resistance between the J1939 Datalink (+) circuit at the
VGT actuator harness connector and the J1939 Datafink (+) circuit at
Measure the resistance between the J1939 DataHnk (-), circuit at the
VGT actuator harness connector and the J 1939 Datalink (-) circuit at
Yes »Go To 5
No » Repair the open in the J1939 circuit. AC1\IA1OR·
'ELEC1RONIC'
Perform POWERTRAIN VERIFICATION TEST - 6.7L. TURBO,
(1.7L)
11
21
"1
.,
51
MODULE·
ENGINE
CONTROLC1
(1.7L.
81b38328
DR - - - - - - - - - ENGINE • ELECTRICAL DIAGNOSTICS· 6.7L DIESEL 9 - 2401
5. J1939 DATALINK SHORTED

Measure the resistance between the J1939 Datalink (+) circuit at the C1
ECM harness connector and all other circuits in the C1 ECM harness
connector.
Measure the resistance between the J1939 Datalink (-) circuit at the C1
connector. 39 (.) 38 (+)
NOTE: Disregard any resistance between 50 and 70 ohms between
the J1939 (+) and the J1939 Datalink (-) pins.
Is the resistance greater than 100 kOhms?
Yes »Go To 6
No »Repair the short in the J1939 circuit. 11
21
Perlorm POWERTRAIN VERIFICATION TEST - 6.7L. 31
(Refer to 9 - ENGINE - STANDARD PROCEDURE) <41
51
MODULE·
ENGINE
CONTROLC1
(1.7L)
81b3832c
6. J1939 DATALINK SHORTED TO GROUND

ECM harness connector and ground.
Measure the resistance between the J1939 Datalink (-) circuit at the C1
Is the resistance greater than 100 kOhms?
39 (-) 38 (+)
Yes »Go To 7
No »Repair the short to ground in the J1939 circuit.
Perlorm POWERTRAIN VERIFICATION TEST 6.7L.
10 1
20 11
30 21
4D 31
50 <41
60 51
MODULE-
ENGINE
CONTROLC1
(1.7l)
81b38330
7. VGT ACTUATOR
Reconnect the VGT actuator harness connector.
Reconnect the C1 ECM harness connector
Is DTC P-C10C Active?
Yes »Replace the VGT Actuator
DURE)
U011A-LOST COMMUNICATION WITH EXHAUST GAS SENSOR MODULE
Ilin ..
I L - - - - - -IIOIUI.E-
~ _ I TOTALLY -----------------l~~
I 'B(+) 1 ElECTRONICS •• TEGRATEI I 11••111
I I FUSED IGNITION I IPOW EI I DIAGNOSTIC DIAGNOSTIC CO.TIOL
L (RUN-START) ..J I _ D!,!.ALlNK _ _ ..E.ATALlN~ _G~N~ _G~N~ _G~N£.... J
1_ _ -_T_-____ _ 51 C2 31 CI 47 YCI 48 yet ~7 YCt
20 YC~ Z902 Z902 Z902
16 16 16
F9SU
BK BK BK
20
PKIlG
EXCEPT
SHIFT ON SHIFT ON
THE FLY THE FlY
- - - - - - • • 17. . - - - e - - - e ...4
I
l .
F960 om 0133 1902
20 18 18 10
PK1G WT WTJOR BK
I
3Ll
,... - - -
FUSED IGNITION
SWITCH OUTPUT
-..OIILI.
IIITI-LOCI
11111.
'" tF960
18
etae
I
.... 1114
I (RUN-START)
..... _ _ _ --l
III WALl PKA.G
lD -J,- - -- - - - 8 v Cil.
y 7y I
F960 om 0133
ia 20 20
PKrtG WT WTlOR
9A 3),. llA
FUSED IGNITION DIAGNOSTIC DIAGNOSTIC I . . ULI!·
SWITCH OUTPUT PORT LOW PORT HIGH
0111.,01
(RUN-START) DATA LINK DATA LINK IUL DIESEL)
02111 02111 02111 02112 021f.l 021/2

02111 HEATER HEATER PUMPcm 021n HEATER HEATER PUMP CELL
PUMP 021/1 CONTROL CONTROL CURRENT 021fl CURRENT 02112 CONTROL CONTROL CURRENT 021/2
10 T 1T 14 T 16 T IT 15 T 6T ~T 12 T tiT 2T 13 T 4T
1902 KSY K902 m K99 Kl03 K41 1(734 K904 K8D K299 K733 K141
20 20 20 20 20 20 20 20 20 21) 20 20 20
"t
BK BRJ\.G BRJOG BUB BRA..G BRA.B DBILB BRA)G DBI1)G BRITN BRfWT BR DBNL
etee
.1 .1 .1 .1 .1 .1
1902
20
BK
021n 02112 02112 021t.! 02112 021/2 I!ISOR·
HEATER PUMP CELL SIGNAL 01Y1E1 ill
e
I 11M
CURRENT
PUMP
RETURN
CONTROL
RETURN
HEATER
CONTROL
SUPPLY
CURRENT
TRIM
,I.n DIIseL}
02111 02111 02111 02111 02 111 02 111 IEI.OI·

PUMP RETURN HEA TER HEA TER PUMP CELL SIGNAL OIYIII 1/1
CURRENT CONTROL CONTROL CURRENT II.7L OI!ln)
RETURN SUPPLY TRIM
1902
10
BK
I
.... GH.
It . . . . .

Theory of Operation
The oxygen sensor is controlled by the smart oxygen module (smart 02 module). This module is a smart device
that receives information, such as dew point flag, engine speed, etc., via the J1939 datalink from the primary engine
electronic control module (ECM). It provides ECM with the oxygen concentration signal. It also performs its own
diagnostics and reports failures back to the primary engine ECM using the J1939 datalink.
• When Monitored:
Ignition on or engine started .
• Set Condition:
The ECM does not receive a message from the smart oxygen module in a calibrated amount of time.
Possible Causes
J1939 DATAUNK
POWER SUPPLY TO SMART 02 MODULE OPEN
POWER SUPPLY TO SMART 02 MODULE SHORTED TO GROUND
SIGNAL CIRCUIT FROM SMART 02 MODULE OPEN
INTERMITTENT COMMUNICATION BETWEEN THE SMART 02 MODULE AND THE ECM ON THE J1939
DATALINK
ECM
Diagnostic Test
1. OTHER DlC'S
With the scan tool, read DlC's.
Are there any Alternator Voltage errors or low voltage errors for the Mass Airflow sensor or EGR Air-
flow Controller?
Yes »Repair the Alternator error or Smart Power Relay power supply.
Perform POWERTRAIN VERIFICATION TEST - 6.7L (Refer to 9 • ENGINE • STANDARD PROCE-
DURE)
No »Go To 2
2. U011 A ACTIVE
Is DlC U011A Active?
Yes »Go To 3
No »Refer to the INTERMITTENT CONDITION Symptom. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING)
3. POWER SUPPLY TO SMART 02 MODULE OPEN

Disconnect the smart 02 module harness connector.
D
Measure the voltage between the smart 02 module power Supply cir-
cuit and the smart 02 module Ground circuit at the smart 02 module 10 9
harness connector.
Is the voltage greater than 6.0 volts?
Yes »Go To 4
No »Repair/Replace the Smart Power Relay harness for an
open. 8

16 9
MODULE-02
SENSOR
(6.7L DIESEL)
81da2b09
4. J1939 DATALINK OPEN

Measure the resistance between the J1939 Datalink (+) circuit at the
smart 02 module harness connector and the J 1939 Datalink (+) circuit
at the C2 ECM harness connector.
Measure the resistance between the J 1939 Datalink (-) ci rcuit at the
smart 02 module harness connector and the J1939 Datalink (-) circuit
at the C2 ECM harness connector. 16

MODULEo02
Yes » Go To 5 31 (+)
SENSOR
No » Repair the open in the J1939 circuit. (6.7L DIESEL)

10
20 11
30 21
40 31
50 41
60 S1
MODULE·
ENGINE
CONTROLC2
(6.7L) 81da2b10
5. J1939 DATALINK SHORTED

connector.
Measure the resistance between
ECM harness connector and all
the J1939 Datalink (-) circuit at the C2
other circuits in the C2 ECM harness
[]
31 (+)
connector.
NOTE: Disregard any resistance between 50 and 70 ohms between
the J1939 (+) and the J1939 Datalink (-) pins.
Is the resistance greater than 100 kOhms? 10
20 11
Ves » Go To 6 30 21
40 31
No » Repair the short in the J1939 circuit.
50 41
Perform POWERTRAIN VERIFICATION TEST - 6.7L 80 51
MODULE-
ENGINE
CONTROlC2
(6.7l)
81da2b17
6. J1939 DATALINK SHORTED TO GROUND

Measure the resistance between the J1939 Datalink (.) circuit at the C2
Is the resistance greater than 100 k Ohms? 31 (+)
Yes »Go To 7
No »Repair the short to ground in the J1939 circuit.
30 21
40 31
50 41
so 51
MODULE·
51 (-)
ENGINE
CONTROlC2
(6.7L)
81da2b45
DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS .. &.7L DIESEL g .. 2407
7. SMART 02 MODULE
Reconnect the smart 02 module harness connector.
With the scan too', read DTC·s.
Yes »Replace the smart 02 module
DURE)
DURE)
U0121-LOST COMMUNICATION WITH ANTI-LOCK BRAKE MODULE
• When Monitored:
than 3 seconds.
• Set Condition:
The ECM doesn't receive an ABS message over the CAN C circuit for 7 consecutive seconds. The circuit is
continuously monitored. One Trip fault.
Possible Causes
CAN C BUS OPEN -OR SHORTED CONDITION

ABS MODULE
TIPM
PCM
Refer to 8 .. ELECTRICAUELECTRONIC CONTROL MODULES .. DIAGNOSIS AND TESTING for diagnostic
Diagnostic Test
1. ACTIVE DTC
With a scan tool, read ECM DTCs.
Yes »Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diag-
No »Refer to the INTERMITTENT CONDITION - DIESEL Diagnostic Procedure.
U0141-LOST COMMUNICATION WITH FCM (TIPM)
• When Monitored:
Ignition run time is greater than 1 second. Battery voltage between 9 and 16 volts.
• Set Condition:
The ECM doesn't receive a FCM (TIPM) message over the CAN C circuit for 7 consecutive seconds. The
circuit is continuously monitored. One Trip fault.
Possible Causes
CAN C BUS OPEN OR SHORTED CONDITION

FCM (TIPM)
ECM
Refer to a - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING for diagnostic
Diagnostic Test
1. ACTIVE DTC
With a scan tool, read ECM DTCs.
Yes »Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTtNG for diag-
U1403-IMPLAUSIBLE FUEL LEVEL SIGNAL RECEIVED
• When Monitored:
Ignition on .
• Set Condition:
The fuel volume message the ECM is receiving is implausible. The circuit is continuously monitored. One Trip
fault.
Possible Causes
CAN B OPEN OR SHORTED

CLUSTER MODULE
TOTALLY INTEGRATED POWER MODULE (TIPM)
ECM
Theory of Operation
The Totally Integrated Power Module isn't receiving a fuel volume signal over CAN B from the Cluster Module. The
TIPM has to send the PCM a fuel volume signal over CAN C. The signal the TIPM sends over CAN C is implau-
sible.
Diagnostic Test
1. ACTIVE DTC
Is the DTC Active at this time?
Yes »Go To 2
2. CAN B BUS HARDWARE DTCS ALSO ACTIVE

With a scan tool check for DTCs in the FCM (TIPM).
Are any CAN B Hardware related DTCs active at this time?
Yes »(Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING) for the
appropriate diagnostic procedures.
Perform BODY VERIFICATION TEST - VER 1.
No »Replace and program the Powertrain Control Module per Service Information.
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS '. 6.7L DIESEL 9 - 2411
U1412-IMPLAUSIBLE VEHICLE SPEED SIGNAL RECEIVED
• When Monitored:
Ignition on .
• Set Condition:
The ECM gets an implausible signal over the CAN C circuit from the ABS Module. The circuit is continuously
monitored. One Trip fault.
Possible Causes
CAN C BUS CIRCUIT SHORTED

CAN C BUS CIRCUIT OPEN
ASS MODULE
ECM
Theory of Operation
The ABS Module sends vehicle speed information over the CAN C Bus circuit to the ECM.
Diagnostic Test
1. ACTIVE DTC
With a scan tool, read DTCs.
Is the U1412-IMPLAUSIBLE VEHICLE SPEED SIGNAL RECEIVED active at this time?
Yes »Go To 2
No »Refer to the INTERMITIENT CONDITION Diagnostic Procedure.
2. U0001-NO COMMUNICATION ON THE CAN C BUS CIRCUIT IS ACTIVE

Continue reading DTCs.
Is the U0001-NO COMMUNICATION ON THE CAN C BUS CIRCUIT ACTIVE at this time?
Yes »Refer to the Diagnostic Procedure for the U0001-NO COMMUNICATION ON THE CAN C BUS CIR-
CUIT.
No »Go To 3
3. ABS MODULE IS ACTIVE ON THE CAN C BUS

With the scan tool, select ECU View.
Verify that the ABS Module active on the bus.
Is the ABS Module active on the bus?
Yes »Go To 4
No »(Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING) for No
Response diagnostic procedures.
9·2412 ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL - - - - - - - - - - DR
4. ACTIVE DTCS IN THE FCM (TIPM)

With the scan tool, select ECU View and select FCM (TIPM).
With the scan tool, read active DTCs.
Is the U0001-NO COMMUNICATION ON THE CAN C BUS CIRCUIT ACTIVE in the FCM at this time?
Yes »Replace the ABS Module per Service Information.
U1421-IMPLAUSIBLE IGNITION KEY OFF TIME RECEIVED
• When Monitored:
Ignition on .
• Set Condition:
The fuel volume message the ECM is receiving is implausible. The circuit is continuously monitored. One Trip
fault.
Possible Causes
CAN B OPEN OR SHORTED

CLUSTER MODULE
FCM (TOTALLY INTEGRATED POWER MODULE)
ECM
Theory of Operation
The Totally Integrated Power Module (TIPM) isn't receiving a fuel volume signal over CAN B from the Cluster Mod-
ule. The TIPM has to send the PCM a fuel volume signal over CAN C. The signal the TrPM sends over CAN C is
implausible.
Diagnostic Test
1. ACTIVE DTC
Yes »Go To 2
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - .ENGINE - STANDARD PROCEDURE)
2. CAN B BUS HARDWARE DTCS ALSO ACTIVE

With a scan tool check for DTCs in the TIPM.
Are any CAN B Hardware related OTCs active at this time?
Yes »(Refer to 8 - ELECTRICAUELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING) for the
appropriate diagnostic procedures.
·CHECKING THE ACCELERATOR PEDAL SENSOR CALIBRATION
Possible Causes
MIS-WIRED APPS
VOLTAGE NOT CHANGING DURING SWEEP
THROTTLE PEDAL NOT MOVING FREELY
APPS
Diagnostic Test
1. MIS-WIRED APPS
Remove the APPS cover.
Inspect both APPS connector and ECM for proper wiring.
Are both connectors wired correctly?
Ves »Go To 2
No »Repair mis-wired APPS connector at APPS or ECM.
DURE)
2. THROTTLE PEDAL NOT MOVING FREELY

Look for proper Throttle operation.
Does the Throttle Pedal move freely between the upper and lower stops?
DURE)
Perform POWERTRAIN VERIFICATION TEST (DIESEL). (Refer to 9 ~ ENGINE - STANDARD PROCE-
DURE)
*CHECKING THE ECM POWER AND GROUNDS
Possible Causes
ECM GROUND CIRCUIT(S) OPEN

FUSED B+ CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
Diagnostic Test
1. ECM GROUND CIRCUIT(S) OPEN

Using a 12-volt test light connected to 12-volts, check each of the ECM ground circuits in ECM harness connector.
Did the test light illuminate for each cavity?
Yes »Go To 2
No »Repair the ECM Ground circuit(s) for an open.
DURE)
2. FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

Using a 12-volt test light connected to ground, check the Fused Ignition Switch Output circuit in ECM harness con-
nector.
Is the test light on?
Yes »Go To 3
No »Repair the Fused Ignition Switch Output circuit for an open.
DURE)
3. FUSED B+ CIRCUIT OPEN

Using a 12-volt test light connected to ground, check each Fused B+ circuit in the ECM harness connector.
Does the test light illuminate brightly for each circuit?
DURE)
No »Repair the Fused B+ Output circuit for an open.
PROCEDURE)
9 - 2416 ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7l DIESEL - - - - - - - - - DR
·CHECKING THE EXHAUST SYSTEM FOR LEAKS
1. CHECKING THE EXHAUST SYSTEM FOR LEAKS

Raise the vehicle in accordance with the Service Information.
WARNING: The normal operating temperature of the exhaust system is very high. Never work around or
attempt to service any part of the exhaust system until it has cooled. Special care should be taken when
working near the catalytic converter. The temperature of the converter rises to a high level after a short
period of engine operating time
Connect Exhaust Cone #B404-ECT to Air Pressure Regulator (with hose) #W-1B-MIL-1146AS.
CAUTION: The air pressure must not exceed 4 psi, otherwise engine damage can occur.
Attach shop air to the air pressure regulator.
Adjust the Air Pressure Regulator to 4 psi
Insert the exhaust cone into the vehicle tail pipe.
If the vehicle is equipped with dual exhaust. Use the #8404-ECT with equipped attached plug, plug one side of the
dual exhaust pipe. Pressurize the other as described above.
Apply SNOOP leak finder liquid or a mixture of liquid dish soap and water to the following areas:
- All welded joints from 6 inches rearward of the downstream 02 sensor forward
- 02 sensor seal points
- 02 sensor boss welds
- Flange/joint connection(s)
- Exhaust manifold to cylinder head connection(s}
- EGR solenoid gasket base and tube seal points (if equipped)
Watch for the liquid/soapy water to bubble.
Use the following definitions to help determine if system or component repair/replacement is necessary:
Type 1 Leak is defined as a leak where very small foam like bubbles (1 mm or less) appear.
Any Type 1 or greater teaks found in welded joints, 02 sensor seal points or 02 sensor boss welds must be
repaired or the component must be replaced.
Type 2 Leak is defined as a leak where larger bubbles (pea size, Bmm or greater) appear.
Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or
EGR gasket and tube seal points must be repaired or the components must be replaced
Repair required if results at 4 psi reveal bubble

Leak Location
size:
Welded joints Type 1 (1 mm) or greater
02 Sensor seal points Type 1 (1 mm) or greater
02 Sensor boss welds Type 1 (1 mm) or greater
Flange I joint connections Type 2 (8 mm) or greater
Exhaust Manifold to cylinder head connections Type 2 (8 mm) or greater
EGR gasket and tube seat pOints Type 2 (8 mm) or greater
. ..
If a leak IS found that matches the above definition, repair or replace the component as necessary.
Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.
Were any exhaust leaks found?
Yes »Repair or replace the leaking exhaust parts as necessary.
DURE)
No »Test complete.
DR ENGINE - ELECTRICAL'DIAGNOSTICS - 6.7L DIESEL 9 - 2417
'If PRESSURE LIMITING VALVE TEST
Possible Causes
PRESSURE LIMITING VALVE DIAGNOSTICS
Diagnostic Test

Using the scan tool, measure the rail pressure and determine if the rail pressure is excessive (above 185,000 kpa/
26,831 psi), if it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Instan fuel system test fitting (9013) into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container.
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container. replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed.
view repair
Repair
Repair complete
DURE)
*ENGINE SURGES
Possible Causes
DTC/PRODUCT IMPROVEMENT
FUEL SUPPLY SYSTEM
INJECTION SYSTEM
FUEL RETURN
INTAKE SYSTEM
OTHER VEHICLE SYSTEMS
BASE ENGINE
Diagnostic Test
1. DTC/PRODUCT IMPROVEMENT
Check for any TSB's related to customer's complaint or DTC's present.
Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB.
Is vehicle repaired?
DURE)
No »Go To 2
2. FUEL SUPPLY SYSTEM

Verify proper fuel quality, grade and level in vehicle.
Use scan tool to monitor fuel rail pressure. If pressure does not fluctuate more then +/- 500 psi of set point than the
fuel system is not the cause of the complaint. Proceed to step3. If condition exist continue.
Verify proper low pressure supply to the Injection Pump by performing the "*IN-TANK FUEL LIFT PUMP FLOW
TEST - DIESEL" Procedure.
Use the u*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL" to check for failed fuel pump.
Perform "*CHECKING PRESSURE LIMITING VALVE ON THE FUEL - DIESEL".
DURE)
No »Go To 3
3. INJECTION SYSTEM
Perform "*INJECTOR RETURN FLOW TEST". If okay continue.
Check for correct injectors and injector shims.
Visually inspect injector wire nuts and pass through connectors for damage or corrosion.
Ves »Repair complete.
DURE)
No »Go To 4
4. FUEL RETURN
Check for kinked or restricted fuel return lines.
Check fuel tank venting.
DURE)
No »Go To 5
.5. INTAKE SYSTEM

Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.
Check for air system leaks. Perform "*INTAKE AIR SYSTEM PRESSURE TEST - DIESEL".
Inspect Turbocharger for wheel clearance and proper wastegate operation.
Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 9' - ENGINE - STANDARD PROCE-
DURE)
No »Go To 6
6. OTHER VEHICLE SYSTEMS

Verify proper operation of the Transmission Clutch.
Verify proper operation of the Transmission.
Verify proper operation of the Vehicle brakes (check for dragging).
Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories.
Verify proper operation of the Accelerator pedal (restricted or out of calibration).
DURE)
No »Go To 7
7. BASE ENGINE
Inspect speed indicator ring for damaged/missing teeth.
Check for internal engine damage.
Repair Complete.
Repair
Repair complete.
DURE)
*ENGINE NO START/HARD START
Possible Causes
DTC/PRODUCT IMPROVEMENT
BATTERY VOLTAGE
STARTING ACCESSORIES
ENGINE TIMING
FUEL SUPPLY SYSTEM
INJECTION SYSTEM
FUEL RETURN
AIR SYSTEM
OTHER VEHICLE SYSTEMS
BASE ENGINE
Diagnostic Test
1. DTC/PRODUCT IMPROVEMENT
Check for any TSBs related to customer's complaint or DTCs present.
Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB.
DURE)
No »Go To 2
2. BATTERY VOLTAGE
Check for low battery voltage.
Is battery voltage okay?
No »Repair low battery voltage.
DURE)
Yes »Go To 3
3. STARTING ACCESSORIES
the Ignition switch (check for proper output voltage and/or open circuit).
Inspect the Starter.
Inspect the Grid Heaters.
Inspect the Fuel Heater.

DURE)
No »Go To 4
DR - - - - - - - - - ENGINE - ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 2421
4. ENGINE TIMING
Inspect for dirty or damaged pins at Crankshaft position sensor (CKP) or Camshaft position sensor (CMP).
Verify proper overhead adjustments.
DURE)
No »Go To 5
5. FUEL SUPPLY SYSTEM

Verify proper fuel quality, grade and level in vehicle.
Use scan tool to monitor fuel rail pressure. If pressure does not fluctuate more then +/. 500 psi of setpoint than the
fuel system is not the cause of the complaint. Proceed to step 6. If condition exist continue.
Verify proper low pressure supply to the Injection Pump by performing the "*IN-TANK FUEL LIFT PUMP FLOW
TEST - DIESEL" Procedure.
Use the "*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL" to check for failed fuel pump.
Perform "*PRESSURE LIMITING VALVE TEST'.
DURE)
No »Go To 6
6. INJECTION SYSTEM
Perform "*INJECTOR RETURN FLOW TEST". If okay go next step.
Check for correct injectors and injector shims.
Visus"y inspect injector wire nuts and pass through connectors for damage or corrosion.
DURE)
No »Go To 7
7. FUEL RETURN
Check for kinked or restricted fuel return lines.
Check fuel tank venting.
DURE)
No »Go To 8
8. INTAKE SYSTEM
Check for inlet restriction. inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.
tI
Check for air system leaks. Perform "*INTAKE AIR SYSTEM PRESSURE TEST· DIESEL •
Inspect Turbocharger for wheel clearance and proper wastegate operation.

Check for exhaust restriction. Verify proper exhaust brake operation. Check for kinked or blocked exhaust pipes.
Check for proper operation of EGA airflow throttle control valve.
DURE)
No »Go To 9
9. OTHER VEHICLE SYSTEMS

Verify proper operation of the Transmission Clutch.
Verify proper operation of the Transmission.
Verify proper operation of the Vehicle brakes (check for dragging).
Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories.
Verify proper operation of the Accelerator pedal (restricted or out of calibration).
Verify no excess Electrical Noise.
Verify no MOisture in harness connector or corroded terminals.
DURE)
No »Go To 10
1o. BASE ENGINE

Check for internal engine damage.
Repair Complete.
Repair
Repair complete.
DURE)
*ENGINE NOISE
• When Monitored:
When standing in front of the truck with engine running, several distinct noises may be heard, these noises
may vary depending on listener location, 2WD vs. 4WD, engine temperature and miles on vehicle.
1. GEAR TRAIN NOISE EVALUATION

Normal: Gear noise is noticeable when standing in front of the engine, may vary with engine temperature, engine
speed, engine load, miles on vehicle, and from engine to engine.
Abnormal: Gears are visually damaged or have backlash or end clearance out of specification. The cause should be
identified and corrected.
Continue
To »Next step
2. FUEL PUMP NOISE EVALUATION

Normal: Pumping noise may vary - the fuel pump is producing between 5,000 and 20,000 psi depending on oper-
ating conditions.
Abnormal: A fuel pump with excessive pressure variation (+/- 500 psi from setpoint) is abnormal. The cause should
be identified and corrected, refer to Engine Surge or Engine Difficult to Start symptoms.
Continue
To »Next step
3. INJECTOR NOISE EVALUATION

Normal: Combustion noise may vary at different operating conditions. May be more noticeable on throttle tip-in and
vary from engine to engine.
Abnormal: loud knock with smoke and vifration. Chlinder cut out test or mechanical blocking of injectors (injector
block off 9011) should be used to identify failed injectors.
Continue
To »Next step
4. VALVE TRAIN NOISE EVALUATION

Normal: Valve settings are correct and no visual damage to parts.
Abnormal: If valve settings are out of specification, they should be reset. Also, correct for any damage to rocker
levers, push rods, or crossheads.
Compete
Refer to
Vehicle manual section 9 - ENGINE - 6.7l DIESEL - SERVICE INFORMATION - Diagnosis and Testing
- Engine Diagnosis - Mechanical for other types of noise and causes.
*FUEL HEATER THERMOSTAT TEST
1. FUEL HEATER THERMOSTAT TEST

To check the operating resistance levels on the thermostat and fuel heater perform the following:
1. Unplug the wiring harness from the thermostat.
2. Check the resistance across the two pins of the thermostat with an Ohmmeter.
3. The ambient temperature must be below the "Circuit close temperature; 10 +/- 3° CIf to perform this check.
4. If necessary, induce this ambient temperature by placing ice packs on the thermostat to produce an "effective
ambient temperature" below the circuit close temperature.
5. The resistance across the two pins should be within the range of 0.3 Ohms to 0.45 Ohms for a properly operating
thermostat and heater.
6. If the resistance from step 2 is out of range. remove the thermostat and check the resistance across the terminal
connections of the heater (the heater can be checked at room temperature).
7. The resistance across the terminal pins of the heater should be within the same range of step 2.
8. Replace the heater if resistance is not within the proper operation range.
9. Replace the heater if resistance is not within the proper operation range. Re-install the thermostat with a new
a-ring.
10. If the heater resistance is within the proper operating.
11. Circuit close temperature; 1c +/- 3° C
12. Circuit open temperature; 180 +/- 4 0 C
13. Fuel Heater Thermostat 0.3 - 0.45 Ohms at less than 1 degree C
14. Fuel Heater 0.3 - 0.45 Ohms at room temperature
View Repair
Repair
Test complete.
DURE)
DR ENGINE .. ELECTRICAL DIAGNOSTICS .. 6.7L DIESEL 9 - 2425
*INJECTOR RETURN FLOW TEST
1. ENGINE RUNS
Review Warranty bulletin 0-05-24.
NOTE: Battery charger may be utilized if cranking speed is below 170 RPM's.
Does the engine run?
Yes »Go To 2
No »Go To 3
2. * INJECTOR RETURN FLOW TEST @ 1200 RPM AND 1400 BAR RAIL PRESSURE
1. Operate the engine until the coolant temperature is above 180 F.
0
2. Remove the banjo connector from the fuel drain tube at the rear of the fuel fifter housing.
3. Install fuel system test fitting 9012 in place of the banjo connector.
4. Remove the vehicle fuel return line from the engine fuel drain tube.
5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank.
6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated
cylinder.
7. Start engine and allow to idle for 30 sec. This step allows the flows to stabilize. Gather appropriate measuring
device to measure col/ected return fuel.
8. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure
override test. Select Start, then press Next.
9. Press the Run button on the screen. As you press the Run button to start the overpressure test, please move the
injector return hose from the bucket and insert into the appropriate measuring device. The engine speed will elevate
rapidly to 1200 rpm and the rail pressure will increase to 20000 psi (1400 bar).
10. While the test is running, please record the FCA duty cycle % and actual rail pressure record the readings on
the Cummins Diesel Diagnostic Worksheet located under e-files, service, Star center in dealerconnect.
11. Measure and Record the amount of fuel collected.
12. If the flow is iess than 160 ml/30 sees, the test has successfully passed and the condition has been fixed
t
13. If the flow is greater than 250 ml/30 seconds, refer to step 20.
14. If the flow is greater than 160 ml/30 secs after step 11, shut off the engine and remove all 6 high pressure fuel
lines. Re-torque the high-pressure connector nut. Inspect for damage, repair/replace as necessary. Reinstall high
pressure fuel lines.
15. Start the engine and perform steps 7 through 10.
16. Measure the amount of fuel in the graduated cylinder.
17. If the amount of fuel is greater than 160 ml/30 sec, shut off the engine and remove the #1 high pressure fuel
line. Cap the #1 fuel port using tool 9011 on the fuel rail and repeat steps 7 through 10.
18. Measure the amount of fuel in the graduated cylinder. If the amount is less than 160 ml.30 sec, remove and
replace the #1 injector and #1 High pressure connector.
19. If the amount of fuel is not less than 160-ml/30 secs, repeat steps 17-18 for cylinders 2-6.
20. If the amount of fuel is greater than 250 ml/30 secs it is recommended that all 6 injectors be replaced.
21. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm
repair.
SPECIFICATION: Less than 160 mil 30 seconds total fuel returns flow
Repair
Test Complete.
3. INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM WHEN THE VEHICLE WILL
111
NOT START
1. Install 9012 fitting in standard location on back of fuel filter head to measure pump and injector return flows.
2. Install hoses to the test fitting and the injector return line and route them to a bucket or other container. Make
sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while
testing.
3. Unplug the injector harnesses at the valve cover. Unplug the connector to the FCA.
4. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key
off when finished.
5. Let all the fuel drain out of each line before continuing.
6. Place the injector return hose into an appropriate measuring device.
7. Crank the engine for 10 seconds. Go from Keyoff to Crank back to Keyoff. Do not leave the ignition on between
tests.
8. Let all of the fuel drain out of the injector hose.
9. Record the amount of injector return for a 10 sec crank.
10. Flow should be less than 40 ml for 10 seconds of cranking
11. If the flow is greater than 40 ml after step 10, remove the #1 fuel injector supply line. Re-torque the high-pres-
sure connector nut. Cap the #1 fuel port using tool 9011 on the fuel rail.
12. Crank the engine and perform steps 7 through 9.
13. Measure the amount of fuel in the graduated cylinder.
14. If the amount of fuel is less than 40 mi. remove the #1 high pressure connector and the #1 fuel injector. Inspect
for damage, repair/replace as necessary.
15. If the amount of fuel is not less than 40 ml, repeat steps 12-14 for cylinders 2-6.
16. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm
repair.
Repair
Note: DTC's will be set by this process. Remember to go in and clear all DTC's from all modules. Test
complete.
*IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE
1.
1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test.
2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for
damage. Fix or replace any damaged component.
3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector.
4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the
voltmeter.
5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6
6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the
voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low
battery voltage.
7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay
voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than
11.5 volts, fix or replace the harness.
8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the
Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and
return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5
volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9.
9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an
Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and
the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms,
fix or replace the harness.
10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using
a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel
module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace
the harness.
11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using
an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel
module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than
10 ohms, go to step 12.
12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the
fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less
than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness.
13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the
fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is
greater than 1 volt, fix or replace the harness.
14. Reconnect the lift pump connector.
FLOW TEST.
1. Remove the fuel pump supply banjo fitting from the fuel injection pump.
2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump.
3. Connect one end of a section of fuel hose to the test fitting.
4. Put the other end of the fuel hose into an empty fuel container.
5. Use the scan tool to actuate the fuel lift pump.
6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10
seconds.
7. Read and record the amount of fuel in the graduated cylinder after 10 seconds.
8. If you have more than S70ml in the graduated cylinder after 10 seconds, the test has successfully passed.
9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the
fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs
of damage, replace as necessary. If no damage is found, replace the fuel filter and retest.
10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with
water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow
is still below spec repair damaged component.
11. If reading is still less than S70ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage
and/or debris in and around the fuel tank module. If module is damaged, replace and retest.
12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix.
Test complete
Repair
Test complete.
DURE)
*FUEL PUMP RETURN FLOW TEST
Possible Causes
I EXCESSIVE FUEL PUMP RETURN FLOW
I .. IFUEL PUMP RETURN FLOW TEST

Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive
(above 185,00 kpaJ26,831 psi). If it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure*Iimiting valve on the fuel rail.
Install fuel system test fitting 9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: Do not drive the vehicle with any portion of this test kit installed
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing
Install fuel system test fitting 9012 in place of the banjo connector.
Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder.
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 1aOOml/minute at idle, the test has successfully passed.
If the flow is greater than 1QOOml/minute at idle, replace the fuel injection pump.
Retest to confirm repair.
View Repair
Repair
Test Complete.
DURE)
9 - 2430 ENGINE - ELECTRICAL DIAGNOSTICS - 6~ 7L DIESEL - - - - - - - - - DR
*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST
1.
If the engine will run do the following:
1. Monitor rail pressure with scan tool while the engine is at idle.
2. Compare the fuel pressure set point with the actual fuel pressure reading.
3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control
Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corro-
sion is found replace the entire Fuel Injection Pump.
t
4. Turn off engine.

5. Disconnect the FCA harness
6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder.
7. Crank the engine until fuel exits this line. This will not be high pressure fuel.
S. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These
are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine
cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump:
Minimum fuel pump flow at 150 rpm cranking speed is 70mL
If the engine is a no start do the following:
1. Remove fuel pump to rail high pressure fuel line.
2. Inspect the fuel pump outtet port for rust, debris, or other signs of contamination.
3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future
complaints. If no contamination is found continue to step 4.
4. Disconnect the Fuel Control Actuator (FCA).
5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated
cylinder.
6. Crank the engine until fuel exits this line. This will not be high pressure fuel.
7. Crank the engine for three (3) 10 seconds intervals.
NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to pre-
vent damage to the starter.
Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30
seconds, replace the pump:
Test complete
Repair
Test complete.
DURE)
DR ENGINE • ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 - 2431
*INTAKE AIR SYSTEM PRESSURE TEST
1. CHARGE AIR COOLER PRESSURE TEST

air inlet tube clamp at the turbocharger.
Remove the air fitter housing and the inlet tube from the vehicle as an assembly.
'nstall the CAC Pressure Tester 9022 into the inner diameter of the turbocharger, securing it in place with the sup-
plied three-fingered band clamp, tighten tool clamp to 8 N.m (72 in Ibs).
CAUTION: Never attempt to start or run the vehicle at any time during this test, engine damage may occur.
Fasten the safety chain around a solid surface behind the turbocharger.
WARNING: Never run CAC Pressure test without the safety chain securely fastened.
Before attaching shop air to the pressure regulator verify that the regulator is at its lowest pressure setting (0 psi).
Attach an air supply to the regulator and slowly increase the pressure untif the pressure gauge reads 8 psi.
WARNING: Never apply more than 20 PSI.
Using a solution of soap and water spray the Turbocharger, Turbocharger wastegate, Charge Air Cooler Heat
Exchange and CAC Hoses while watching for teaks.
Before any attempt to repair the CAC system is made, it's necessary to completely discharge the system. This can
be accomplished by turning the regulator knob counter-clockwise.
Allow for adequate time to pass before removing the CAC Pressure tester from the turbocharger inlet.
Position the Air Filter Housing over the three mounting studs located on the inside front fender well and press down
firmly to lock housing into place.
Install Air Inlet Tube over the Turbocharger inlet and torque the band clamp to 35 in.lbs.
View Repair
Repair
Test complete.
DURE)
*OFF-IDLE ENGINE SPEED LOW DURING COLD START

Theory of Operation
Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the
maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maxi-
mum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission
selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine
speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the
engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is
controlled to a low speed. This delay in maximum engine and turbocharger shaft speed allows for sufficient oillubri-
cation to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important
for long term turbocharger durability. The maximum engine speed for the 5.9l engine is temporarily limited to 1,600
RPM's when the above conditions are met. The 6.7l engine speed is temporarily limited to 1,200 RPM's when the
above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent
upon engine coolant temperature. Refer to the table to determine the amount of Time Delay.
NOTE: The time delay values supplied in the table are an approximation and may vary per application.
ENGINE TEMPERATURE TIME DELAY

• 35° F (·37°C) 45.2 sees.
- 20° F (-28°C) 34.6 sees.
- 10° F (-23°C) 28.8 sees.
- 0° F (-17°C) 24.2 sees.
+ 10° F (-12°C) 20.2 secs.
+ 20° F (-7°C) 17.0 secs.

+ 35° F (2°C) 13.0 sees.
+ 45° F (7°C) 10.8 secs.
+ 55° F (13°C) 9.0 secs.
+ 70° F (21°C) 7.0 secs.
STANDARD PROCEDURE
ECM/PCM PROGRAMMING
MODULE REPROGRAMING
Replacement ECM's will require programming utilizing the StarSCAN® or equivalent. The ECM will not operate the
engine until itis programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed".
CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not ran-
domly select a calibration. Once a calibration is selected and programmed, the controller cannot be repro-
grammed to a different calibration. The module can only be reprogrammed to a more recent version of that
cal ibration.
SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED:
NPN Battery Charger

CH9401 StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
CH9409 StarSCAN® Documentation Kit
CH9410 StarSCAN® Ethernet Cable, 12 ft.
CH9412 StarSCAN® Software Update Device Kit
TechCONNECT PC or equivalent
StarSCAN® Software Update CD
**REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:

NOTE: The StarSCAN® or equivalent diagnostic scan tool fully supports Internet connectivity. However, in
order to take advantage of this feature you must first configure the StarSCAN® or equivalent for your deal-
ership's network. For instruction on setting up your StarSCAN® or equivalent for the dealer's network; refer
to the StarSCAN® or equivalent Quick Start Networking Guide available on DealerCONNECT > Service>
StarSCAN and StarMOBILE or equivalent Tools> Online Documentation or at www.dcctools.com website
under the "download center".
NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
1. Open the hood, install a battery charger and verity that the charging rate provides approximately 13.5 volts. Set
the battery charger timer to maintain the charging voltage for the duration of the flash process.
2. Connect the CH9410 StarSCAN® or equivalent ethernet cable to the StarSCAN® or equivalent and the dealer's
network drop.
3. Connect the CH9404 StarSCAN® or equivalent vehicle cable to the StarSCAN® or equivalent and the vehicle.
4. Power ON the StarSCAN® or equivalent.
5. Retrieve the old ECU part number. Using the StarSCAN® or equivalent at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight the ECM in the list of modules.
c. Select "More Options"
d. Select "ECU Flash"
e. Record the part number at the top of the "Flash ECM" screen for later reference.
DR - - - - - - - - - ENGINE· ELECTRICAL DIAGNOSTICS • 6.7L DIESEL 9 • 2433
NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from
the label on the controller. If the label on the controller is not legible, record the "Reference No." for use
later. The "Reference No." is located in the Reference No. box at the top, center of the Engine Data Plate.
Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side
of the breather cover or affixed to the APPS bracket.
Engine No, Cf'L

MoteurNo, 56100101 8228
Idle Speed (1JlI!l)
WesseRalenti
WARMNG: Injury may result and warranty is voided if FirillgOrder
fuel rate, rpm or aHitWes exceed JXItiished maximum Onler d'A6urooge 15 3 6 2 0.0
values tor !his model and applrcation. 'Ialve lash mid
RUX Soup '8 Froid 0.020 0.00
AVERTISEMENT: Dan(Jl!r de blessures el d'annulation de ThiS qine CilI1lolll1s III Calilamia Aegulalioos applicable III XXJO( model year medium I1Ity vehicles. This engine is
la garanlie. Si de'bit de comoostible, tr/mn OU certifiea to operate Dn liesel fuel. ooOj 1 Certified.
attitude, de'passent las lIaleurs maximum announcc'es
pour ell IOOdele et son ubllS8lion.
813377b9
6. Replace the ECM with the appropriate Generic ECM. Refer to the detailed service information available in Tech-
CONNECT, under: Service Info, a-Electrical, Electronic Control Module, Engine Control Module, Removal.
7. Program the ECM as follows:
a. Using the StarSCAN® or equivalent at the "Home" screen, Select uECU View"
d. Select "ECU Flash"
e. Select "Browse for New File". Follow the on screen instructions.
f. Highlight the appropriate calibration based on the part number recorded in Step 5 Step e.
g. Select "Download to Scantool".
h. Select "Close" after the download is complete, then select I<Back".
i. Highlight the listed calibration.
j. Select "Update Controller". Follow on screen instructions.
k. When the update is complete, select "OK".
I. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number.
8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules?
a. Yes » go to Step 13.
b. No » go to Step 14.
9. Program the ECM to the Wireless Control Module (WCM).
a. Highlight the WCM.
b. Select "Misc. Function".
c. Highlight "ECM Replaced".
9 • 2434 ENGINE .. ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
d. Select I'Start"
e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
f. When complete proceed to Step 14.
10. Program the VIN into the ECM.
a. Scroll through the list of controllers and highlight the ECM.
b. Select 'IMisc. Function".
c. Highlight "Check ECM VIN".
d. Select "Start"
e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes,
select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes
from the window. Enter the VIN. Select "Finish" after completing the last step.
f. Unplug the scan tool from the Data Link Connector.
g. At the "Vehicle Disconnected" screen, press "OK".
h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Hamel!
screen.
NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC,
SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the
"Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are
any DTCs shown on the list.
NOTE: The following step is required by law when reprogramming a ECM andlor TCM.
11. Type the necessary information on the "Authorized Modification Label" pIn 04275086AB and attach near the
VECI label.
REPAIR PROCEDURE USING SOFTWARE

I I
lillill'll1l~erCli'lD1fIlt~~r ~IlJl1i1}i]OIJilmi!lj) ~IFII~ :a-~IIM~-:'..
UPDATE CD TO RETRIEVE THE FLASH rniill:'O~1WG ~1!ll~~~W~Ii:INl~:
FILE:
NOTE: If this flash process is interrupted/aborted,
the flash should be restarted.
NOTE: For detailed information on the operation of
the StarSCAN®, refer to the Quick Reference doc-
umentation provided in the StarSCAN® or equiva- 80f3.4528
lent documentation kit. In addition, more recent
information may also be available at the www.dc-
clools.com website. Look under "Training Aids" and also under "Download Center> Frequently Asked Ques-
tions" for more help.
1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set
the battery charger timer to maintain the charging voltage for the duration of the flash process.
2. Connect the CH9404 StarSCAN® or equivalent vehicle cable to the StarSCAN® or equivalent or equivalent and
the vehicle.
4. Retrieve the old ECU part number. Using the StarSCAN® or equivalent at the "Home" screen:
d. Select'IECU Flash"
e. Record the part number at the top of the "Flash ECM" screen for later reference.
5. Replace the ECM with the appropriate Generic ECM. Refer to the detailed service information available in Tech-
CONNECT, under: Service Info, 8-Electrical, Electronic Control Module, Engine Control Module. Removal.
6. Insert the StarSCAN® or equivalent Software Update CD into the TechCONNECT or equivalent PC. The Star-
SCAN® Software Update CD will start automatically. Select "Download Flash Updates".
7. At the "Select a method for looking up controller flash updates." screen:
a. Select "Enter part number". Enter the "Part Number" recorded in Step 4 when prompted to do so.
b. Using the mouse highlight the appropriate "Calibration". Select "Next".
c. Follow the on screen instructions.
d. When completed, proceed to Step B.
B. With the StarSCAN® or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN®
or equivalent USB port.
9. Connect the StarSCAN® or equivalent to the'vehi-
cle (if not already connected).
11. Download the flash file from the USB key to the
StarSCAN® or equivalent. Using the StarSCAN®
or equivalent at the "Home" screen:
a. Select "Flash Download", then select "Retrieve
files from the USB storage device"
b. Highlight the appropriate calibration. Select
"Download to Scan Tool"
c. When the download is complete, select "Close"
and "Back".
12. Reprogram the ECU. Using the StarSCAN® or
equivalent at the "Home" screen:
a. Select "ECU View".
b. Select "More Options".
c. Select "ECU Flash".
d. Highlight the appropriate calibration.
e. Select "Update Controller". Follow the pn screen instructions.
f. When the update is complete. select "OK".
g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number.
13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules?
14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen:
b. Scroll through the list of controliers and highlight the WCM.
c. Select "Misc. Function".
d. Highlight "ECM Replaced".
e. Select "Start"
f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
g. When complete proceed to Step 16.

15. Program the VIN into the ECM.
a. Scroll through the list of controllers and highlight the ECM.
b. Select "Misc. Function".
9 .. 2436 ENGINE - ELECTRICAL DIAGNOSTICS • 6.7L DIESEL - - - - - - - - - DR
c. Highlight "Check ECM VIN".

d. Select "Start"
e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes,
select "Show Keyboard Place the cursor to the right of the last box and then backspace to delete the boxes
lt
•
from the window. Enter the VIN. Select "Finish" after completing the last step.
f. Unplug the scan tool from the Data Link Connector.
g. At the "Vehicle Disconnected" screen, press "OK".
h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home"
screen.
16. Is the vehicle is equipped with a 3.7L or 4.7L engine?
17. Using the StarSCAN® or equivalent at the "Home" screen:
b. Scroll through the list of controllers and highlight the ECM.
c. Select "Misc. Function".
d. Highlight "Learn ETC".
e. Select "Start"
f. Follow the on screen instructions. Select "Nextt' after each step. Select "Finish" after completing the last step.
NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM,
etc.) within the vehicle, if so equipped. Some OTC's may cause the MIL to illuminate. Check an modules
using "ECU View" from the Home screen, record the OTC's, and erase these OTC~s prior to returning the
vehicle to the customer. Erase any OTC's in the ECM only after all other modules have had their OTC's
erased.
NOTE: The following step is required by law.
18. Type the necessary information on the "Authorized Modification Label" pin 04275086AB and attach near the
VECI label. **
POWERTRAIN VERIFICATION TEST
Diagnostic Test
1. POWERTRAIN VERIFICATION TEST

1. the DTC before continuing.
2. Check if any of the following conditions exist.
3. The ECM has been disconnected or replaced.
4. The battery power has been disconnected.
5. If the ECM has been replaced, do the following:
6. Record injector correlation codes.
7. For ABS and Airbag Systems: Action: Enter correct VIN and Mileage in ECM. Erase ABS and Airbag Module
codes.
NOTE: If the Engine Control Module has been replaced and the correct VIN and mileage have not been pro-
grammed, a DTC will be set in the ABS, Airbag Modules and SKIM module.
8. If the ECM has not been replaced, do the following.
9. Inspect the vehicles to ensure that all engine components are connected. Reassemble and reconnect compo-
nents as necessary.
10. Attempt to start the engine.
11. If the engine is unable to start, look for any Technical Service Bulletins that may relate to this condition. Return
to Symptom list if necessary.
12. if this verification procedure is being performed after a No Trouble Code repair, do the following.
13. Check to see if the initial symptom still exists. If the initial or another symptom exists, the repair is not complete.
Check all pertinent Technical Service Bulletins and return to the Symptom list if necessary.
14. If this verification procedure is being performed after a Trouble Code repair, do the following.
15. Connect the scan tool to the data link connector and erase trouble codes.
16. With the scan tool, reset all memory values.
17. If this test is for an AlC trouble code, ensure it is operating during the following road test.
18. Drive the vehicle for at least five minutes, For some of the drive, go at least 64 km/h (40 MPH). At some point
stop the vehicle and turn the engine off for 10 seconds or more; then restart and continue. Ensure the transmission
shifts through all gears.
19. Upon completion of the road test, turn the engine off and read trouble codes with the scan tool. If a trouble code
has been set, return to the Symptom list and follow the path specified.
Are any DTC(s) present?
Yes »Repair is not complete. refer to appropriate symptom.
No »Repair is complete.
DR - - - - - - - - - - ENGINE - 6.7l DIESEL - SERVICE INFORMATION 9 - 2973
ENGINE • 6.7L DIESEL • SERVICE INFORMATION
TABLE OF CONTENTS
page page
ENGINE - 6.7L DIESEL - SERVICE INSPECTION ............................... 3017

INFORMATION INSTALLATION
DESCRIPTION ............................. 2975 ROCKER HOUSiNG ....................... 3017
DIAGNOSIS AND TESTING CYLINDER HEAD COVER ................. 3018
ENGINE DIAGNOSIS - MECHANICAL ....... 2975 CYLINDER HEAD COVER GASKET ........ 3019
SMOKE DIAGNOSIS CHARTS ............. 2978 VALVES & SEATS-INTAKE/EXHAUST
CYLINDER COMPRESSION/LEAKAGE DESCRiPTION ............................. 3020
TESTS .................................. 2981 STANDARD PROCEDURE
STANDARD PROCEDURE VALVES, GUIDES AND SPRINGS .......... :3020
FORM-IN-PLACE GASKETS AND SEALERS. 2983 VALVE LASH ADJUSTMENT AND
REPAIR DAMAGED OR WORN THREADS .. 2984 VERIFICATION .......................... 3025
HYDROSTATIC LOCK ..................... 2984 REMOVAL - VALVE SPRINGS .............. 3026
REMOVAL - ENGINE ........................ 2985 INSTALLATION ............................. 3028
INSTALLATION ENGINE ................... 2989
M ARM-ROCKER
SPECIFICATIONS DESCRIPTION ............................. 3029
SPECIFICATIONS - 6.7l DIESEL ........... 2993 REMOVAL ................................. 3029
TORQUE ................................. 2996 CLEANING ................................. 3030
SPECIAL TOOLS INSPECTION ............................... 3030
6.7L DIESEL ENGINE ..................... 2998 INSTALLATION ............................. 3031
PLATE-ENGINE DATA ENGINE BLOCK
DESCRIPTION ............................. 3001 STANDARD PROCEDURE
ELEMENT-AIR CLEANER CYLINDER BLOCK REFACING ............. 3033
REMOVAL ................................. 3002 CYLINDER BORE - DE-GLAZE ............. 3033
INSTALlATION ............................. 3003 OVERSIZE BORE ......................... 3034
AIR CLEANER HOUSING CAM BORE REPAIR ...................... 3035
REMOVAL INSPECTION ............................... 3035
INSTALLATION ........................... 3004 CAMSHAFT & BEARINGS (IN BLOCK)
INSTALLATION ............................. 3004 REMOVAL
BREATHER-CLOSED CRANKCASE CAMSHAFT BEARINGS ................... 3037
DESCRIPTION ............................. 3005 CAMSHAFT .............................. 3037
REMOVAL ................................. 3006 INSPECTION ............................... 3039
INSTALLATION INSTALLATION
FILTER ELEMENT INSPECTION ........... 3006 CAMSHAFT BEARINGS ................... 3041
CYLINDER HEAD CAMSHAFT .............................. 3041
DESCRIPTION ............................. 3008 BEARINGS - CONNECTING ROD
REMOVAL ................................. 3008 STANDARD PROCEDURE
CLEANING CONNECTING ROD BEARING AND
CYLINDER HEAD ......................... 3010 CRANKSHAFT JOURNAL CLEARANCE .... 3043
CROSSHEADS ........................... 3010 CRANKSHAFT & GEAR
PUSH RODS .............................. 3010 DESCRIPTION ............................. 3044
INSPECTION REMOVAL GEAR .......................... 3044
CYLINDER HEAD ......................... 3011 INSTALLATION - GEAR ..................... 3044
CROSSHEADS ........................... 3011 BEARINGS - CRANKSHAFT MAIN
PUSH RODS .............................. 3012 STANDARD PROCEDURE
INSTALLATION ............................. 3012 MAIN BEARING CLEARANCE .............. 3045
COVER-CYLINDER HEAD SEAL - CRANKSHAFT OIL - FRONT
REMOVAL REMOVAL ................................. 3047
ROCKER HOUSiNG.......... . .......... 3016 INSTALLATION ............................. 3048
CYLINDER HEAD COVER ................. 3016 SEAL - CRANKSHAFT OIL - REAR
CYLINDER HEAD COVER GASKET ........ 3017 REMOVAL ................................. 3050
CLEANING ................................. 3017 INSTALLATION ............................. 3050
9 - 2974 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
RETAINER - CRANK REAR OIL SEAL INSTALLATION ............................. 3077

REMOVAL ................................. 3051 FILTER~ENGINE OIL
INSTALLATION ............................. 3051 REMOVAL ................................. 3079
TAPPETS - VALVE INSTALLATION ............................. 3079
REMOVAL ................................. 3053 OIL pAN-GASKET
CLEANING ................................. 3054 REMOVAL ................................. 3080
INSPECTION ............................... 3054 INSTALLATION ............................. 3080
INSTALLATION ............................. 3054 PAN - ENGINE OIL
PISTON & CONNECTING ROD REMOVAL ................................. 3081
DESCRIPTION ............................. 3057 CLEANING ................................. 3082
STANDARD PROCEDURE INSPECTION ............................... 3082
HEAD GASKET SELECTION ............... 3057 INSTALLATION ............................. 3082
REMOVAL ................................. 3058 VALVE-OIL PRESSURE RELIEF
CLEANING ................................. 3058 REMOVAL ................................. 3084
INSPECTION CLEANING ................................. 3084
PISTONS ................................ 3058 INSPECTION ............................... 3084
CONNECTING ROD ....................... 3060 INSTALLATION ............................. 3084
INSTALLATION ............................. 3060 SWITCH-OIL PRESSURE
RINGS~PISTON REMOVAL ................................. 3085
STANDARD PROCEDURE INSTALLATION ............................. 3085
PISTON RING FITTING .................... 3062 PUMP-ENGINE OIL
DAMPER-CRANKSHAFT REMOVAL ................................. 3086
REMOVAL ................................. 3064 CLEANING ................................. 3086
INSPECTION ............................... 3064 INSPECTION ............................... 3086
INSTALLATION ............................. 3064 INSTALLATION ................... , ......... 3087
MOUNT-FRONT MANIFOLD ~ INTAKE
REMOVAL ................................. 3065 REMOVAL ................................. 3089
INSTALLATION ............................. 3066 CLEANING ................................. 3089
MOUNT-REAR INSPECTION ............................... 3089
REMOVAL ................................. 3067 INSTALLATION ............................. 3089
INSTALLATION ............................. 3069 MANIFOLD ~ EXHAUST
LUBRICATION REMOVAL ................................. 3091
DESCRIPTION ............................. 3072 CLEANING ................................. 3091
OPERATION ............................... 3072 INSPECTION ............................... 3091
DIAGNOSIS AND TESTING INSTALLATION ............................. 3091
ENGINE OIL PRESSURE .................. 3074 VALVE TIMING
OIL STANDARD PROCEDURE
STANDARD PROCEDURE TIMING VERIFiCATION .................... 3093
ENGINE OIL LEVEL ....................... 3075 CASE - FRONT
ENGINE OIL SERViCE .................... 3075 REMOVAL ................................. 3094
COOLER-ENGINE OIL & LINES INSTALLATION ............................. 3095
REMOVAL - OIL COOLER .................. 3077 COVER - TIMING
CLEANING REMOVAL ................................. 3097
CLEANING AND INSPECTION ............. 3077 INSTALLATION ............................. 3097
DR - - - - - - - - - - - ENGINE - 6.7l DIESEL - SERVICE INFORMATION 9 - 2975
ENGINE - 6.7L DIESEL - SERVICE INFORMATION

DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longitu-
dal ribs for superior strength and noise reduction. The
block incorporates metric straight thread O-ring fittings
at lubrication oil access points. The engine is manu-
factured with the cylinders being a non-sleeved type
cylinder.
B192c264
The cylinders are numbered front to rear; 1 to 6. The

firing order is 1-5-3-6-2-4.
J9409· 107

ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL 1. Low oil level. 1. (a) Check and fill with clean engine oil.
PRESSURE LOW
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong 2. (a) Verify the correct engine oil is being
specification. used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
9 • 2976 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
(b) Look for reduced viscosity from fuel

dilution.
3. Improperly operating pressure 3. Verify the pressure switch is functioning
switch/gauge. ·correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. CheCk/replace valve.
6. If cooler was replaced, shipping 6. Check/remove shipping plugs.
plugs may have been left in cooler
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings 10. Inspect and replace connecting rod or
installed. main bearings. Check and replace directed
piston cooling nozzles.
11. Directed piston cooling nozzles 11. Check directed piston cooling nozzles
under piston, bad fit into main position.
carrier.
12. Loose oil rifle plug with saddle-jet 12.Tighten oil rifle plug.
styJe nozzles
13. Loose directed piston cooling 13. Tighten directed piston cooling nozzle.
nozzle.
14. Both J-jet and saddle jet style 14. ~nstall correct style jet.
cooling nozzle installed.
LUBRICATING OIL 1. Pressure switch/gauge not 1. Verify pressure switch is functioning

PRESSURE TOO HIGH operating properly. correctly. If not. replace switch/gauge.
2. Engine running too cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING ~
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck 4. Check and replace valve.
closed or bir'!ding
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or 3. (a) Make sure the correct oil is being
viscosity. used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES-
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. on cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the 5. Check the breather tube area for signs of
breather. oil loss. Perform the required repairs.
DR - - - - - - - - - - ENGINE .. 6.7L DIESEL - SERVICE INfORMATION 9 - 2977
6. Turbocharger leaking oil to the air 6. Inspect the air ducts for evidence of oil
intake. transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline 2. Verify by operating from a temporary
contaminated fuel. tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 4. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.

2. Damaged fan or improperly 2. Check and replace the vibrating
operating accessories. components.
3. Improperly operating vibration 3. Inspect/replace vibration damper.
damper
4. Improperly operating electronically 4. Inspect/replace fan drive.
controlled viscous fan drive.
5. Worn or damaged generator 5. Check/replace generator.
bearing.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power 7. Inspect the crankshaft and rods for
component. damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline 8. Check/repair driveline components.
components.
EXCESSIVE ENGINE 1. Drive belt squeal, insufficient 1. Check the automatic tensioner and
NOISES tension or abnormally high loading. inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
Check for proper operation of over running
alternator pulley.
2. Intake air or exh~ust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
7. High Pitched Squeal. #7. Using soapy water solution check the
EGR cooler to exhaust manifold joint.
Check all clamps and hoses on the
pressure side of the turbocharger
9 .. 2978 ENGINE .. 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
OFF-IDLE ENGINE SPEED LOW DURING COLD START

Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the
maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maxi-
mum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission
selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine
speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the
engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is
controlled to a low speed. This delay in maximum engine and turbocharger shaft speed allows for sufficient oil lubri-
cation to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important
for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600
RPM's when the above conditions are met. The 6.7l engine speed is temporarily limited to 1,200 RPM's when the
above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent
upon engine coolant temperature. Refer to the table to determine the amount of Time Delay.
NOTE: The time delay values supplied in the table are an approximation and may vary per application.

- 35° F (-37°C) 45.2 sees.
- 20° F (-28°C) 34.6 sees.
- 10° F (-23°C) 28.8 secs.
- 0° F (-17°C) 24.2 secs.
+ 10° F (-12°C) 20.2 secs.
+ 20° F (-7°C) 17.0 secs.
+ 35° F (2°C) 13.0 secs.
+ 45° F (7°C) 10.8 sees.
+ 55° F (13°C) 9.0 secs.
+ 70° F (21°C) 7.0 secs.
SMOKE DIAGNOSIS CHARTS

The following charts include possible causes and corrections for excess or abnormal exhaust smoke. Small
amounts of white smoke or water vapor (at certain times) are to be considered normal for a diesel powered engine.
NOTE: Visible black smoke at the tail pipe is an indication of an aftertreatment (diesel particulate filter) fail-
ure. Follow inspection/replacement guidelines in the exhaust section of the service manual to correct after..
treatment failure. The diesel particulate filter MAY have failed due to the possible causes listed below.
EXCESSIVE BLACK SMOKE

POSSIBLE CAUSE CORRECTION
Aftermarket components installed. Inspect for aftermarket components or evidence of
modifications
Air filter dirty or plugged. Check Filter Minder® at air filter (Refer to 9 .. ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT-
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system (Refer to 11 - EXHAUST
SYSTEMITURBOCHARGER SYSTEM/CHARGE AIR
COOLER AND PLUMBING .. DIAGNOSIS AND
TESTING) including all hoses and tubes for cracks,
loose clamps and/or holes in rubber ducts. Also check
intake manifold for loose mounting hardware.
DR - - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 • 2979
EXCESSIVE BLACK SMOKE

Diagnostic Trouble Codes (DTC's) active or multiple, Refer to Powertrain Diagnostic Procedures Information.
intermittent DTC's.
Engine Control Module (ECM) not calibrated or ECM Refer to Powertrain Diagnostic Procedures Information.
calibration out of date. Check for Technical Service Bulletin (TSB) updates.
Exhaust system restriction is above specifications. Check exhaust pipes for damagelrestrictions. Repair as
necessary.
Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary. Refer to Owners manual for
proper fuel specifications.
Fuel injector malfunctioning. A DTC may have been set. Perform "Cylinder
Performance Test" or "Cylinder Cutout Test" using scan
tool to isolate individual cylinders. Also refer to
Powertrain Diagnostic Procedures Information and, to
(Refer to 9 - ENGINE· DIAGNOSIS AND TESTING).
Fuel injection pump malfunctioning. A DTC may have been set. If so, refer to Powertrain
Diagnostic Procedures Information.
Fuel return system restricted. Check fuel return lines for restriction (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
Intake manifold restricted. Remove restriction. Remove the intake air horn to
inspect for grid heater fouling, inspect the EGR airflow
control valve to ensure valve is in the open position
Raw fuel in intake manifold. Fuel injectors leaking on Fuel injectors leaking on engine shutdown. Do Fuel
engine shutdown. Injector Test (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. Turbocharger damaged. (Refer to 11 - EXHAUST
SYSTEMrrURBOCHARGER SYSTEM/
TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor (Refer to 11 - EXHAUST SYSTEMrrURBOCHARGER
wheel and/or diffuser vanes. SYSTEMrrURBOCHARGER - CLEANING).
Turbocharger externally damaged. Check for excessive oil in compressor and/or turbine
housing and in turbocharger exhaust pipe. (Refer to 11
- EXHAUST SYSTEMrrURBOCHARGER SYSTEM/
TURBOCHARGER - INSPECTION).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEMrrURBOCHARGER
SYSTEMrrURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE

Aftermarket components installed. Inspect for aftermarket components or evidence of
modifications
Diagnostic Trouble Codes (DTC's) active or multiple, Refer to Powertrain Diagnostic Procedures Information.
intermittent DTC's. Check for TSBs
Intake manifold heater circuit not functioning correctly in A DTC should have been set. Refer to Powertrain
cold weather. Diagnostic Procedures Information. Also check heater
elements for correct operation.
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
In cold ambient temperatures, engine block heater is (Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
malfunctioning (if equipped). HEATER - REMOVAL).
EXCESSIVE WHITE SMOKE

Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration. A DTC should have been set.
Refer to Powertrain Diagnostic Procedures Information.
Engine Control Module (ECM) not calibrated or has A DTC should have been set. Refer to Powertrain
incorrect calibration. Diagnostic Procedures Information. Perform fuel
injection pump performance test.
Low supply flow to the injection pump. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary. Refer to owners manual for
correct fuel specification.
Fuel heater element or fuel heater temperature sensor Refer to Fuel Heater Testing (Refer to 14 - FUEL
malfunctioning. This will cause wax type build-up in fuel SYSTEM/FUEL DELIVERY/FUEL HEATER -
filter. DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform the cylinder
cut-out test using the Scan Tool to isolate individual
cylinders. If unable to isolate individual cylinder, perform
Injector Return Flow Test to identify failed injector or
fuel connector tube. In the event that return flow is
normal, use the injector blocking tool (tool #9864), to
block the high pressure fuel line at the rail one at a
time. This test may isolate and injector nozzle that is
leaking fuel into the cylinder. Also refer to Powertrain
Diagnostic Procedures Information and, (Refer to 9 -
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Perform fuel injection
pump performance test in section 14.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
c Procedures Information.
I -
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
NOTE:
Visible blue smoke at the tail pipe is an indication of an aftertreatment (diesel particulate filter) failure. Follow
inspection/replacement guidelines in the exhaust section of the service manual to correct aftertreatment failure. The
diesel particulate filter MAY have failed due to the possible causes listed below.
EXCESSIVE BLUE SMOKE

Dirty air cleaner or restricted turbocharger intake duct. Check Filter Minder® at air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEADIINTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEMITURBOCHARGER
SYSTEMITURBOCHARGER - DIAGNOSIS AND
TESTING)
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
CYLINDER COMPRESSION/LEAKAGE TESTS

CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the
indicated compression pressures may not be valid for diagnostic purposes.
1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank.
NOTE: Failure to plug fuel line will result in fuel leak.
2. Remove fuel transfer pump relay from PDC.

3. Start the engine and idle until the engine stalls (runs out of fuel).
4. Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL)
9 .. 2982 ENGINE .. 6.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
5. Remove the cylinder head cover carrier gasket. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL}
6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool
9864 to cap this fuel rail on the cylinder being tested.
7. Remove the fuel connector tube nut and fuel connector tube.
8. Remove the exhaust rocker lever.
9. Use Tool 9010 to remove the injector and copper sealing washer.
10. Install the exhaust rocker lever and torque to 36 N·m (27 ft. Ibs.).
11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood.
12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may
have drained into the cylinder when the injector was removed.
13. Connect the compression test gauge.
14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the
average of the three readings.
NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 200/0 from cylinder to
cylinder.
15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leak-
age test procedure on each cylinder according to the tester manufacturer instructions.
16. Upon completion of the test check and erase any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE

The combustion pressure leakage test provides an accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water jacket.
• Any causes for combustion/compression pressure loss
1. Start and operate the engine until it attains normal operating temperature.
2. Disconnect injector harness connectors.
3. Disconnect CCV tube and breather drain tube from valve cover.
4. Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL)
5. Disconnect harness from injectors.
6. Remove the cylinder head cover carrier gasket. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
7. Bring the cylinder to be tested to TDC.
8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested.
9. Install capping Tool 9864 onto the rail.
10. Remove the high pressure connector nut and high pressure connector with Tool 9015.
11. Remove the exhaust and intake rocker lever.
12. Use Tool # 9010 to remove the injector and copper sealing washer.
13. Install compression test Tool # 9007 into the' injector bore.
14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester
manufacturer's instructions.
15. Upon completion of the test check and erase any engine related fault codes.
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 • 2983
STANDARD PROCEDURE
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when apply-
ing form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material
unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage
while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the
proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV
GEN II. Mopar® ATF-RTVI and Mopar® Gasket Maker gasket materials, each have different properties and can not
be used in place of the other.
MOPAR® ENGINE RTV GEN II
Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a speciaUy designed
black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the
air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After
one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPAR® ATF RTV
Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties
to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is avail-
able in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always
inspect the package for the expiration date before use.
MOPAR® GASKET MAKER
Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when
squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for
use between two machined surfaces. Do not use on flexible metal flanges.
MOPAR® GASKET SEALANT
Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing
threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts
under all temperatures. This material is used on engines with multi-fayer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 40z.l16 oz. can
w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION

Assembling parts using a form-in-place gasket requires care but it's easier than using precut gaskets.
Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3
mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 114 in.)
drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Com-
ponents should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to prevent smearing material off the location.
Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both
surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can
be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-
layer steel gaskets.
REPAIR DAMAGED OR WORN THREADS

CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consists of:
• Drilling out worn or damaged threads.
• Tapping the hole with a special Helj-Coli Tap, or equivalent.
• Installing an insert into the tapped hole to bring the hole back to its original thread size.
HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem). follow the steps below.
1. Disconnect the negative cable(s) from the battery.
2. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
3. Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cyl-
inder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
4. With all injectors removed, rotate the crankshaft using the crankshaft barring tool (PN 7471-B).
5. Identify the fluid in the cylinders (coolant. fuel, oil, etc.).
6. Be sure all fluid has been removed from the cylinders.
7. Repair engine or components as necessary to prevent this problem from occurring again.
8. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
9. Install fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
10. Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
11. Install the drain plug. Tighten the plug to 50 N·m (37 ft. Ibs.) torque.
12. Install a new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
13. Fill engine crankcase with the specified amount and grade of oil (Refer to LUBRICATION & MAINTENANCE!
FLUID TYPES - SPECIFICATIONS).
14. Connect the negative cable(s) to the battery.
15. Start the engine and check for any leaks.
DR - - - - - - - - - - ENGINE .. 6.7l DIESEL - SERVICE INFORMATION 9 .. 2985
REMOVAL - ENGINE
1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid
heater relay.
3. Disconnect electrical connections from rear of alter-
nator.
4. Recover AlC refrigerant. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Raise vehicle on a hoist.
6. Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50 N·m (37 ft. Ibs.)
torque.
9. Lower the vehicle.
10. Remove fan (3) and fan drive (2). Refer to (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
8131cea6
11. Remove fan shroud mounting bracket (3) and

shroud. Refer to (Refer to 7 - COOLING/ENGINE!
RADIATOR FAN - REMOVAL).
12. Remove radiator upper hose.
13. Disconnect the coolant recovery bottle hose from
the radiator fill neck.
14. Disconnect heater core supply and return hoses
from the cylinder head fitting and coolant pipe.
15. Raise vehicle on a hoist.
16. Remove transmission and transfer case (if
equipped).
17. Disconnect exhaust pipe from turbocharger exten-
sion pipe.
18. Disconnect engine harness to vehicle harness
connectors.
9 • 2986 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
19. Remove starter motor (2) (Refer to 8 - ELECTRI-

CAUSTARTING/STARTER MOTOR - REMOVAL).
20. Remove flywheel/flexplate.
21. Remove transmission adapter.
22. Disconnect AlC suction/discharge hose from the
rear of the Ale compressor.
23. Lower vehicle.
24. Disconnect lower radiator hose from radiator out-
let.
25. Automatic transmission models:
26. Disconnect transmission oil cooler lines from in
front of radiator using special tool #6931
27. Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
28. If AlC equipped, disconnect AlC condenser refrig-
erant lines.
29. Disconnect charge air cooler piping.

30. Remove charge air cooler mounting bolts {1}.
31. Remove charge air cooler {2} from vehicle.
a087e199
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 - 2987
32. Remove the AlC condenser (1).

33. Remove damper from front of engine.
34. Remove lower fan shroud bracket (3) from

engine.
35. Remove upper fan shroud brackets from engine.
36. Disconnect engine block heater connector.
37. Disconnect AlC compressor and pressure sensor
electrical connectors.
38. Remove the passenger battery ground cable from
the engine block. Remove the driver side battery
ground cable from the engine block.
39. Remove power steering pump from engine by
removing 3 bolts.
40. Disconnect the ECM power connector.
41. Disconnect the fuel supply and return hoses.
9 .. 2988 ENGINE· &.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
42. Remove the cylinder head cover (1). (Refer to 9 -

ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
43. Disconnect the wire harnesses from the injectors
(3).
44. Remove the cylinder head cover carrier gasket
(2).
NOTE: Extreme care should be used to keep dirtJ

debris from entering the fuel lines. Plastic caps
should be used on the ends of the fuel lines.
45. Loosen # 6 fuel line shield bolts and rotate shield

out of the way.
46. Remove cylinder # 5 and # 6 high pressure fuel
lines.
47. Remove the rear engine lift bracket
48. Remove cylinder # 4, # 5, and # 6 intake and

exhaust rocker arms (1), pedestals (2), and push
tubes. Note the original location for reassembly.
49. Remove the fuel connector tube nut and fuel con-
nector tube. Remove cylinder # 5 and # 6 fuel
injector.
50. Remove rocker housing.
8Ob46d23
DR - - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 - 2989
51. Remove two cylinder head bolts (1) according to

the diagram and install Tool # 9009 (2). Torque
bolts to 105 N·m (77 ft. Ibs.).
52. Loosen but do not remove engine mount through
bolts and nuts.
53. Disconnect hood support struts and position hood
out of the way.
54. Attach a chain with two hooks to the engine lift
brackets.
55. While keeping engine level, lift straight up out of
the mounts.
56. Rotate nose of engine upward and pull out of
chassis.
8102e513
INSTALLATION - ENGINE
1. Remove cylinder head bolts (1,3) according to the
diagram. Install special Tool 9009 (2). Torque bolts
to 105 N·m (77 ft. Ibs.)
2. Lower engine into the engine compartment and
install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88
N·m (65 ft. Ibs) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install
into cylinder head.
6. Torque in 4 steps to:
• Step 1-Tighten to 70 N·m (52 ft. Ibs.) torque.
• Step 2-8ack off 360 0 •
• Step 3-Tighten to 105 N·m (77 ft. Ibs.) torque.
0
• Step 4-Rotate 90 •
8102e513
7. Install rocker housing. Torque to 24 N·m (18 ft. Ibs). Refer to (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
8. Replace injector o-ring and sealing washer on injectors # 5 and # 6. Install injectors and torque using the fol·
lowing steps:
• Step 1-lnstall injector hold-down capscrews and torque to 5 N·m (44 in. Ibs.) torque.
• Step 2-Loosen injector hold-down capscrews.
• Step 3-lnstall HPC connector tube and nut. Torque nut to 15 N·m (11 ft. Ibs.) torque.
• Step 4-Torque injector hold-down capscrews to 10 N·m (89 in. Ibs.) torque.
• Step 5-Torque HPC connector tube nut to 50 N·m (37 ft. Ibs.) torque.
9. Install rear engine lift bracket. Torque to 77 N·m (57 ft. Ib).
9 - 2990 ENGINE - 6.7l DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
10. Install # 5 and # 6 high pressure fuel lines. Follow correct torque sequence per section 14. Torque fuel line
fittings to 40 N·m (35 ft. Ib).
11. Install push tubes, rocker arms (1), and pedestals
(2) for cylinders # 4, # 5, and # 6. Torque the
mounting bolts to 36 N·m (27 ft. Ibs).
12. Reset valve lash on cylinders # 4, # 5, and # 6.
Torque adjusting nuts to 24 N·m (18 ft. Ibs).
13. Set the valve lash for the intake valve at 0.254
(.010 in. Ibs.) and exhaust valve at 0.66 mm (.026
in. Ibs).
14. Install injector wiring/gasket.
8Ob46d23
814b3452
15. Install cylinder head cover carrier gasket (2).

16. Connect injector harness nuts to injectors (1). Torque to 1.25 N·m (11 in. Ibs. )
17. Connect injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
DR - - - - - - - - - - ENGINE .. 6.7L DIESEL .. SERVICE INFORMATION 9 .. 2991
18. Install cylinder head cover (1) (Refer to 9 -

COVER(S) - INSTALLATION).
19. Connect CCV tube (4) and lube oil drain tube (2)
to cylinder head cover (1).
t d/
'-...::.~ I
20. Connect fuel supply and return hoses.

21. Connect ECM power connector.
22. Install the power steering pump.
23. Install the damper. Torque to 40 N·m (30 ft. Ib)
plus 60 degrees.
24. Install lower fan shroud bracket (3). Torque to 24
N·m (18 ft. Ib).
9 - 2992 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - - DR
25. Install upper fan shroud brackets, but do not

tighten fasteners at this time.
26. Connect the engine block heater connection.
27. Connect the AlC compressor and pressure sensor
connectors
28. Install the charge air cooler (2). Install and tighten
the charge air cooler mounting bolts (1) to 2 N·m
(17 in. Ibs).
29. Connect the charge air cooler tubes (4). Torque all
clamps to 8 N·m (72 in. Ibs).
80876199
30. Install the alc condenser (1).

31. Connect the alc refrigerant lines to the alc con-
denser.
32. Install the radiator upper support panel.
33. Install radiator.
34. Connect the transmission quick-connect oil cooler
lines.
35. Raise vehicle.
36. Connect alc compressor suction/discharge hose
(if equipped).
37. Install the radiator lower hose and clamps.
38. Install the battery negative cables to the engine
block on the driver and passenger side.
39. Install the transmission adapter with a new cam-
shaft rectangular ring seal. Torque to 77 N·m (57
ft. Ib).
40. Install the flywheel and adapter or flexplate. Torque to 137 N·m (101 ft. Ib).
NOTE: If the engine is equipped with a flexplate or crankshaft adapter, a new clamp ring must be used. If
the engine has a flywheel with washers, the washers can be reused.
41. Install the starter motor (2). Torque to 43 N·m (32 ft. Ib). (Refer to 8 - ELECTRICAUSTARTING/STARTER
MOTOR - INSTALLATION).
42. Connect engine to vehicle harness connectors.
43. Install the transmission and transfer case (if equipped).
44. USing a new clamp, connect the exhaust pipe to the turbocharger elbow.
45. Connect the transmission auxiliary oil cooler lines (if equipped).
47. Connect the heater core supply and return hoses.
48. Install the cooling fan (3) and fan drive (2). (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
6Blcea6
49. Install the fan shroud mounting bracket (3) and

shroud. (Refer to 7 - COOLING/ENGINE/RADIA-
TOR FAN - INSTALLATION).
50. Install the windshield washer bottle.
51. Install the upper radiator hose and clamps.
52. Raise vehicle.
53. Change oil filter and install new engine oil.
54. Fill the cooling system with coolant. (Refer to 7 -
COOLING - STANDARD PROCEDURE).
55. Connect grid heater harness at grid heater relay.
56. Connect electricar connections to rear of alterna-
tor.
57. Start the engine and inspect for engine oil cool-
t
ant. and fuel leaks.
SPECIFICATIONS
SPECIFICATIONS - 6.7L DIESEL
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cyl. Turbo Diesel
Displacement 6.7 Liters
409 ( Cubic Inches)
Bore 107.0 mm (4.21 in.)
9 - 2994 ENGINE - 6.7L DIESEL· SERVICE INFORMATION - - - - - - - - - - DR
Stroke 124.0 mm (4.88 in.)
Compression Ratio 17.2:1
Cylinder Pressure (Minimum) 350 psi.
Horsepower High Output 68 RE Aff and G 56 MIT 350 HP @ 3013 RPM
Torque Rating High Output ( 68RE AIT and G 56 MIT) 650 LB-FT @ 1400 RPM
Lubrication System Pressure Feed-Full Flow With Bypass Valve
Firing Order 1-5-3-6-2-4
Cylinder Block Cast Iron
Crankshaft Induction Hardened Forged Steel
Cylinder Head Cast Iron With Valve Seat Inserts
Combustion Chambers High Swirl Bowl
Camshaft Chilled Ductile rron
Pistons Cast Aluminum
Connnecting Rods Cross Rolled Micro Alloy
PISTONS
Metric Standard
Skirt Diameter 107.255 - 107.273 mm 4.226 - 4.2233 in.

(Measure the skirt 21.5 mm (0.84
in) from the bottom of the piston)
Ring Groove Clearance

Intermediate (Min)' 0.040 mm .0016 in
(Max) 0.110 mm 0.0043 in.
Oil Control ( Min) 0.040 mm .0016 in.
(Max) 0.085 mm .0033 in.
PISTON PINS
Metric Standard
Pin Diameter ( Min) 39.997 mm 1.5747 in.
(Max) 40.003 mm 1.5749 in.
Bore Diameter (Min) 40.006 mm 1.5750 in.
(Max) 40.012 1.5753 in.
PISTON RINGS
Metric Standard
Ring Gap The top piston ring is not measured The clearance for the top piston ring
due to the type of piston ring used. can not be measured accurately
with a typical feeler gauge.
Top Ring 0.30 - 0.46 mm 0.012 - 0.018 in.
DR - - - - - - - - - - ENGINE· 6.7L DIESEL· SERVICE INFORMATION 9 • 2995
Intermediate 0.82 - 1.18 mm 0.032 - 0.047 in.

Oil Control 0.22 - 0.58 mm 0.010 - 0.023 in.
CONNECTING RODS
Metric Standard
Pin Bore Diameter (Min. wi bushing 40.019 mm 1.5764 in.
installed)
Pin Bore Diameter (Max. wi bushing 40.042 mm 1.5765 in.
installed)
Side Clearance (Min) 0.100 mm 0.004 in.
Side Clearance (Max) 0.330 mm 0.013 in.
CYLINDER HEAD
Overall Flatness End To End (max) 0.305 mm (0.012 in.)
Overall Flatness Side To Side (Max) 0.076 mm (0.003 in.)
Intake Valve Seat Angle 30°
Exhaust Valve Seat Angle 45°
Valve Stem Diameter
(Min) 6.96 mm (0.2740 in.)
(Max) 7.01 mm (0.2760 in.)
Valve Rim Thickness (Min.) 0.79 mm (0.031 in.)
Injector Protrusion
mm in
2.45 MIN 0.96
3.15 MAX 0.124
Injector Protrusion
NOTE:
Do NOT use thicker or double stacked injector sealing washers to correct injector protrusion. This will cause
misalignment of the high pressure fuel connector.
I
OIL PRESSURE
SPECIFICATION SPECIFICATION
At Idle 69 kPa (10 psi)
@ 2500 rpm 207 kPa (30 psi)
Regulating Valve Opening Pressure 517 kPa (75 psi)
Oil Filter Bypass Pressure Setting 344.75 kPa (50 psi)
9 .. 2996 ENGINE .. 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - - DR
TORQUE
TORQUE CHART 6.7l DIESEL ENGINE
DESCRIPTION N·m In. Lbs. fFt.Lbs.

Connecting Rod-Bolts
Step 1 30 - 22
Step 2 60 - 44
Step 3 Rotate 60 degrees

CAUTION:
The 5.9L and 6.7l engine has different torque procedures for new and previously installed main bearing
capscrews. Failure to use the correct torque procedure can result in engine damage.
Crankshaft Main Cap-Bolts (Previously Used)
Step 1 60 44
Step 2 80 59
Step 3 Rotate 90°

Crankshaft Main Cap-Bolts (New Main Bearing Capscrews) N·m In. Lbs. Ft. Lbs.
Step 1 120 - 89
Loosen Loosen
Step 2 -
completely completely
Step 3 60 - 44
Step 4 85 - 63
Step 5 Rotate 120 0
Cylinder Head-Bolts
Step 1 70 - 52
Step 2 Back off 360 degrees
Step 3 105 - 77
Step 4 Verify 105 - 77
Step 5 Rotate All Bolts 114 Turn

Cylinder Head Cover Bolts 24 - 18
Breather Cover Bolts 10 89 -
HPC Nut 50 - 37
Flexplate to Engine 137 - 101
Flywheel to Engine ( NV 5600 ) 137 - 101
Flywheel/Cran kshaft Adapter 137 - 101
G 56 Dual Mass Flywheel

Fuel Delivery Lines-Banjo 24 - 18
Fuel Drain Line-Banjo 24 - 18

Fuel line-rail to cylinder head 40 - 30
Fuel line-pump to fuel rail 37 - 27
Fuel rail holddown bolt 24 - 18
Oil Pan-Bolts 28 - 21
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMA"I"ION 9 - 2997
DESCRIPTION N·m In. Lbs. Ft. Lbs.
Oil Pan-Drain Plug 50 - 37

Oil Pressure Regulator-Plug 80 - 59
Oil Pressure Switch to block fitting 18 - 13
Oil Pressure Switch to block fitting to block 30 - 22
Oil Pump-Bolts
Step 1, Push the pump firmly against the cylinder block while
installing all four (4) mounting bolts finger tight.
- - -
Step 2 8 - 6
Step 3 24 - 18
Oil Suction Tube (Flange)-Bolts 24 - 18
Oil Suction Tube (Brace)-Bolt 43 - 32
Rocker Arm/Pedestal-Bolts 36 - 27
SPECIAL TOOLS
6.7L DIESEL ENGINE
Adapter - 8462
Handle C-4171
Engine Support Fixture ... 8534

Crankshaft Barring Tool- 7471 - B
Crankshaft Front Oil Seal Installer ... 8281
~~.
%~
TAPPET INSTALLATION TOOL .. 8502
Valve Spring Compressor . . 8319A
Test Plug .. 8442 STEEL BRACKET .. 8534-A

Compression Test Adapter - 9007 FUEL TEST FITTING - 9013
Engine Lift Bracket - 9009 Fuel Injector Tube (Connector) Remover - 9015
Fuel Injector Remover - 9010 TURBO TEST ADAPTER - 9022
FUEL BLOCKOFF PLUG - 9864

9 .. 3000 ENGINE - 6.7L DIESEL - SERVICE ·INFORMATION - - - - - - - - - - DR
Charge Air Test Adspter- 9861 Wiring Harness Test Pins - 9865
Turbocharger Wrench - 9866

Fuel Pressure Test Adapter - 9863
Fuel Block Off Cap - 9864

DR - - - - - - - - - - ENGINE· 6.7L DIESEL· SERVICE INFORMATION 9 .' 3001
PLATE.. ENGINE DATA

DESCRIPTION
The engine data plate contains specific information
that is helpful to servicing and obtaining parts for the
engine. The data plate is on the cylinder head cover.
Information that can be found on the data plate
includes:
• Engine Part Number
• Date of Engine Manufacture
• Engine Serial Number
• Control Parts List (CPL)
• Engine Rated Horsepower
• Engine Firing Order
• Engine Displacement 8Ob4fb42
• Valve Lash Reset Specifications

If the engine data plate is missing or not legible, the engine serial number is used for engine identification. The
engine serial number is stamped on the right side of the block, on top of the oil cooler cavity.
9 • 3002 ENGINE· 6.7L DIESEL· SERVICE INFORMATION - - - - - - - - - - DR
ELEMENT-AIR CLEANER
REMOVAL
There is no longer a Filter Minder on the MYOa Diesel
Engines. There will be an EVIC message which will
display when the filter restriction reaches it's maxi-
mum. The customer will be required to replace it
with-in 250 miles (402 KM)
Filter Removal
1. The housing cover is equipped with spring clips
and is hinged with plastic tabs. Unlatch clips from
top of air cleaner housing and tilt housing cover up
for cover removal.
2. Remove air cleaner element from air cleaner hous-
ing (5).
80f340dd
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMA1'ION 9·3003
INSTALLA-rION
1. Before installing new air cleaner element (filter).
clean inside of air cleaner housing.
2. Position air cleaner cover to tabs on front of air
cleaner housing. Latch spring clips to seal cover to
housing.
80f3400d
9·3004 ENGINE· 6.7L DIESEL· SERVICE INFORMATION - - - - - - - - - - DR
AIR CLEANER HOUSING

REMOVAL
INSTALLATION
1. Disconnect. the MAF (2) sensor.
2. Disconnect the TBAP (3) sensor.
3. Remove the intake air tube from the throttle body.
4. Remove the intake air housing nut.
5. Lift entire housing assembly from 4 locating pins.
INSTALLATION
1. Position the housing assembly on the locating pins.
2. Install the housing nut and torque to 8 N.m (70 in.
Ibs).
3. Install the intake air tube.
4. Connect the TBAP (3) sensor.
5. Connect the MAF (2) sensor.
BREATHER-CLOSED CRANKCASE
DESCRIPTION
The Closed Crankcase Ventilation System (CCV) con-
sists of several parts to make it functional. One part is
the filter. The filter is serviceable and prevents oil mist
from entering the discharge tube of the CCV system.
It is not cleaned, but replaced at 60,000 mile intervals.
The crankcase breather assembly is integrated into
the cylinder head cover (3) and is serviced separately.
The external fittings (2) to the breather tube and
breather drain tube are serviceable.
The crankcase breather assembly is integrated into
the cylinder head cover and corresponding breather
cover. Crankcase gasses travel into the breather cav-
ity under the breather cover where they pass through
a filtering media (serviceable maintenance component)
which separates the oil from the crankcase gasses.
The oil drains back into the engine block through two
hoses (2) on the left side of the engine.
The crankcase gasses are directed through the Crank-
case Depression Regulator (CDR) valve which allows
the system to maintain a constant positive pressure in
the crankcase. The CDR valve is a non-serviceable
component located on the underside of the breather
cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor.
The closed crankcase ventilation valve is used to vent
the crankcase gases back into the intake of engine. If
the crankcase ventilation filter becomes too restrictive,
under high intake vacuum situations, the closed crank-
case ventilation prevents the engine from syphoning
crankcase gases/oil from the crankcase of the engine.
The closed crankcase ventilation valve is located
under the crankcase ventilation filter cover at the top
of the engine.
8 8
81a63022
TESTING
1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation
valve to close during engine operation:
• High air intake restriction. Check for high intake restriction
• A restricted crankcase ventilation filter. Change the filter
• A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change
if necessary
9·3006 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running
and/or removed from the engine.
NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve.
3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to
check the closed crankcase ventilation valve.
4. If air does not go through the closed crankcase ventilation valve, replace the valve.
REMOVAL
1. Remove any engine heat shields or EGR shields if
equipped.
2. Using hose clamp pliers, loosen the breather
plumbing from the breather cover connections.
3. Carefully remove the breather hoses (2) from the
breather cover assembly (3).
4. Remove the capscrews surrounding the parameter
of the breather cover (3).
5. Separate the breather cover (3) assembly from the
cylinder head cover (1).
FILTER ELEMENT REMOVAL

1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the
element straight up from its sealing surface.
INSTALLATION
FILTER ELEMENT INSPECTION
1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked.
2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for
cracks or damage.
3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abra-
sions.
FILTER ELEMENT INSTALLATION

1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel.
2. Install the new filter element, lubrication of the new sealing surface is not recommended.
3. Press the new filter into the cylinder head cover cavity until fully seated.
4. Install the breather cover assembly.
DR - - - - - - - - - - ENGINE· 6.7l DIESEL - SERVICE INFORMATION 9 - 3007
BREATHER COVER INSTALLATION
1. Inspect the filter element for proper installation. The

filter should be completely seated around the cir-
cumference of the sealing surface.
2. Install the breather cover to the cylinder head
cover.
3. Install the capscrews surrounding the breather
cover.
4. Install the breather drain hoses onto the hose
barbs. Do not damage or hose connection during
installation.
5. Install engine shields or covers if equipped.
9 - 3008 ENGINE· 6.7L DIESEL -. SERVICE INFORMATION - - - - - - - - - - DR
CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The
arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder
head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle,
which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened
intake and exhaust valve seat inserts.
REMOVAL
1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Remove the right engine mount. {Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - REMOVAL}
6. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from enter-
ing.
7. Lower vehicle.
8. Disconnect air inlet temperature/pressure sensor.
9. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of
dirt or foreign material.
10. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
11. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt
or foreign material.
12. Remove the turbocharger coolant lines.
13. Remove EGR cooler and associated hardware. (Refer to 7 - COOLING/ENGINE/EGR COOLER - REMOVAL)
14. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumb-
ing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
15. Remove cooling fan/drive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)
16. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
17. Remove cooling fan support from cylinder block.
18. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
19. Disconnect radiator upper hose from the thermostat housing.
20. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
21. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.
22. Remove the intake air grid heater wire from the grid heater.
23. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection ..
24. Remove the charge air cooler-to-air inlet housing pipe.
25. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
26. Remove the air inlet housing.
27. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be
used on the ends of the fuel Ii nes.
28. Remove the high pressure pump to fuel rail fuel line as follows:
a. Loosen fuel line nuts at fuel pump and at fuel rail.
b. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
29. Remove the fuel rail to cylinder head fuel lines as follows:
a. Loosen No. 6 high pressure fuel line shield and position out of way.
DR - - - - - - - - - - ENGINE .. 6.7L DIESEL" - SERVICE INFORMATION 9 - 3009
b. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
30. Remove the engine lift bracket from the rear of the cylinder head.
31. Remove the fuel rail as follows:
a. Remove fuel rail pressure sensor connector.
b. Remove banjo fitting at pressure limiting valve.
c. Remove fuel rail boJts and fuel rail.
32. Remove the low pressure lines as follows:
a. Remove the fuel drain banjo fitting on the front side of fuel filter housing.
b. Remove the fuel drain banjo fitting on rear side of fuel filter housing.
c. Remove the fuel drain line support bracket on rear side of filter housing.
d. Disconnect fuel drain hose.
e. Remove banjo fitting ,at bottom of fuel filter housing.
1. Disconnect fuel supply hose at fuel filter.
33. Disconnect fuel heater, and water in fuel sensor.
34. Remove the fuel filter assembly-to-cylinder head bolts and rem"ove filter assembly from vehicle.
35. Remove wire harness P-clip from cylinder head (located behind filter housing).
36. Remove the "breather cover and cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
37. Remove injector harness nuts from injectors.
81038916
38. Remove the rocker levers (1), cross heads and

push rods. Mark each component so they can be
installed in their original positions.
NOTE: The #5 cylinder exhaust and the #6 cylinder

intake and exhaust push rods are removed by lift·
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
8Ob4fa25
39. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2)
sealing washers.
40. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
41. Remove rocker housing bolts and rocker housing and gasket.
42. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 77 N·m (57 ft. Ibs.).
43. Starting on the outside and working towards the center, remove twenty six (26) cylinder head-to-block bolts.
44. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
45. Remove the head gasket and inspect for failure.
CLEANING
CYLINDER HEAD
CAUTION: Do not wire brush head surface while fuel injectors are still installed. Fuel injector damage can
result.
Remove fuel injectors before cleaning (if not already removed during cylinder head removal).
Clean the carbon from the injector nozzle seat with a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution (88°C or 140°F).
After rinsing, use compressed air to dry the cylinder head.
Polish the gasket surface with 400 grit paper. Use a sanding block to maintain a flat surface.
CROSSHEADS
Clean all crossheads in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits.
Rinse in hot water and blow dry with compressed air.
PUSHRODS
Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If necessary, use a
wire brush or wheel to remove stubborn deposits.
INSPECTION
CYLINDER HEAD
Inspect the cylinder head for cracks in the combustion
surtace. Pressure test any cylinder head that is visibly
cracked. A cylinder head that is cracked between the
injector bore and valve seat can be pressure tested
and reused if OK; however, if the crack extends into
the valve seat insert bore, the cylinder head must be
replaced.
Visually inspect the cylinder block and head combus-
tion surtaces for focalized dips or imperfections. Check
the cylinder head and block combustion surfaces for
overall out-of-flatness. If either the visual or manual
inspection exceeds the limits, then the head or block
must be surtaced.
Check the top surtace for damage caused by the cylinder head gasket leaking between cylinders.
Inspect the block and head surtace for nicks, erosion, etc.
Check the head distortion. Maximum overall variation end to end is 0.305 mm (0.012 inch), and maximum overall
variation side to side 0.076 mm ( .003 in.).
DO NOT proceed with the in-chassis overhaul if the cylinder head or block surtace is damaged or not flat (within
specifications) .
Check block surface for distortion. Maximum variation end-to-end is 0.076 mm ( .003 in.), side-to-side 0.051 mm
(.002).
Visually inspect the cylinder head bolts for damaged
threads, corroded/pitted surfaces, or a reduced diam- C CYLINDER HEAD CAPSCREW LENGTH GAUGE
eter due to bolt stretching.
If the bolts are not damaged, their "free length" should
be measured using the cap screw stretch gauge pro-
vided with the replacement head gasket. Place the
head of the bolt against the base of the slot and align
the bolt with the straight edge of gauge. If the end of
the bolt touches the foot of the gauge, the bolt must C CVLlNDER HEAD CAPSCREW LENGTH GAUGE
be discarded. The maximum bolt free length is
132.1 mm (5.200 in.).
8Ob4faa9
CROSSHEADS
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces.
Replace any crossheads that exhibit abnormal wear or
cracks.
8Ob4fa27
9 .. 3012 ENGINE .. 6.7l DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
PUSHRODS
Inspect the pushrod ball and socket for signs of scor-
ing. Check for cracks where the ball and the socket
are pressed into the tube.
8Ob4fa24
Roll the push rod on a flat work surface with the socket
end hanging off the edge. Replace any pushrod that
appears to be bent.
80b4fa23
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
1. Install a new gasket with the part number side up,

and locate the gasket over the dowel sleeves.
2. Using an engine lifting crane, lower the cylinder
head onto the engine.
3. Lightly lubricate head bolts under bolt head and on
threads, with engine oil and install. Using the
sequence shown , tighten bolts in the following
steps:
a. Torque bolts to 70 N·m (52 ft. Jbs.).
b. Back off 360 degrees in sequence.
c. Torque bolts to 105 N·m (77 ft. Ibs.).
d. Re-check all bolts to 105 N·m (77 ft. Ibs.).
e. Tighten all bolts an additional 1/4 turn (90°).
DR - - - - - - - - - - ENGINE .. 6.7l DIESEL - SERVICE INFORMATION 9 .. 3013
4. Install push rods into their original locations. Verify

that they are seated in the tappets.
8Ob4fa25
5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
6. Install rocker housing and bolts. Tighten to 24 N·m {18 lb. ft.}.
7. Install fuel injector (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
8. Lubricate valve stem tips and install the cross-
heads in their original locations.
9. Lubricate the rocker arms (1) and pedestals (2)
and install them in their original locations. Install
the bolts and torque them to 36 N·m (27 ft. Ibs.).
10. Verify that the valve lash settings are maintained
at 0.254 mm (0.010 in) for the intake valve and
0.660 mm (0.026 in) for the exhaust valve. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EX-
HAUST VALVES & SEATS - STANDARD
PROCEDURE).
81038916
11. Install cylinder head cover gasket onto rocker housing.

12. Install injector harness nuts. Tighten to 1.25 N·m (11 in.lbs.).
13. Connect injector harness connectors at cylinder head cover gasket.
14. Install wire harness P-clip to cylinder head behind filter housing 24 N·m (18 ft. Ibs.).
15. Connect the IAT/MAP sensor connector.
16. Install the fuel filter housing assembly and hand tighten mounting bolts, Do not torque at this time.
17. Connect WIF sensor, and fuel heater.
CAUTION: Failure to follow procedure will result in fuel leaks and/or fuel system failure.
18. Install the fuel rail and high pressure fuel lines as follows:
a. Hand tighten fuel rail bolts.
b. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
c. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.
9 • 3014 ENGINE· 6.7L DIESEL • SERVICE INFORMATION - - - - - - - - - - DR
d. Hand tighten fuel pump to fuel rail line.

e. Torque fuel line nuts at cylinder head to 40 N·m ( 35 ft. Ibs.).
f. Torque fuel line nuts at fuel rail to 40 N·m (35 ft. Ibs.)
g. Using a back up wrench, torque fuel pump to fuel rail line to 40 N·m (35 ft. Ibs.). At injection pump.
h. Torque fuel pump to fuel rail line to 40 N·m (35 ft. Ibs.) at fuel rail.
i. Torque fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 24 N·m (18 ft. Ibs.).
j. Torque rail bolts to 24 N·m (18 ft. Ibs.).
k. Connect fuel pressure sensor.
I. Torque fuel filter mounting bolts to 32 N·m (28 ft. Ibs.).
19. Reposition number 6 fuel line shield and torque to 43 N·m (32 ft. Ibs.).
20. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary.
21. Connect fuel return line at back of cylinder head hand tight.
22. Connect fuel return line at filter housing hand tight.
23. Torque banjo connections at cylinder head and fuel filter housing to 24 N·m (18 ft. Ibs.)
24. Install bracket to rear of filter housing. Torque to 24 N·m (18 ft. Ibs.).
25. Using new gaskets, install the air inlet housing. Torque bolts to 24 N·m (18 ft. Ibs.).
26. Install wire harness P-clip and push on clip to air inlet housing.
27. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
28. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 N·m (100 in. Ibs.).
29. Connect intake grid heater wire.
30. Secure engine harness to front of cylinder head with bolt at four locations.
31. Connect engine coolant temperature sensor connector.
32. Connect radiator upper hose to thermostat housing.
33. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
34. Install wire harness push-on clip below bracket.
3S. Install wire harness P-clip to top of bracket.
36. Install fan support and torque to 32 N·m (24 ft. Ibs.).
37. Install cooling fan/drive refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
38. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
39. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Starting
from the center bolts out, Torque bolts to 43 N·m (32 ft. Ibs.), then retorque from the center out again.
40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts.Torque to 24 N·m (18 ft.
Ibs.).
41. Install exhaust bolt retention straps across cylinders S & 6.
42. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24 N·m (18 ft. Ibs.).
43. Install the right motor mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION)
44. Perform the turbocharger pre-lube procedure. (Refer to 11 - EXHAUST SYSTEMITURBOCHARGER SYSTEM/
TURBOCHARGER - INSTALLATION)
4S. Connect the turbocharger oil supply line. Torque to 24 N·m (18 ft. Ibs.).
46. Connect the turbocharger coolant lines. Torque the banjo bolts to 24 N·m (18 ft. Ibs.)
47. Install the EGR cooler and associated hardware. (Refer to 7 - COOLING/ENGINE/EGR COOLER - INSTALLA-
TION)
48. Install air cleaner housing and duct.
49. Connect air inlet temperature/pressure sensor.
SO. Raise vehicle on hoist.
NOTE: Do not reuse the clamp for the exhaust pipe to turbocharger elbow connection.
51. Install the exhaust pipe to turbocharger elbow using a new clamp. Torque bolts to 11 N·m (100 in. Ibs.).
52. Lower vehicle.
53. Fill engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
54. Start engine and check for leaks.
9·3016 ENGINE - 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
COVER-CYLINDER HEAD
REMOVAL
ROCKER HOUSING
1. Remove the breather cover and the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION)
2. Remove injector harness nuts from injectors.
3. Remove cylinder head cover gasket. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION)
4. Remove rocker housing bolts.
5. Remove rocker housing and gasket.
CYLINDER HEAD COVER

1. Disconnect both negative battery cables. (Refer to
8 - ELECTRICAUBATTERY SYSTEM/CABLES -
REMOVAL)
2. Remove the Breather Cover Capscrews (8-M6
screws).
3. Remove the CCV breather and filter cover (3).
4. Disconnect CCV Tube (4) at the CDR valve (one
spring clamp) and remove 10mm nut from tube
bracket at EGR Cooler support bracket stud.
5. Disconnect CDR valve Tube to Air Inlet Silencer
(Spring Clamp).
6. Disconnect CDRNalve cover pressure sensor con-
nector.
7. Remove Oil fill cap.
8. Remove CCV oil drains (2) from valve cover (2
hoses).
9. Disconnect both injector harness connectors (1).
10. Remove six (6) valve cover capscrews (10mm).
11. Remove the valve cover.
12. Loosen injector wire nuts from the valve cover
gasket (8mm)
13. Remove gasket.
DR - - - - - - - - - - ENGINE· 6.7L DIESEL - SERVICE INFORMATION 9 - 3017
CYLINDER HEAD COVER GASKET
614b3452
1. Remove cylinder head cover.

2. Disconnect injector harness connectors (3) at cylinder head cover gasket.
3. Remove injector solenoid nuts (1) at injectors.
4. Remove cylinder head cover gasket (2).
CLEANING
Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket
dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket and rocker housing gasket, are reusable. However, should cracks, nicks, or
tears be present in the rubber/silicone construction, the defective components should be replaced. Also replace gas-
ket if it is no longer flexible. Inspect cylinder head cover rubber isolated capscrews for cracks, nicks, or tears.Do not
reuse gasket if it has been removed from the groove in the rocker housing or cylinder head cover.
INSTALLATION
ROCKER HOUSING
1. Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove.
2. Inspect rocker housing gasket for proper installation in groove. Gasket bead must be centered in groove. A gas-
ket bead that is tilted to the side will cause an oil leak.
CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, The
gasket could fall out or be damaged.
9 - 3018 ENGINE· 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
3. Install the rocker housing. Carefully guide the rocker housing evenly down onto the cylinder head.
4. Install rocker housing bolts and tighten finger tight.
5. Torque bolts, working from center out, to 24 N·m (18 ft. Ibs.).
CYLINDER HEAD COVER

NOTE: Gasket must be completely dry and free of
oil before installation.
1. Wipe oil from the valve cover gasket, rocker box,

and valve cover.
2. Inspect valve cover gasket for tears, or splits.
Replace if necessary.
3. Install the valve cover gasket on the rocker box~
4. Install the injector nuts (8 mm) to injector studs.
Torque to 1.25 Nm (11 in. Ibs.).
5. Install valve cover and valve cover capscrews
(10mm). tighten from center out. Torque to 24 Nm
(18 ft. Ibs.).
6. Install the valve cover CCV drain hoses (2).
7. Remove any oil from the CCV seal area and install
the CCV filter.
8. Install the CCV cover and capscrews (6mm).
Torque to 10 Nm (89 in. Ibs.).
9. Connect CDR valve tube to Air Inlet Silencer
(spring clamps).
10. Connect the BreatherNalve Cover Pressure sensor.
11. Install oil fill cap.
12. Connect the batteries.
13. Start the vehicle and check for leaks.
CYLINDER HEAD COVER GASKET
614b3452
1. Clean oil from cylinder head cover gasket

2. Inspect cylinder head cover gasket for cuts or damage. Replace if damaged.
3. Place cylinder head cover gasket on top of rocker housing (2),
4. Install injector solenoid nuts (1) at injectors. Torque to 1.25 N·m ( 11 in. Ibs. ).
5. Connect injector harness connectors (3) at cylinder head cover gasket.
9 - 3020 ENGINE - 6.7L DIESEL • SERVICE INFORMATION - - - - - - - - - - DR
VALVES & SEATS-INTAKE/EXHAUST

DESCRIPTION
The intake valves (1) are made of heat resistant steel,
and have chrome plated stems to prevent scuffing.
The exhaust valves are made of iron alloys (2). The
intake and exhaust valves are both similar in head
diameter and overall length. but they have unique face
angles which makes them non-interchangeable. The
valves are distinguished by unique dimples on the
exhaust valve head (2).
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
® 80b5cbSO
STANDARD PROCEDURE
VALVES, GUIDES AND SPRINGS
REMOVAL
1. Remove cylinder head (Refer to 9 - ENGINE/CYL-
INDER HEAD REMOVAL).
2. Support cylinder head on stands, or install head
bolts upside down (through combustion surface
side) to protect injector tips from damage from
work bench.
3. Install the valve spring compressor mounting base
(1) as shown.
4. Install the compressor top plate, washer, and nut.

Using a suitable wrench, tighten the nut (clockwise)
to compress the valve springs and remove the
locks.
5. Rotate the compressor nut counter-clockwise to
relieve tension on the springs. Remove the spring
compressor (1).
6. Remove the retainers (5), springs (4), valve seals

(3) (if necessary), and valves (2). Arrange or num-
ber all components so they can be installed in their
~CD
original locations. ®--.. . . .
7. Repeat the procedure on all cylinders to be G)
serviced.
80b5cb55
CLEANING
Clean the valve stems with crocus cloth or a Scotch-Brite™ pad. Remove carbon with a soft wire brush. Clean
valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with com-
pressed air.
9·3022 ENGINE· 6.7L DIESEL· SERVICE INFORMATION - - - - - - - - - - DR
INSPECTION
Visually inspect the valves for abnormal wear on the

heads, stems, and tips. Replace any valve that is
worn out or bent.
Measure the valve stem diameter in three places as

shown.
1
I
MEASURE AT THESE POINTS
J9109-14.4
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore diameter

Min. 7.027 mm (0.2767 in.)
Max. 7.077 mm (0.2786 in.)
Installed valve guide depth

Intake
Min. 0.584 mm ( 0.023 in.)
Max. 1.092 mm ( 0.043 in.)
Exhaust
Min. 0.965 mm ( 0.028 in.)
Max. 1.473 mm (0.058 in.)
Measure the cylinder head valve guide bore.
8Ob5cb54
Measure valve margin (rim thickness).

VALVE RIM
THICKNESS
t
J9109-146
Measure the valve spring free length and maximum

inclination.
BOb5cb53
9 .. 3024 ENGINE - 6.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
Test valve spring force with tool C-647 (1). Specifica-

tion 72.0 - 80.7 Ibs. when compressed to 35.33 mm
(1.39 in.).
INSTALLATION
1. Install new valve seals. The yellow seals are for the
intake valves and the green seals are for the
exhaust valves.
2. Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head.
3. Install the valve (2), springs (4), and retainer (5).

4. Install the valve spring compressor tool S319-A

(1 )as shown.
5. Compress the valve springs and install the valve
retaining locks.
6. Remove the compressor and repeat the procedure
on the remaining cylinders.
7. Install new o-ring and sealing washer on injector.
S. Lubricate a-ring and injector bore.
9. Verify sealing washer (shim) was removed with old
injector.
10. Install injector Refer to (Refer to 14 - FU EL SyS-
TEM/FUEL INJECTION/FUEL INJECTOR
INSTALLATION).
11. Install the cylinder head (Refer to 9 - ENGINE!
CYLINDER HEAD - INSTALLATION).
VALVE LASH ADJUSTMENT AND VERIFICATION

NOTE: To obtain accurate readings, valve lash
measurements AND adjustments should only be
performed when the engine coolant temperature is
less than 60 C (140 F).
0 0
The 24-valve overhead system is a "low-maintenance"

design. Routine adjustments are no longer necessary.
however, measurement should still take place when
troubleshooting performance problems, or upon com-
pletion of a repair that includes removal and installa-
tion of the valve train components or injectors.
1. Disconnect battery negative cables.
2. Remove cylinder head cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
3. Using the crankshaft barring tool #7471-8, rotate crankshaft to align damper TDC mark to 12:00 o'clock position.
a. If both number one cylinder rocker levers are loose, continue to next step.
b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees.
9 .. 3026 ENGINE - 6.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 I
EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and cross-
head. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the
limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment!
resetting is required.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.) MIN. 0.533 mm (0.021 in.) MIN.
0.381 mm (0.015 in.) MAX. 0.863 mm (0.034 in.) MAX.
NOTE:
If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within
these ranges has no adverse affect on performance, emissions, fuel economy or level of engine noise.
5. If adjustment/resetting is required, loosen the lock

nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
• INTAKE 0.254 mm (0.010 in.)
• EXHAUST 0.660 mm (0.026 in.) Tighten the lock
nut to 24 N·m (18 ft. Ibs.) and recheck the valve
lash.
6. Using the crankshaft barring tool, rotate the crank-
shaft one revolution (360°) to align the damper
TDC mark to the 12 o'clock position.
7. With the engine in this position, valve lash can be
measured at the remaining rocker arms: INTAKE
3-5-6 I EXHAUST 2-4-6. Use the same method
as above for determining whether adjustment is
necessary, and adjust those that are found to be
outside of the limits.
8. Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTAL-
LATION).
9. Connect the battery negative cables.
REMOVAL - VALVE SPRINGS

1. Disconnect the battery negative cables.
2. Remove the cylinder head cover (Refer to 9 -
3. Disconnect the injector harness connectors at cyl-
inder head cover gasket. Remove all injector sole-
noid nuts. Remove cylinder head cover gasket.
4. Remove injector(s) for cylinder(s) to be serviced.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL) or (Refer to 14 ..
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).
5. Remove the rocker housing.
6. Remove the rocker arms and cross heads from the
cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
7. Using the crankshaft barring tool # 7471-8 (2), rotate the engine to position the damper mark in the 12 o'clock
position. At this engine position, cylinders #1 and #6 can be serviced.
8. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover
next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just
made on the cover.
10. Divide the crankshaft damper into three equally sized segments as follows:
a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by
three (3).
b. Measure that distance in a counterclockwise direction from the first balancer mark and place another mark
on the balancer.
c. From the second damper mark, again measure in a counterclockwise direction and place a mark on the
damper at the same distance you measured when placing the second damper mark. The damper should
now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock
pOSition.
d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair.
11. Compress the valve springs at cylinders. # 1 and
# 6 as follows:
a. Install the valve spring compressor mounting
base as shown in.
b. Install the top plate, washer, and nut. Using a
suitable wrench tighten the nut (clockwise) to
compress the valve springs and remove the
collets.
c. Rotate the compressor nut counterclockwise to
relieve tension on springs. Remove spring
compressor.
d. Remove and replace retainers, springs, and
seals as necessary.
80b4fb43
e. Do not rotate the engine until the springs
and retainers are reinstalled.
1. Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
g. Release the spring tension and remove the
compressor. Verify that the collets are seated
by tapping on the valve stem with a plastic
hammer.
12. Using the crankshaft barring tool (2), rotate the

engine until the next crankshaft damper paint
mark aligns with the mark you placed on the
cover. In this position, cylinders # 2 and # 5
can be serviced.
13. Repeat the valve spring compressing procedure
previously performed and service the retainers,
springs, and seals as necessary.
14. Using the crankshaft barring tool, rotate the
engine until the next crankshaft damper paint
mark aligns with the mark you placed on the
cover. In this position, cylinders # 3 and # 4
can be serviced.
15. Repeat the spring compressing procedure previ·
ously performed and service the retainers,
springs, and seals as necessary.
INSTALLATION
1. Install rocker housing. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)
2. Install fuel injectors and high pressure fuel lines.
3. Lubricate the valve tips and install the crossheads in their original locations.
4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original loca-
tions. Tighten bolts to 36 N·m (27 ft. Ibs.) torque.
5. Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEADIINTAKE/EXHAUST VALVES & SEATS
6. Install cylinder head cover gasket onto rocker housing. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION)
7. Install injector solenoid nuts.
8. Connect injector harness connectors.
9. Install cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION)
10. Connect battery negative cables.
DR - - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 - 3029
ARM-ROCKER
DESCRIPTION
The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersect-
ing the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves.
The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability.
REMOVAL
8Ob4fa26

2. Remove cylinder head cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
3. Remove the rocker arm/pedestal fasteners and
remove rocker arm (1) and pedestal (2) from cylin-
der head. Mark the arms and pedestals so they
can be installed in their original position.
CAUTION: When removing the rocker arms, the

sockets may come loose and fall into the engine.
Make sure they stay with the arm upon
removal/installation.
81038916
4. Lift the push rod(s) up and out of the engine. Mark
them so they can be installed in their original posi-
tion.
NOTE: The # 5 cylinder intake and exhaust, and #

6 cylinder intake and exhaust push rods must be
raised through the provided cowl panel access
holes.
5. Lift the crossheads off of the valve stems. Mark

them so they can be installed in their original
position.
SOb4fa25
CLEANING
Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits.
Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply
compressed air to lubrication orifices to purge contaminants.
INSPECTION
Rocker Arms
1. Remove rocker shaft and inspect for cracks and
excessive wear in the bore or shaft. Remove
socket and inspect ball insert and socket for signs
of wear. Replace retainer if necessary.
Measure the rocker arm bore and shaft.
SOb4fa28
8Ob4fa29
Push Rods
Inspect the push rod ball and socket for signs of scor-
ing. Check for cracks where the ball and the socket
are pressed into the tube.
Roll the push rod on a flat work surface with the
socket end hanging off the edge. Replace any push
rod that appears to be bent.
8Ob4fa24
Cross heads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces.
80b4fa23
SOb4la27
INSTALLATION
1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets.
2. Lubricate the valve tips and install the crossheads in their original locations.
3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original loca-
tions. Tighten bolts to 36 N·m (27 ft. Ibs.) torque.
4. Verify valve lash adjustment (Refer to 9 .. ENGINE/CYLINDER HEADJINTAKE/EXHAUST VALVES & SEATS
.. STANDARD PROCEDURE).
5. Install cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTAL-
LATION)
DR ~--------- ENGINE· 6.7L DIESEL - SERVICE INFORMATION 9 - 3033
ENGINE BLOCK
STANDARD PROCEDURE
CYLINDER BLOCK REFACING
1. Prior to removing the piston and connecting rod
assemblies, measure and record piston protrusion.
Measuring piston protrusion prior to disassembly ®~l=':';=.=---=---::f::=-:--=--"r-----,~
will aid in determining if the cylinder block, if
required, can be resurfaced.
2. Measure the overall flatness of the engine block.
3. The engine block must be within 0.076 mm (0.003 @
in) end-to-end and 0.051 mm (.002 in.) side-to-
side.
4. Inspect for any localized dips or imperfections. If
present, the cyHnder head deck MUST be resur-
faced.
NOTE: The combustion deck of the block can

ONLY be resurfaced if after the resurface, the cor- 80af;2c94
rect piston protrusion can be achieved. No spe-

cific head gasket with an increased thickness is available for combustion deck resurfacing. If the
combustion deck can NOT be resurfaced such that the correct piston protrusion an be reached, the cylinder
block MUST be replaced.
CYLINDER BORE - DE-GLAZE

1. New piston rings may not seat in glazed cylinder
TOP OF BLOCK
bores.
2. De-glazing gives the bore the correct surface finish
required to seat the rings. The size of the bore is
not changed by proper de,:,glazing.
3. Cover the tube and tappet holes in the top of the
block with waterproof tape.
4. It crankshaft is installed, wrap connecting rod jour-
nals with clean cloth. Cover cloth with waterproof
tape.
5. A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles. For the rough
hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
6. Use a drill, a fine grit Flex-hone and a mixture of
equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores. 300 TO
7. The crosshatch angle is a function of drill speed 400 RPM
and how fast the hone is moved vertically.
8. Vertical strokes MUST be smooth continuous
passes along the full length of the bore.
9. Inspect the bore after 10 strokes.
10. Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.
11. Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
12. Check the bore cleanliness by wiping with a t
1 STROKE ( + ~ )I PER SECOND J9109-81
white, lint free, lightly oiled cloth. If grit residue is
still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete block
assembly with solvent and dry with compressed air. Place a clean shop towel around the top main bearing
saddle to deflect water and residue from piston cooling nozzels. Remove directed piston cooling nozzles if
installed.
13. Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning
process is complete.
OVERSIZE BORE
OverSize pistons and rings are available in one size - 0.50 mm (0.0197 inch).
Any combination of standard or 0.50 mm (0.0197 inch) overbore may be used in the same engine.
If more than 0.50 mm (0.0197 inch) overbore is needed the block must be replaced.
Cylinder block bores may be bored one time. The bore size is 0.50 mm (0.0197 inch) oversize.
After boring to size, use a honing stone to chamfer the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION MEASUREMENT
BORING DIAMETER DIMENSION REBORE - 107.490 mm (4.2319 in.) Minimum
REBORE - 107.510 mm (4.2327 in.) Maximum
HONING DIAMETER DIMENSIONS STANDARD - 102.020 ± 0.020 mm (4.0165 ± 0.0008
in.)
REBORE - 107.45 mm (4.4.2303 in) Nominal
CHAMFER DIMENSIONS Approx. 1.25 mm (0.049 in.) by 30°
A correctly honed surface will have a crosshatch

TOP OF BLOCK
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit hon-
ing stones.
A maximum of 1.2 micrometer (48 microinch) surface
finish must be obtained.
After finish honing is complete, immediately clean the
cylinder bores with a strong solution of laundry deter-
gent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white, lint-free, lightly- oiled cloth. There should be no grit residue
present.
If the block is not to be used right away, coat it with a rust- preventing compound.
DR - - - - - - - - - - ENGINE· 6.7l DIESEL - SERVICE INFORMATION 9·3035
CAM BORE REPAIR

For standard bushings, not oversized. maximum front
and rear cam bushing bore diameter is 59.248 mm.
(2.3326 in.). DO NOT bore the intermediate cam bore
to the front cam bore oversize dimensions. Maximum
front and rear camshaft bushing installed diameter is
54.147 mm. (2.1318 in.). Minimum installed diameter
is 54.083 mm. (2.1293 in.). Maximum intermediate
camshaft bore diameter is 54.164 mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 200.k of an area of
J9109-5.4.
anyone bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair
individually damaged cam bores. The standard front and rear bushing (1) cannot be used to repair intermediate
bores.
Instan an cam bushings flush or below the front and rear cam bore surface. The front camshaft bushing should be
installed flush with front face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through
freely.
INSPECTION
Measure the combustion deck face using a straight
edge (1) and a feeler gauge (2). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum vari-
ation side-fa-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 - ENGINE!
ENGINE BLOCK ~ STANDARD PROCEDURE).
BORE SPECIFICATIONS
_i..-.
",... ........... 1 - -
'- ./ 25.4 mm
/' ~ (1 IN.)
'- ;,-
-- --
'- .,,;
80bb0c56
BORE DIAMETER
Min. 106.990 mm (4.2122 in.)
Max. 107.010 mm (4.213 in.)
OUT OF ROUNDNESS
Max. 0.038 mm (0.0015 in.)
TAPER
9 .. 3036 ENGINE .. 6.7l DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
I
BORE DIAMETER
Max. I 0.076 mm (.003 in.)
Inspect the cylinder bores for damage or excessive wear.
Measure the cylinder bores. If the cylinder bores exceed the limit, (Refer to 9 - ENGINE/ENGINE BLOCK - STAN-
DARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive wear.
Measure the camshaft bores (Refer to 9 - ENGINE - SPECIFICATIONS).
If a bore exceeds the limit, (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE).
Inspect the tappet bores for scoring or excessive wear.
Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet
bore 16.055 mm. (0.632 in.).
If out of limits, replace the cylinder block.
CAMSHAFT & BEARINGS (IN BLOCK)

REMOVAL
CAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.lf
the bores without a bushing are worn beyond the limit, the engine must be removed for machining and
installation of service bushings. If badly worn, replace the cylinder block.
1. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
2. Remove the bushing from the No.1 bore.
3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing.
CAMSHAFT
2. Recover AlC refrigerant (if AlC equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
4. Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
5. Lower vehicle.
7. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Disconnect the coolant recovery bottle hose from the radiator filler neck.
9. Disconnect lower radiator hose from radiator outlet.
10. Automatic Transmission models: Disconnect transmission oil cooler lines from front of radiator using Special
Tool 6931 (unless equipped with finger-release disconnect).
11. Remove radiator mounting screws and lift radiator out of engine compartment.
12. Remove upper radiator support panel.
13. If AlC equipped, disconnect AlC condenser refrigerant lines.
14. Disconnect charge air cooler piping from the cooler inlet and outlet.
15. Remove the two charge air cooler mounting bolts.
16. Remove charge air cooler (and AlC condenser if equipped) from vehicle.
17. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
18. Remove accessory drive belt tensioner.
19. Remove the fan support/hub assembly.
20. Remove crankshaft damper. (Refer to 9 - ENGINE/ENGINE 8LOCKIVIBRATION DAMPER - REMOVAL)
21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the sealing surfaces. Remove dust seal with cover.
22. Using Special Tool 7471-8 Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the
crankshaft and the camshaft gears.
23. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
9 - 3038 ENGINE· 6.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
24. Remove the rocker arms, cross heads, and push

rods. Mark each component so they can be
installed in their original positions.
NOTE: The # 5 cylinder intake and the # 6 cylinder

intake and exhaust pushrods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
8Ob4fa25
25. Raise the tappets as follows, using the wooden

dowel rods provided with the Miller Tool Kit 8502.
a. Insert the slotted end of the dowel rod into the
tappet. The dowel rods for the rear two cyl-
inders will have to be cut for cowl panel
clearance. Press firmly to ensure that it is
seated in the tappet.
b. Raise the dowel rod to bring the tappet to the
top of its travel, and wrap a rubber band
around the dowel rods to prevent the tappets
from dropping into the crankcase.
c. Repeat this procedure for the remaining
cylinders.
26. Verify that the camshaft timing marks are aligned

with the crankshaft mark.
27. Remove the bolts from the thrust plate.
28. Remove engine mount through bolts.
29. Install engine support fixture special tool # 8534,
and steel bracket/wing nut special tool #
8534A.
30. Raise engine enough to allow camshaft removal.
31. Remove the camshaft, gear and thrust plate.
6103b556
DR - - - - - - - - - - ENGINE - 6.7l DIESEL • SERVICE INFORMATION 9 - 3039
INSPECTION
Camshaft
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)

Min. 54.028 mm. (2.127 in.)
Max. 54.048 mm. (2.128 in.)
Journal diameter (No.2 through No.6)

Min. 53.962 mm. (2.1245 in.)
Max. 54.013 mm. (2.1265 in.)
Diameter of peak of lobe
Intake
Min. 47.175 mm (1.857 in.)
Max 47.855 mm.
Exhaust
Min. 45.632 mm. (1.797 in.)
Max. 46.312 mm. (1.823 in.)
1. Inspect the valve lobes (1) and bearing journals (2)

for cracks, pitting, scoring, or generally excessive
wear. Replace any camshaft that exceeds the
allowable limits.
2. Measure the bearing journals and lobes.
CAUTION: If Camshaft lobes are worn, requiring

camshaft replacement, it is necessary to replace
the tappets also. (Refer to 9 - ENGINE/ENGINE
BLOCK/SOLID LIFTERS - REMOVAL).
8Ob4fa37
9 - 3040 ENGINE - 6.7L DIESEL,· SERVICE INFORMATION ----~~---- DR
Camshaft Bushing/Bores
Camshaft bores No. 2-6 do not use a bushing.

1. Inspect the camshaft bushing and bores for signs
of excessive wear.
2. Measure the camshaft bushing and bores with a '
telescoping bore gauge and micrometer. If out of
specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
SOb4fa38
3. Inspect the camshaft bushing (1) oil holes for align-

ment with cylinder block.
J9109-5.4
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary,
camshaft and gear are replaced as an assembly. (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS
(IN BLOCK) - REMOVAL).
Thrust Plate
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)

MAX. 9.60 mm (0.378 in.)
Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness
using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these
specifications:
1M -~..:....-~-------- ENGINE - 6'.7L DIESEL • SERVICE INFORMATION 9 • 3041
INSTALLATION
CAMSHAFT BEARINGS
1. Apply a coating of Loctite® 640 Adhesive to the
backside of the new bushing. Avoid getting adhe-
sive in the oil hole.
2. Use a universal cam bushing installation· tool and
install the front bushing (1) so that it is even with '
the front face of the cylinder block. The oil hole
must be aligned: A 3.2 mm (0.128 j'nch) diameter
rod must be able to pass through the hole.
3. Measure the installed bushlngs at the front bore.
The minimum inside diameter is 54.083 mm
J9109-54
(2.1293 inch). and the maximum inside diameter is
is 54.147 mm. (2.1318 in.).
CAMSHAFT
1. Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
2. Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable
equivalent.
CAUTION: When installing the camshaft, DO NOT

push it in farther than it will go with the thrust
washer in ptace.
3. Install the camshaft and thrust plate. Align the tim-

ing marks as shown.
810:3b556
BACKLASH - 0.075 - 0.250 mm (0.003 - 0.010 inch)

CLEARANCE - 0.025 - 0.500 mm (0.001 - 0.020 inch)
4. Install the thrust plate bolts and tighten to 24 N·m (18 ft. Ibs.) torque.
5. Measure camshaft back lash and end clearance.
6. Remove the wooden dowel rods and rubber bands from the tappets.
7. Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the
tappets.
8. Lubricate the valve tips with engine oil and install the crossheads in their original locations.
9. Lubricate the cross heads and push rod sockets with engine oil and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 N·m (27 ft. Ibs.) torque.
10. Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEADJINTAKElEXHAUST VALVES & SEATS
11. Install the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION)
12. Install gear housing cover (Refer to 9 - ENGINENALVE TIMING/GEAR HOUSING COVER - INSTALLATION).
Install front crankshaft dust seal.
13. Install the crankshaft damper. (Refer to 9 - ENGINE/ENGINE BLOCKNIBRATION DAMPER - INSTALLATION).
14. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
16. Install accessory drive belt tensioner. Torque bolt to 43 N·m (32 ft. Ibs.).
17. Install the accessory drive bett (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
18. Install the charge air cooler (with ale condenser and auxiliary transmission oil cooler. if equipped) and tighten
the mounting bolts to 2 N·m (17 in. Ibs.) torque.
19. Connect charge air cooler inlet and outlet pipes. lighten clamps to 11 N·m (95 in. Ibs.) torque.
20. Install the radiator upper support panel.
21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11
N·m (95 in. Ibs.) torque.
23. Connect radiator lower hose and install clamp.
24. Connect transmission auxiliary oil cooler lines (if equipped).
25. Lower vehicle.
26. Install the fandrive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud.
28. Connect the coolant recovery hose to the radiator filler neck.
29. Add engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
30. Charge AlC system with refrigerant (if AlC equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
32. Start engine and check for engine oil and coolant leaks.
BEARINGS - CONNEC-rING ROD

STANDARD PROCEDURE
CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE
DESCRIPTION MEASUREMENT
CONNECTING ROD BORE, BEARINGS REMOVED MIN. 72.99 mm (2.874 in.)
MAX. 73.01 mm (2.875 in.)
CONNECTING ROD BORE, BEARINGS INSTALLED MIN. 69.05 mm (2.719 in.)
MAX. 69.10 mm (2.720 in.)
1. Measure the connecting rod bore with bearings

removed and the bolts tightened to 100 N·m (73 ft.
Ibs.) torque ..
2. Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N·m (73 ft.
Ibs.) torque.
Measure within 20° arc from each side of the parting
line. Also measure 90° from parting line.
Record the smallest and largest diameter.
Measure the diameter of the rod journal at the location
shown. Calculate the average diameter for each side
of the journal.
Determine minimum bearing clearance by calculating
the differance between the smallest connecting rod SObb()c.4e
bore diameter with the bearing installed and the aver-
age diameter for each side of the crankshaft journal.
Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore
diameter and the average diameter with the bearing installed for each side of the crankshaft journal.
If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the crankshaft to the next
smaller size and use oversize rod bearings.
9·3044 ENGINE - 6.7l DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
CRANKSHAFT & GEAR

DESCRIPTION
The crankshaft is a forged steel, internally balanced
unit. It is supported by seven main bearings, with posi-
tion number six designated as the thrust journal. The
crankshaft is held in place by main caps and 12 mm
capscrews. The crankshaft also has internal cross
drillings to supply the connecting rods with engine oil.
80c411b5
REMOVAL - GEAR
1. Remove the gear housing cover. (Refer to 9 - ENGINENALVE TIMING/GEAR HOUSING COVER - REMOVAL)
2. Split the gear and remove it from the crankshaft.
INSTALLATION - GEAR
1. Remove all burrs and make sure the gear surface
on the end of the crankshaft is smooth.
2. If removed install a new alignment pin. Drive the
t
pin in using a ball- peen hammer, leaving it pro-

truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch)
above the crankshaft.
WARNING: WEAR PROTECTIVE GLOVES TO PRE-

VENT INJURY.
J9109-94
CAUTION: DO NOT heat the gear longer than 45
minutes.
3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (30QoF). Do not use torch, gear failure will
occur.
4. Apply a thin coat of lubricant to the nose of the crankshaft.
5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the
gear contacts the shoulder.
BEARINGS - CRANKSHAFT MAIN

STANDARD PROCEDURE
MAIN BEARING CLEARANCE
MAIN BEARING BORE DIAMETER CHART
80bbOc4b
ITEM MAIN BEARING BORE DIAMETER (MAXIMUM)

BEARINGS INSTALLED 83.106 mm (3.2719 in.)
BEARINGS REMOVED Min 87.983 mm (3.4639 in.)
Max. 88.019 mm (3.4653 in.)
Inspect the main bearing bores for damage or abnormal wear.
1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 N·m
(130 ft. Ibs.).
2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to
176 N·m (130 ft. Ibs.) torque.
CRANKSHAFT MAIN JOURNAL DIAMETER CHART
80bbOc-la
ITEM SPECIFICATION
Minimum diameter 82.962 mm (3.2662 in.)
Maximum diameter 83.013 mm (3.2682 in.)
Maximum out of roundness 0.050 mm (.002 in.)
Maximum taper 0.013 mm (.0005 in.)
Thrust distance (at NO.6 position) Min. 0.065 mm (.003 in.)
Max. 0.432 mm (.017 in.)
3. Measure the diameter of the main journal at the locations shown. Calculate the average diameter for each side
of the journal.
4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the
crankshaft journal is within limits, replace the main bearings. If not within specifications. grind the crankshaft to
next size and use oversize bearings.
5. Measure thrust distance at the No.6 position.
SEAL - CRANKSHAFT OIL - FRONT

REMOVAL
i. Disconnect both battery negative cables.
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan
shroud.
8. Remove viscous fan/drive assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
9. Remove cooling fan shroud and fan assembly from the vehicle.
11. Remove the cooling fan support/hub from the front of the engine.
12. Raise the vehicle on hoist.
13. Remove the crankshaft damper.
14. Remove power steering pump.
16. Remove the gear cover-to-housing bolts and gen-
tly pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove
crank seal dust shield with cover.
17. Support the cover on a flat work surface with
wooden blocks, and using a suitable punch (1)
and hammer, drive the old seal out of the cover
from the back side of the cover to the front side.
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free of all oil residue, to
prevent leaks. The crankshaft and seal surface
must be completely dry when the seal is installed.
1. Clean cover and housing gasket mating surfaces.

Use a suitable scraper and be careful not to dam-
age the gear housing surface. Remove any old
sealer from the oil seal bore. Thoroughly clean the
front seal area of the crankshaft. Do not sand this
surface. The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to pre-
vent seal leaks.
2. Inspect the gear housing and cover for cracks and
replace jf necessary. Carefully straighten any bends
or imperfections in the gear cover with a ball-peen
hammer on a flat surface. Inspect the crankshaft
front journal for any grooves or nicks that would
affect the integrity of the new seal. 80b46d26
3. Apply a bead of Mopar® Stud & Bearing Mount to

the outside diameter of the seal. Do not lubricate the inside diameter of the new seal.
4. With the cover supported by wood blocks, install the seal into the rear of the cover using crankshaft seal installer
Special Tool 8281 and driver handle C-4171. Strike the driver handle until the installation tool bottoms out on the
inside of the cover.
CAUTION: Do not distort or damage seal.
5. Install the plastic seal pilot (provided with seal kit)

into the crankshaft seal.
6. Apply a bead of Mopar® Silicone Rubber Adhesive
L
Sealant or equivalent to the gear housing cover
sealing surface.
7. Install the cover to the gear housing, aligning the
seal pilot with the nose of the crankshaft.
NOTE: Failure to follow the cover installation pro-

cedure can result in misalignment of the crank-
shaft seal to the crankshaft, causing an oil leak.
8. Install the cover bolts and hand snug 2 capscrews

SOb46d27
at the 3 o'clock and 9 o'clock pOSition, to keep the
cover from moving when the first capscrew is
torqued. Torque to 24 N·m (18 ft. Ibs.) torque. Remove pilot tool.
9. Install dust shield over nose of crankshaft.
10. Install the crankshaft damper. Torque the bolts to 40 N·m (30 ft. Ibs.). Then rotate an additional 60°. Use the
engine barring tool to keep the engine from rotating during tightening operation.
11. Install the fan support/hub assembly and torque bolts to 32 N·m (24 ft. Ibs.).
12. Install power steering pump.
13. Install accessory drive belt tensioner. Torque bolt to 43 N·m (32 tUbs.).
14. Install cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
15. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
16. Refill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
DR - - - - - - - - - - ENGINE· 6.7L DIESEL· SERVICE INFORMATION 9 . 3049
18. Start engine and check for oil leaks.
9 • 3050 ENGINE - 6.7l DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
SEAL - CRANKSHAFT OIL - REAR

REMOVAL
2. Remove the transmission and transfer case (if
equipped).
3. Remove the clutch cover and disc (if manual trans-
mission equipped) (Refer to 6 - CLUTCH/CLUTCH
DISC REMOVAL).
4. Remove the flywheel or converter drive plate.
5. Remove the flywheel adapter plate.
6. Drill holes 1800 apart into the seal. Be careful not
to contact the drill against the crankshaft.
7. Install # 10 sheet metal screws (1) in the drilled \Ic
holes and remove the rear seal with a slide ham- ;\ I
mer (4).
J9109-60
INSTALLATION
CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent
seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap
and water solution on outside diameter of seal to ease assembly.
1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the
inside bore of the crankshaft seal retainer with a clean shop towel.
2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is
excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that
is available in the aftermarket.
3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft.
4. Remove the seal pilot.
5. Install the installation tool over crankshaft.
6. Using a ball peen hammer, strike the tool (2) at the
12, 3, 6, and 9 o'clock positions until the alignment
tool bottoms out on the retainer.
NOTE: Always install a new clamping ring, never

reuse the old clamping ring.
7. Install the flywheel or converter drive plate, and

clamping ring. Tighten the bolts to 137 N·m (101 1t.
Ibs.) torque.
S. Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
9. Install the transmission and transfer case (if
equipped).
8Ob4faab
10. Lower vehicle.
12. Check engine oil level and adjust, if necessary.
RETAINER - CRANK REAR OIL SEAL

REMOVAL
1. Disconnect the battery negative -cables.
3. Remove the oil pan drain plug and drain the engine
oil. Re-install plug and torque to 50 N·m (44 ft. Ibs.)
CD
torque.
4. Remove transmission and transfer case (if
equipped) from vehicle.
5. Remove flywheel or torque converter drive plate.
6. Remove flywheel adapter plate.
7. Disconnect starter cables from starter motor.
a. Remove starter motor (Refer to a - ELECTRICAU
STARTING/STARTER MOTOR - REMOVAL) and
transmission adapter plate assembly.
9. Remove four 4 oil pan rear bolts. Slide a feeler 8Ob48d30
gauge between the seal retainer and oil pan gasket
to break the seal.
10. Remove the six 6 retainer-to-block bolts (3).
11. Remove the rear seal retainer, and gasket (2).
12. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch.
INSTALLATION
1. If using the old seal retainer, the crankshaft seal
must be replaced.
2. Inspect oil pan gasket for nicks or cuts. If gasket is
damaged, the oil pan must be removed and gasket
must be replaced. Wipe oil pan gasket dry and
apply light coating of RTV.
3. Using the retainer alignment/seal installation tool
provided in the seal service kit, install the align-
ment tool into the retainer and install to the cylinder
block, using a new gasket. Tighten the six (6)
mounting bolts by hand.
4. The seal alignment tool is used to align rear cover
properly. Starting with the center two bolts, tighten
the retainer in a circular pattern to 10 N·m (89 in.
Ibs.). Remove the alignment tool.
9 - 3052 ENGINE· 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on out-
side diameter of seal to ease assembly.
5. Make sure the provided seal pilot (1) is installed

into the new crankshaft seal (3). Use the align-
ment/installation tool and press the seal onto the
crankshaft. Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
80b4faab
6. Remove the alignment tool and trim the retainer

gasket (1) even with the oil pan mounting surface.
7. Remove the seal pilat.
8. Apply a small amount of Mopar® Silicone Rubber
Adhesive Sealant to the oil pan rail T-joints.
9. Install the four (4) oil pan rear mounting bolts and
torque to 28 N·m (21 ft. Ibs.).
10. Install new rectangular ring seal for cam bore.
11. Install the flywheel housing and bolts. Torque
12. Install the flywheel housing and bolts. Torque
NOTE: A new clamping ring must be used on early SOb41b4O

or late builds, automatic or manual. Do not reuse
clamping ring.
13. Install the dual mass flywheel with crankshaft adapter. Tighten bolts to 137 N·m (101 ft. Ibs.).
14. Install the starter motor Refer to (Refer to 8 - ELECTRICAUSTARTING/STARTER MOTOR - INSTALLATION).
15. Install the transmission and transfer case (if equipped).
16. Lower vehicle.
17. Fill the crankcase with new engine oil.
DR - - - - - - - - - - ENGINE - 6.7L DIESEL • SERVICE INFORMATION 9 • 3053
TAPPETS - VALVE
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit.
1. Remove camshaft (Refer to 9 - ENGINE/ENGINE

REMOVAL).
2. Insert the trough (1) (provided with tool kit) the full
length of the camshaft bore. Make sure the cap
end goes in first and the open side faces up
(towards tappets).
3. Remove only one tappet at a time. Remove rub-

ber band from one cylinder pair and attach tappet
dowel not being removed to the next cylinder pair.
80b4faaO
4. Raise dowel rod (disengage from tappet) and allow

tappet to fall into trough.
5. Carefully remove trough (do not rotate) and tap-
pet. If the tappet is not being replaced, mark it so it
can be installed in its original location.
9 • 3054 ENGINE - 6.7l DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
6. Re-install trough (1) and repeat procedure on

remaining tappets.
CLEANING
Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or compressed air.
INSPECTION
1. Visually inspect the tappet the tappet socket, stem,
and face for excessive wear, cracks, or obvious
damage.
2. Measure the tappet stem diameter. Replace the
tappet if it falls below the minimum size.
_Iw
-:::·~
~',:;~ ABNORMAL
~~:. WEAR
STEM DIAMETER ':S'I- J9109-152
INSTALLATION
1. Insert the trough (1) the full length of the camshaft
bore. Again, make sure the cap end goes in first
and the open side faces up (towards tappets).
2. ~ower the tappet installation tool through the push
rod hole and into the trough.
3. Retrieve the tappet installation tool using the

hooked rod provided with the tool kit
4. Lubricate the tappet with clean engine oil or suit-

able equivalent and install the tappet to the instal-
lation tool.
5. Pull the tappet up and into position. If difficulty is
experienced getting the tappet to make the turn
into the tappet bore, wiggle the trough while gently
pulling up on the tappet.
80b4faa4
6. With the tappet in place, rotate the trough one half

turn so the open side is down (toward crankshaft).
7. Remove the tappet installation tool from the tappet.
8. Re-install a dowel rod, and secure the rod with a
rubber band.
9. Rotate the trough one half turn and repeat the pro-
cedure for the remaining tappets.
10. Install the camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION).
DR - - - - - - - - - - ENGINE .. 6.7l .DIESEl .. SERVICE INFORMATION 9 - 3057
PISTON & CONNEC-rING ROD

DESCRIPTION
PISTONS
The pis~on is constructed of aluminum and is gravity
cast, free floating design. The piston incorporates a
centrally located high swirl combustion bowl, and uti-
lizes a "keystone" style top compression ring, and a
"Tapered Face" intermediate ring, for superior cylinder
wan scraping. Piston cooling nozzles cool the piston
and pin with engine oil supplied by the crankshaft
main journals. All pistons are gallery cooled and utilize
J-jet piston cooling nozzles. Pistons are directional in
order to provide clearance to piston cooling nozzles~
D~--
TO~ RING TOP
CONNECTING RODS
The connecting rods are a split angle design. They
have a pressed-in-place wrist pin bushing that is lubri-
cated by piston cooling nozzle oil spray. INTERMEDIATE RING 0.::::--
Machined connecting rods are no longer used In
the diesel engine. Do not install machined con-
necting rods into an engine that has fractured split OIL CONTROL RING ~) 1)] »»
connecting rods.
Fractured split connecting rods are first manufactured
as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough
and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the
bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the
connecting rod must be assembled on the intake or camshaft side of the engine.
Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting
rod or cap is damaged, the entire assembly must be replaced.
STANDARD PROCEDURE
HEAD GASKET SELECTION
1. Measure piston protrusion for all six pistons.
2. Calculate the average piston protrusion. Maximum allowable protrusion is 0.516 mm (0.020 inch).
NOTE: There is only one head gasket available for the 6.7L engine.
REMOVAL
1. Disconnect the battery cables.
2. Remove the cylinder head (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL).
3. Remove the oil pan and suction tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
4. Remove bolts and the block stiffener.
5. Using Miller Tool 7471-8 crankshaft barring tool, rotate the crankshaft so all of the pistons are below TOC.
6. Before removing the piston(s) from the bore(s):
a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush.
b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove
more metal than necessary to remove the ridge.
7. Remove the J-jet cooling nozzles.
NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring.
8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston
is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston
diameter. DO NOT stamp over the piston pin.
9. Mark the connecting rod and cap with the corresponding cylinder numbers.
10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not
damaged.
11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore.
12. Store the piston/rod assemblies in a rack.
CLEANING
CAUTION: DO NOT use bead blast to clear:- the pistons. DO NOT clean the pistons and rods in an acid tank.
PISTON
Clean the pistons and pins in -a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the
pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and
again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air.
CONNECTING ROD
Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air.
INSPECTION
PISTONS
PISTON SKiRT DIAMETER (MIN.)

Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Mea-
sure the piston skirt diameter. If the piston is out of limits, replace the piston.
DR - - - - - - - - - - ENGINE· 6.7L DIESEL· SERVICE INFORMATION 9 - 3059
The upper groove only needs to be inspected for dam-
age. Use a new piston ring (2) to measure the clear-
ance in the intermediate ring groove. Minimum
clearance is 0.045 mm (0.0018 inch), maximum clear-
ance is 0.095 mm (.0037 inch). If the clearance of the
intermediate ring exceeds specifications, replace the
piston (3).
Use a new oil ring to measure the clearance in the oil
groove. Minimum clearance is 0.040 mm (0.0016
inch), maximum clearance is 0.085 mm (.0033 inch). If
the clearance exceeds specifications, replace the
piston. CD
J9109-64
Measure the pin bore (2). The maximum diameter is

40.012 mm (1.5753 inch), Minimum is 40.006 mm
(1.575 inch). If the bore is over limits, replace the pis-
ton (1).
Inspect the piston pin for nicks, gouges and excessive

wear. Measure the pin diameter (1). The minimum
diameter is 39.990 mm (1.5744 inch), maximum
40.003 mm (1.5749 inch). If the diameter is out of lim-
its, replace the pin (1).
t
-0-
+
J9109 .. 66
CONNECTING ROD
Inspect the connecting rod for damage and wear. The
I-Beam section of the connecting rod cannot have CD
dents or other damage. Damage to this part can
cause stress risers which will progress to breakage.
Measure the connecting rod pin bore (1). The maxi-
mum diameter is 40.042 mm (1.5765 inch), minimum
diameter is 40.019 mm (1.5756 inch). If out of limits,
replace the connecting rod.
J9109-67
INSTALLATION
1. Lubricate the cylinder bores with clean engine oil.
2. Generously lubricate the rings and piston skirts
with clean engine oil.
3. Orientate the rings on the piston (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON RINGS - STAN-
DARD PROCEDURE).
4. Compress the rings using a piston ring compressor
tool (1). If using a strap-type ring compressor,
make sure the inside end of the strap does not J9109-83
hook on a ring gap and break the ring.
5. Bar the crankshaft so the rod journal for the piston

to be installed is at BOC (Bottom Dead Center).
6. Make sure the front of the piston is oriented prop-
erly according to the marking on the top of the pis-
ton and the connecting rod is oriented properly.
818cbffO
7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly accord-
ing to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the
cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the
engine.
8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the
block. Carefully pull the connecting rod onto the crankshaft journal.
9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts.
10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side
of the engine.
a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The
split face will face toward the exhaust side of the engine if properly installed.
11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps.
• Tighten the bolts to 30 N·m (22 ft. Ibs.) torque.
• Tighten the bolts to 60 N·m (44 ft. Ibs.) torque.
• Rotate 60° clockwise.
12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does
not rotate freely, check the installation of the rod bearing and the bearing size.
13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance
between the cap and crankshaft.
14. Install J-jet piston cooling nozzles.
15. Install block stiffener. Torque to 43 N·m (32 ft. Ibs.).
16. Install the suction tube and oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).
17. Install the cylinder head onto the engine (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
18. Install a new filter and fill the crankcase with new engine oil.Prefill the filter with clean oil.
19. Connect the battery negative cables and start engine.
RINGS-PISTON
STANDARD PROCEDURE
PISTON RING FITTING
1. Determine the piston diameter and obtain the
appropriate ring set. The piston rings can be iden-
tified as shown.
TOP
TOP RING
INTERMEDIATE RING
OIL CONTROL RING
8087e454
2. Position each ring in the cylinder and use a piston

(1) to square it with the bore at a depth (3) of 89.0 CD
mm (3.5 inch).
J9109-70
PISTON RING GAP CHART

TOP RING 0.26 - 0.36 mm (0.010 - 0.014 in.)
INTERMEDIATE RING 0.85-1.15 mm (0.033 - 0.045 in.)
OIL CONTROL RING 0.25-0.55 mm (0.010 - 0.022 in.)
3. Use a feeler gauge to measure the piston ring gap.
4. The top surface of all of the compression rings are

identified with the word TOP or the supplier's
MARK. Assemble the rings with the word TOP or
the supplier's MARK up.
5. Position the oil ring expander (2) in the oil control
ring (1) groove (bottom groove).
NOTE: There is no (TOP) mark on the oil ring.
6. Install the oil control ring (1) with the end gap
OPPOSITE the ends on the expander.
J9109·72
7. Install the intermediate piston ring in the second

groove.
8. Install the top piston ring in the top groove.
J9109-74
9. Position the rings as shown .

• Install top and second compression rings on pis-
ton with ring gaps 180 0 apart.
• Install oil control ring with ring gap 90° from top
and second ring. Do not position gaps over
wrist pin hole.
J9109-73
DAMPER - CRANKSHAFT
REMOVAL
2. Remove the four (4) damper to crankshaft bolts and remove damper.
INSPECTION
NOTE: The Crankshaft damper is of viscous
design and the speed indicator is incorporated
into the crankshaft damper.
1. Inspect the damper hub for cracks and replace if

any are found.
2. If the crankshaft damper is leaking fluid, discard
. and replace the crankshaft damper.
o
000
80b46d32
INSTALLATION
1. Install the crankshaft- damper and bolts. Tighten bolts to 40 N·m (30 ft. Ibs.) torque, plus an additional 60°.
NOTE: The damper must be installed so the hole is located over the dowel pin.
2. Install the accessory drive belt (Refer to 7 • COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
DR - - - - - - - - - - ENGINE - 6.7L DIESEL· SERVICE INFORMATION 9·3065
MOUNT-FRONT
REMOVAL
CAUTION: If replacing a engine mount I bracket, be certain to inspect all ot.,er engine mounts I brackets in
the system. Failure to tollow this caution may result in damage to the vehicle.

2. Remove the viscous fan/drive assembly (Refer to 7
COOLING/ENGINE/RADIATOR FAN
REMOVAL).
4. Install engine support fixture tool# 8534 and steel
bracket tool # 8534A
5. Loosen the thru-bolt and nut.
6. Lift the engine SLIGHTLY and remove the insulator
to block bolts.
7. Remove the RH mount (2) from the engine.
8103b816
8. Remove the LH insulator (2) from the vehicle.

9 • 3066 ENGINE - 6.7L DIESEL • SERVICE INFORMATION - - - - - - - - - - DR
INSTALLATION
CAUTION: If replacing a engine mount I bracket, be certain to inspect all other engine mounts I brackets in
the system. Failure to follow this caution may result in damage to the vehicle.
1. With engine raised SLIGHTLY. position the LH

insulator (2) to the mount. Install the bolts and
torque to specification.
2. With engine raised SLIGHTLY, position the RH
insulator (2) to the mount. Install the bolts and
torque to specification.
3. Lower the engine using tool # 8534, while guiding
the mount and thru~bolt into the frame mounted
support cushion brackets.
4. Install the th ru bolt nut and tighten the nut to 95
N·m (70 ft. Ibs.) torque.
5. Remove the engine support fixture tool # 8534.
7. Install the viscous fan/drive assembly (Refer to 7 ~
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
8103b816
MOUNT-REAR
REMOVAL
CAUTION: If replacing a engine mount I bracket, be certain to Inspect all other engine mounts J brackets in
the system. Failure to follow this caution may result In damage to the vehicle.
1. Raise the veh;cle on a hoist.

2. Position a transmission jack in place.
3. Remove support cushion stud nuts (6).
4. Raise rear of transmission until cushion studs (8)

clear frame.
S. Remove the nuts holding the support cushion (5) to
the transmission support bracket (8).
6. Remove support cushion (5).
7. Remove the bolts (3) holding the transmission sup-

port to the bracket (4).
8. Remove the bolts (7) holding the transmission sup-

port to the transmission.
9. Remove the transmission support (8).
10. Remove the nuts (1) from the transmission

bracket.
11. Remove the bracket (3) from the transmission.
B1tBd9B6
INSTALLATION
CAUTION: If replacing a engine mount I bracket, be certain to inspect all other engine mounts I brackets in
the system. Failure to follow this caution may result in damage to the vehicle.
1. If removed, position the brackets to the transmis-

sion. Install attaching fasteners (1,2), Do not
tighten at this time ..
81b8d9B6
9 - 3070 ENGINE - 6.7l DIESEL - SERVICE I'NFORMATION - - - - - - - - - - DR
2. Position support cushion (5) to transmission sup-

port bracket (3). Install stud nuts (4) and tighten to
3. Position assembled support cushion (5) and
bracket (3) to transmission.
4. Install the support bracket bolt (7) and tighten to 54
5. Install the support bracket bolts (3) and tighten to

6. Torque the bracket to transmission nuts (11) to 30

7. Using the transmission jack, lower the transmission

and support cushion (5) onto the crossmember.
8. Install the support cushion nuts (6) and tighten to
9. Remove the transmission jack.
9 - 3072 ENGINE - 6.7L DIESEL - SERVtCE INFORMATION - - - - - - - - - - DR
LllBRICATION
DESCRIPTION
A gear driven gerotor type oil pump is mounted behind the front gear cover in the lower right portion on the engine.
OPERATION
A gerotor style oil pump draws oil from the crankcase through the suction tube and delivers it through the block
where it enters the oil cooler cover and pressure regulator valve. When oil pressure exceeds 517 kPa (75 PSI), the
valve opens exposing the dump port,· which routes excess oil back to the oil pump.
At the same time, oil is directed to a cast in passage in the oil cooler cover, leading to the oil cooler element. As the
oil travels through the element plates, it is cooled by engine coolant traveling past the outside of the plates. It is
then routed to the oil filter head and through a full flow oil filter. If a plugged filter is encountered, the filter by-pass
valve opens, allowing unfiltered oil to lubricate the engine. This condition can be avoided by frequent oil and filter
changes, per the maintenance schedules found in the owners manual. The by-pass valve is calibrated to open when
it sees a pressure drop of more than 345 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the engine and the turbocharger. The turbocharger receives filtered,
cooled and pressurized oil through a supply line from the filter head. The oil lubricates the turbocharger and returns
to the pan by way of a drain tube connecting the bottom of the turbocharger to a tube in the cylinder block.
FLOW THROUGH
COOLER AND FIL-
TER.
GEROTOR
LUBRICATING FILTER BYPASS
OIL PUMP VALVE
Oil is then carried across the block to an angle drilling which intersects the main oil rifle (3). The main oil rifle (3)
runs the length of the block and delivers oil to the crankshaft main journals and valve train. Oil travels to the crank-
shaft through a series of transfer drillings (one for each main bearing) and lubricates a groove in the main bearing
upper shell. From there another drilling feeds the camshaft main journals. J-jet piston cooling nozzles (1,4) are sup-
DR - - - - - - - - - - EN'G1NE ;. 6.7L DIESEL - SERVICE INFORMATION 9 - 3073
plied by a separate oil rifle. Plugs are used in ~ace of saddle. jets when J~jets are used. Crankshaft internal cross-
drillings supply oil to the connecting rod journals. "
8Ob3b270
Another series of transfer drillings intersecting the main oil rifle supply (14) the valve train components. Oil travels
up the drilling, through a hole in the head gasket. and through a drilling in the cylinder head (one per cylinder),
where it enters the rocker arm pedestal (3) and is divided between the intake and exhaust rocker arm (1). Oil travels
g .. 3074 ENGINE .. 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
up and around the rocker arm mounting bolt, and lubricates the rocker shaft (2) by cross driflings that intersect the
mounting bolt hole. Grooves at both ends of the rocker shaft supply oil through the rocker arm where the oil travels
to the push rod and socket balls.

ENGINE OIL PRESSURE
1. Remove the 1/8 npt plug from the top of the oil filter housing.
2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter.
3. Start engine and warm to operating temperature.
4. Record engine oil pressure and compare with engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)

At Idle 68.9 kPa (10 psi)
At 2500 rpm 206.9 kPa (30 psi)
If minimum engine oil pressure is below these ranges, (Refer to 9 - ENGINE· DIAGNOSIS AND TESTING).
5. Remove oil pressure gauge and install the 1/8 npt plug.
DR - - - - - - - - - - ENGIN'E - 6.7L DIESEL - SERVICE ·INFORMATION 9 - 3075
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine

oil must be maintained at an acceptable level. The
acceptable oil level is in the SAFE RANGE (3) on the
engine oil dipstick.
CD
NOTE: Note: The best time to check the engine oil
level is after the engine is at operating tempera-
ture and has been turned off (not running) for 30
minutes. BOa82c95
1. Position vehicle on level surface.

2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil
dipstick.
3. Wipe dipstick clean.
4. Replace dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the SAFE RANGE area on the dipstick.
7. Replace dipstick.
ENGINE OIL SERVICE

WARNING: Hot oil can cause personal injury.
NOTE: Change engine oil and filter at intervals specified in the owner's manual.
1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.
2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and
drain the used engine oil into the container.
3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist.
• Thin, black oil indicates fuel dilution .
• Milky discoloration indicates coolant dilution.
4. Clean the area around the oil filter head. Remove the filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
5. Install new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface
on the oil pan and drain plug.
7. Install the drain plug. Tighten the plug to 50 N·m (37 ft. Ibs.) torque.
8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the
correct oil for the operating conditions (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIP-
TION).
9. Fill the engine with the correct grade of new oil (Refer to LUBRICATION & MAINTENANCE/FLUID CAPACITIES
- SPECIFICATIONS).
10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug.
11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again.
USED ENGINE OIL DISPOSAL

Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine.
DR - - - - - - - - - - ENGINE· 6.7L DIESEL .. SERVICE INFORMATION 9 .. 3077
COOLER-ENGINE OIL & LINES

REMOVAL - OIL COOLER
1. Disconnect Negative battery cables (Refer to 8 -
ELECTRICAUBATTERY SYSTEM/CABLES
REMOVAL)
2. Drain Coolant. (Refer to 7 - COOLING - STAN-
DARD PROCEDURE)
3. Disconnect Ambient Air and MAF Sensors on Air
Filter housing.
4. Loosen hose clamp at Turbocharger Inlet.
5. Move clamp on Engine Breather hose at Inlet
elbow at turbocharger and remove hose.
6. Remove Air Filter housing cover and inlet hose and
set aside. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - REMOVAL)
7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. (Refer
to 8 - ELECTRICAUCHARGING/GENERATOR - REMOVAL)
8. Loosen the three clamps and hoses from the Coolant outlet tube.
9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm).
10. Remove Coolant outlet tube.
11. Loosen turbocharger oil supply hose from oil cooler housing.
12. Remove oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - REMOVAL)
13. Loosen and remove the 14 oil cooler attachment capcrews (10 mm).
14. Remove oil cooler housing and oil cooler from engine block.
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element.
INSTALLATION
1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material
2. Using new gaskets install oil cooler, oil cooler housing to cylinder block.
NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up
with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine
damage.
3. Tighten mounting capscrews in a cris-cross pattern. Torque to 24 N.m (18 ft-Ib)

4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18
ft-Ib
5. Connect tube to hoses and secure with hose clamps
6. Swing generator into place and torque through bolts to spec
9 - 3078 ENGINE .. 6.7L DIESEL - SERVICE INFORMATION - - - - - - - - - - DR
7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place
8. Tighten hose clamp at Turbocharger to spec.
9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place
10. Connect Ambient Air and MAP sensors
11. Fill Engine with coolant (Refer to 7 - COOLING· STANDARD PROCEDURE)
12. Connect battery cables
13. Start engine and check for leaks.
FILTER-ENGINE OIL
REMOVAL
1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench.
2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure
it is removed.
INSTALLATION
1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine.
2. Apply a light film of lubricating oil to the sealing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal.
3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional V2 turn.
9 .. 3080 ENGINE .. 6~ 7l DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
OIL PAN-GASKET
REMOVAL
1. Disconnect the battery.
2. Remove the intake air assembly.
3. Remove the inner radiator shroud retaining bolts.
4. Remove the inner radiator shroud.
5. Raise and support the vehicle.
6. Remove the front suspension rear tie bar.
7. Remove the left engine mount through bolt.
8. Remove the right engine mount through bolt.
9. Remove the rack and pinion retaining bolts.
10. Drain the engine oil.
12. Install the engine lift fixture.
13. Use the engine lift fixture to raise the engine.
14. Raise the vehicle on the hoist.
15. Remove the oil pan retaining bolts.
16. Lower the oil pan enough to allow the removal of the oil pan gasket.
17. Remove the oil pan gasket.
INSTALLATION
1. Clean the oil pan gasket surfaces to be sure the surfaces are free of debris and oil.
2. Install a new oil pan gasket.
3. Install the oil pan bolts in a cross pattern.
4. Install the rack and pinion bolts.
6. Lower the engine into the mounts.
7. Remove the engine lift fixture.
8. Fill the engine with oil.
10. Install the left engine mount through bolt.
11. Install the right engine mount through bolt.
12. Install the front suspension rear tie bolts.
14. Install the radiator shroud.
15. Install the radiator shroud bolts.
16. Install the intake air assembly.
17. Connect the battery.
PAN - ENGINE OIL

REMOVAL
4x4
1. Open the hood.
3. Remove the intake air assembly.
4. Remove the radiator shroud retaining bolts.
5. Install engine support fixture # 8534B.
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
7. Drain the engine oil (Refer to 9 - ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE).

8. Loosen the front engine mount bolts.
10. Use the engine support fixture #8534B to rarse engine out of the front mounts.
11. Remove the engine oil dipstick.
13. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.
14. Remove oil pan and suction tube.
15. Remove the 2 bolts from the front of the engine block stiffener.
16. Remove the oil pan.
4x2
1. Open the hood.
2. Remove the negative battery cables.
4. Remove the transmission oil cooler lines.
5. Remove the propeller shaft.
6. Remove the starter bolts.
7. Support the starter.
8. Remove the torque converter botts.
9. Remove the exhaust hanger bolts.
10. Remove the gear shift cable.
11. Remove the wiring harness.
12. Remove the transmission mount.
13. Remove the crossover bolts.
14. Position the transmission jack.
15. Remove the bell housing bolts.
16. Remove the transmission.
17. Remove the flywheel housing bolts (8),
18. Remove the flex plate bolts (8).
19. Remove the engine oil dip stick.
20. Drain the oil.
21. Remove the steering rack bolts.
22. Remove the oil pan bolts.
23. Remove the aU pickup bolts.
9 - 3082 ENGINE - 6.7L DIESEL - SERVICE INFORMATIDN - - - - - - - - - - DR
24. Remove the oil pan.
CLEANING
Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required
around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component.
Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any
minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding.
INSTALLATION
4x4
1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner.
2. Clean the oil pan.
3. Clean the oil pan T-joints.
4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone
Rubber Adhesive Sealant or equivalent.
5. Position the new oil pan gasket.
6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the
suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 N·m (18 ft. Ibs.) torque.
Tighten the remaining tube brace bolts to 43 N·m (32 ft. lbs.) torque.
7. Starting in the center and working outward, tighten the oil pan bolts to 28 N·m (21 ft. Ibs.) torque.
8. Install the engine oil dipstick.
9. Install the engine block stiffener.
10. Install the flywheel to crankshaft adapter. Torque to 137 N·m (101 ft. Ibs.).
11. Lower vehicle.
12. Lower the engine into the motor mounts and tighten the through bolts to 88 N·m (64 ft. Ibs.).
13. Remove the engine support fixture #8534.
14. Install battery negative cables.
15. Fill the crankcase with new engine oil.
16. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary.
17. Remove the engine support fixture #8534B.
18. Install the fan and fan shroud. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out
of position causing excessive contact with the radiator coolant tubes.
19. Fill the engine oil.

21. Close the hood.
4x2
1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner.
2. Clean the oil pan.
3. Clean the oil pan T-joints.
4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone
Rubber Adhesive Sealant or equivalent.
5. Position the new oil pan gasket.
DR - - - - - - - - - - ENGINE - 6.7L DIESEL· SERVICE INFORMATION 9 .. 3083
6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the
suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 N·m (18 ft. Ibs.) torque.
Tighten the remaining tube brace bolts to 43 N·m (32 ft. Ibs.) torque.
7. Starting in the center and working outward, tighten the oil pan bolts to 28 N·m (21 ft. Ibs.) torque.
8. Install the steering rack bolts.
9. Install the flex plate.
10. Instan the flywheel to crankshaft adapter. Torque to 137 N·m (101 ft. Ibs.).
11. Install transmission and transfer case (if equipped).
12. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 N·m (57 ft. Ibs.)
torque.
NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamp·
ing ring.
13. Install the EGR cooler. (Refer to 7 - COOLING/ENGINE/EGR COOLER - INSTALLATION)

14. Install the fan and fan shroud. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
NOTE: Make sure that the fan shroud seal Is properly seated in the radiator fan shroud and that it is not out
of position causing excessive contact with the radiator coolant tubes.
15. Remove the transmission jack.

16. Install the crossmember bolts.
17. Install the transmission mount.
18. Install the wiring harness.
19. Install the gear shift cable.
20. Install the exhaust hanger bolts.
21. Install the torque converter bolts.
22. Install the starter.
23. Install the starter bolts.
24. Instan the transmission oil cooler lines.
25. Connect the negative battery cables.
26. Close the hood.
VALVE-OIL PRESSURE RELIEF

REMOVAL
2. Remove the threaded plug (2), spring (4) and valve
(5). Insert a finger or a seal pick to lift the plunger
from the bore. CD
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
J9109-14
CLEANING
1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger
bore requires cleaning. it is necessary to remove the oil filter head to avoid getting debris into the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks and
VALVE OPEN
excessive wear. Polished surfaces are acceptable. -HEIGHT: 41.25mm (1.62 inch)
Verify that the plunger moves freely in the bore. • LOAD: 126 N (26.4 Ib)
Check the spring for height and load limitations. FREE LENGTH: 6Smm (2.6 inch)
Replace the spring if out of limits shown in the figure.
J9509-161
INSTALLArlON
1. Install the plunger, spring, and plug as shown in. Tighten the plug to 80 N·m (59 ft. Ibs.) torque.
3. Start the engine and verify that it has oil pressure.
DR - - - - - - - - - - ENGINE· 6.7l DIESEL - SERVICE INFORMATION 9 • 3085
SWITCH-OIL PRESSURE
REMOVAL
NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be
installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque
the fitting bolt to 18 N·m (13 ft. Ibs)

2. Disconnect the oil pressure switch connector.
3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise).
4. Remove the banjo screw from the oil pressure switch mounting block.
INSTALLATION
1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch
port) should pOint to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft Ibs.
2. If the switch is not being replaced, replace and lubricate the o-ring.
3. Install the oil pressure switch and tighten to 18 N·m (159 in. Ibs.) torque.
4. Connect oil pressure switch connector.
6. Start engine and check for oil leaks at the switch.
PUMP-ENGINE OIL
REMOVAL
2. Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
3. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
4. Remove the fan support/hub assembly.
5. Remove crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCKNIBRATION DAMPER
REMOVAL).
8. Remove the gear housing cover (Refer to 9 -
ENGINENALVE TIMING/GEAR HOUSING COVER
8Ob46d36
- REMOVAL).
9. Remove the four mounting bolts (2) and pull the oil pump (1) from the bore in the cylinder block.
CLEANING
Clean all parts in solvent and dry with compressed air. Clean the old sealer residue from the back of the gear
housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as follows:
1. Visually inspect the lube pump gears for chips,
cracks or excessive wear.
2. Remove the back plate (1).
3. Mark TOP on the gerotor planetary (3) using a felt
tip pen.
4. Remove the gerotor planetary (3) inspect for
excessive wear or damage. Inspect the pump
housing and gerotor drive (2) for damaged and
excessive wear.
- J9109-l56
5. Install the gerotor planetary in the original position.

6. Measure the tip clearance (1). Maximum clearance
is 0.1778 mm (0.007 inch). If the oil pump is out of
limits, replace the pump. CD
J91(19·21
DR - - - - - - - - - - ENGINE· 6.7l DIESEL - SERVICE INFORMATION 9 - 3D87
7. Measure the clearance of the gerotor drive/gerotor

planetary (2)to port plate (1). Maximum clearance CD
is 0.127 mm (0.005 inch). If the oil pump is out of
limits, replace the pump.
8. Measure the clearance of the gerotor planetary to

the body bore (1). Maximum clearance is 0.381
mm (0.015 inch). If the oil pump is out of limits,
replace the pump.
9. Measure the gears backlash (3,4). The limits of a

used pump is 0.15- 0.25 mm (0.006-0.010 inch). If
the backlash is out of limits, replace the oil pump.
10. Install the back plate.
J9109-24
INSTALLATION
1. Lubricate the pump with clean engine oil. Filling the
pump with clean engine oil during installation will
help to prime the pump at engine start up.
2. Install the pump. Verify the idler gear pin is
installed in the locating bore in the cylinder block.
Tighten the oil pump in 3 steps, in the following
sequence.
• Step 1: Push the pump firmly against the cylinder
block and install the four (4) bolts finger tight.
• Step 2: Torque the bolts to 8 N·m (72 in. Ibs).
• Step 3: Torque the bolts to 24 N·m ( 18 ft. Ibs)
g.• 3088 ENGINE - 6.7L DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
3. The back plate on the pump seats against the bot~
tom of the bore in the cylinder block. When the
pump is correctly installed. the flange on the pump
wiU not touch the cylinder block.
IDLER GEAR
4. Measure the idler gear to pump drive gear back- TO PUMP
DRIVE GEAR
lash and the Jdler gear to crankshaft gear backlash.
The backlash should be 0.15- 0.25 mm
(0.006-0.010 inch). If the backlash is out of limits,
replace the oil pump.
5. If the adjoining gear moves when you measure the J9109-25
backlash. the reading will be incorrect. L..---------~ _ _ _ _ _ _ _ _ ____J
6. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing sur-
face. .
7. Install the gear housing cover (Refer to 9 .' ENGINENALVE TIMING/GEAR HOUSING COVER - INSTALLA-
TION).
8. Instafl the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCKNIBRATION DAMPER - INSTALLATION).
9. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION)
11. Install accessory drive belt tensioner. Torque bolt to 43 N·m (32 ft. Ibs.).
12. install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
13. Install the cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 .. 3089
MANIFOLD - INTAKE
REMOVAL
1. Disconnect the batteries. (Refer to 8 - ELECTRICAUBATTERY SYSTEM/CABLES - -REMOVAL)
2. Disconnect the EGA air Transfer tube temperature sensor.
3. Disconnect the EGR Valve Actuator Connector
4. Disconnect the Engine Oil level tube at the Air Inlet bracket
5. Loosen the CAC Outlet tube clamps at the CAC Outlet and Air Inlet and remove the tube. (Refer .to 11 -
EXHAUST SYSTEMITURBOCHARGER SYSTEM/CHARGE AIR COOLER AND PLUMBING - REMOVAL)
6. Loosen and remove both v-band clamps at each end of the Air Transfer tube
7. Remove the P-clip mounting capscrew
8. Remove the Air Transfer tube
9. Loosen and remove six (6) Air Inlet mounting capscrews.
10. Remove the air inlet.
11. Remove the injector fuel lines.
12. Disconnect the Fuel Rail Pressure sensor at the rear of the fuel rail manifold.
13. Remove the High Pressure fuel line from the dump/overflow valve.
14. Remove the fuel rail.
15. Remove the grid heater wiring connector.
16. Disconnect the TMAP sensor.
17. Remove the intake manifold capscrews.
18. Remove the intake manifold.
CLEANING
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block gasket surfaces using a suitable solvent.
The plenum pan rail must be clean and dry (free of aU foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness with a straightedge.
INSTALLATION
1. Clean the Intake Manifold and Cylinder Head Gasket area.
2. Install a new intake manifold gasket.
3. Position the intake manifold and Install the intake manifold capscrews finger tight.
4. Position the fuel rail and install the fuel rail manifold capscrews finger tight.
5. Torque the intake manifold capscrews to 24 N.m (18 ft. Ibs.).
6. Connect the fuel rail pressure sensor.
7. Connect the intake mainfold grid heater. Torque the capscrew to 10 N.m (89 in. Ibs.).
8. Install the fuel lines. (Aefer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - INSTALLATION)
9. Torque the fuel rail mounting capscrews to 24 N.m (18 ft. Ibs.).
10. Clean the Air Inlet gasket area.
11. Clean the Intake Manifold to air inlet area.
12. Install the new Air Intake connection gasket.
13. InstaU the air intake connection to the intake manifold
14. torque the intake manifold to 24 N.m (18 Ibs. ft.).
15. Install the Oil Level Gauge tube and torque to 24 N.m (18 Ibs. ft.).
16. Clean the gasket area of the Air Transfer Tube (both ends).
17. Clean the EGR cooler and EGR control valve gasket area.
18. Using new gaskets, install the Air Transfer Tube.
19. Install the V-band clamps.
20. Install the P-clip to the bracket. Torque the mounting capscrew to 24 N.m (18 Ibs. ft.).
21. Torque the V-band clamps to 10 N.m (89 Ibs. in.).
22. Connect the EGR Valve Actuator connector.
23. Connect the EGR Gas Temperature connector.
24. Connect the batteries.
25. Start the engine and check for leaks.
DR - - - - - - - - - - ENGINE .. 6.7L DIESEL - SERVICE INFORMATION 9 .. 3091
MANIFOLD .. EXHAUST
REMOVAL
1. Disconnect the battery negative cables. (Refer to 8
- ELECTRICAUBATTERY SYSTEM/CABLES -
REMOVAL)
2. Drain the coolant. (Refer to 7 - COOLING - STAN-
DARD PROCEDURE)
4. Remove the EGR cooler. (Refer to 7 - COOLING/
ENGINE/EGR COOLER - REMOVAL)
5. Remove the air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL)
6. Remove the air filter inlet hose from the turbo inlet.
7. Remove the delta P line bracket capscrew nuts and
remove the delta P line from the exhaust manifold
and thermostat housing.
8. Remove the heat shield and noise panel (if
equipped) from the exhaust manifold.
9. Remove the four (4) turbo to exhaust manifold nuts
(15 mm). 81 af5eB1
10. Remove the two (2) rear exhaust manifold cap-
screw lock plates.
11. Remove the Cab Heater tubing/bracket from the exhaust manifold stud (15 mm).
12. Remove the exhaust manifold.
CLEANING
Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite™ pad or
equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the
exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20
mm (.008 inch).
Inspection of turbocharger mounting flange: Using a straight edge across the longest sections of the flange, mea-
sure the flatness using a feeler gauge. Warpage shall not exceed 0.1 mm (0.0039 in). When measuring the exhaust
manifold flanges, the total sum of exhaust flange and the turbocharger flange cannot exceed 0.1 mm (0.00039 in).
If this is the case, the component with the greatest warpage must be replaced.
INSTALLATION
1. Clean the exhaust manifold gasket surfaces.
2. Clean the cylinder head exhaust port gasket surfaces.
3. Clean the turbo mounting flange on the exhaust manifold.
4. Clean the turbo mounting flange on the turbocharger.
5. Install the exhaust manifold to turbocharger gasket and capscrews.
6. Install the exhaust manifold gasket.
NOTE: The five (5) exhaust manifold capscrews with studs are used at the #1 and #2 cylinder locations for
the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket.
7. Install the exhaust manifold spacers and capscrews.

9 • 3092 ENGINE· 6.7L DIESEL . SERVICE INFORMATION - - - - - - - - - - DR
8. Starting from the center and moving in a pattern outward, torque the exhaust manifold bolts to 43 N.m (32 ft.
Ibs.)
9. Install the exhaust manifold capscrew lock plates.
10. Install the exhaust manifold heat shields/noise panels. Torque the mounting nuts to 24 N.m (18 ft. Ibs.).
11. Torque the turbocharger mounting nuts to 43 N.m (32 ft. Ibs.).
12. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat capscrews.
13. Torque the delta-P tube 15 mm nut to 24 N.m (18 ft. Ibs.).
14. Torque the delta-P tube 6 mm nut to 10 N.m (89 in. Ibs.).
15. Torque the delta-P flare nuts to 10 N.m (89 ft. Ibs.).
16. Install the EGR cooler. (Refer to 7 - COOLING/ENGINE/EGR COOLER - INSTALLATION)
17. Install the air filter housing. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL)
18. Fill the coolant. (Refer to 7 - COOLING - STANDARD PROCEDURE)
19. Connect the battery negative cables. (Refer to 8 - ELECTRICAUBATTERY SYSTEM/CABLES - INSTALLA-
TION)
20. Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE
TIMING VERIFICATION
1. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVEA(S) -
REMOVAL).
2. Remove fuel injector from cylinder number 1 (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR
- REMOVAL).
3. Using Special Tool 7471 B rotate the engine until the TDe mark on the damper is at 12 o'clock.
4. Using a 8 in.x 1/4 in. dowel rod inserted into cylinder number 1, rock the crankshaft back and forth to verify
piston number 1 is at TDC.
5. With cylinder number still at TDC, inspect the keyway on the crankshaft gear for proper alignment (12 o'clock
position).
6. If the keyway is not at 12 o'clock position replace the crankshaft gear assembly.
7. If the keyway is at 12 o'clock position, remove front gear cover and verify timing mark alignment between the
camshaft gear and crankshaft gear, if not aligned inspect keyway on camshaft gear.
8. Inspect keyway on camshaft gear for proper alignment with the key in the camshaft, if alignment is off replace
the camshaft/gear assembly.
9. If timing marks alignment is off and no damage is found at either the crankshaft or camshaft gear keyways,
realign timing marks as necessary.
CASE - FRONT
REMOVAL
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
11. Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCKNIBRATION DAMPER - REMOVAL).
12. Remove the lower fan shroud bracket.
13. Remove the upper fan shroud bracket that is mounted to the gear housing.
15. Remove the power steering pump.
16. Remove the accessory drive belt tensioner.
the gasket surfaces.
18. Remove the fuel injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP -
REMOVAL).
19. Disconnect the camshaft position sensor connector.
20. Disconnect and remove engine speed sensor.
21. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
22. Remove the six front oil pan fasteners.
23. Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will
be reused if it is not damaged.
24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
25. Remove the gear housing and gasket.
26. Clean the gasket material from the cylinder block and gear housing.
DR - - - - - - - - - - ENGINE - 6.7L DIESEL - SERVICE INFORMATION 9 . 3095
INSTALLATION
1. Inspect oil pan gasket. If torn, gasket must be
replaced.
2. Install a new gear housing gasket onto cylinder
block and trim any excesss gasket material flush to
oil pan rail.
3. Place a small amount of mopar® engine RTV to the
corners of the block and pan gasket T-joint to
ensure a good seal.
4. Install the gear housing. Torque bolts to 24 N·m (18
ft. Ibs.).
81?3ac39
5. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the
new housing.
6. Connect the camshaft position sensor connector.
7. Install and connect engine speed sensor.
B. Install the injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - 'NSTAL-
LATION).
9. Install the camshaft (Refer to 9 - ENGINE/ENGINE
INSTALLATION). Align the crankshaft and camshaft
gear marks as shown.
8103~556
10. Install a new front crankshaft seal into the gear cover.
11. Apply a bead of Mopar® Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to
surround all through holes.
9 .. 309& ENGINE .. 6.7l DIESEL .. SERVICE INFORMATION - - - - - - - - - - DR
12. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts at
the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to
24 Nm {18 Ft Ibs}.
13. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This center's the seal on the crank-
shaft.
14. Tighten the bolt to 24 N·m (18 ft. Ibs.) torque in a circular pattern.
15. Remove the seal pilot. Install front seal dust shield.
16. Raise the vehicle.
17. Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCKIVIBRATION DAMPER - INSTALLATION).
Torque bolts to 40 Nm (30 ft. Ibs.), plus an additional 60°.
18. Install the lower fan shroud bracket. Torque bolts to 24 N·m (18 ft. Ibs.) torque.
19. Install the upper fan shroud brackets. Hand tighten only.
20. Lower vehicle.
21. Install the fan supportJhub assembly and tighten bolts to 32 N·m (24 ft. Ibs.) torque.
23. Install the accessory drive belt tensioner. Torque bolt to 43 N·m (32 ft. Ibs.) torque.
25. Install the upper cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
26. Torque the upper fan shroud brackets to 24 N·m (18 ft. Ibs.) torque.
27. Connect the coolant recovery bottle hose to the radiator filler neck.
28. Install the radiator upper hose and clamps.
29. Add engine oil.
30. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
31. Connect the battery cables.
32. Start engine and inspect for leaks.
COVER - TIMING
REMOVAL
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
4. Lower vehicle.
12. Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCKNIBRATION DAMPER - REMOVAL).
the gasket suriaces.
INSTALLATION
1. Install a new front crankshaft oil seal.
2. Obtain a seal pilot (1) installation tool from a crank-
shaft front seal service kit and install the pilot into
the seal.
3. Apply a bead of Mopar® Silicone Rubber Adhesive
SeaJant or equivalent to the gear housing cover. Be
sure to surround all through holes.
4. Using the seal pilot to (1) align the cover , install
the cover to the housing and install the bolts.
Tighten the bolts at the 3 and 9 o'clock position fin-
ger tight, then in a clockwise direction starting at
the 3 o'clock position, torque to 24 Nm (18 Ft. Ibs).
5. Snug, but do not torque one bolt at the 3 o'clock 80b46d27
and 9 o'clock pOSitions. This centers the seal on
the crankshaft.
6. lighten the bolts to 24 N·m (18 ft. Ibs.) in a circular pattern.
7. Remove the seal pilot. Install front seal dust shield.
8. Raise the vehicle.
9. Install the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCKNIBRATION DAMPER - INSTALLATION).
10. Lower vehicle.
11. Install the fan support/hub assy, and tighten bolts to 32 N·m (24 ft. Ibs.) torque.
13. Install accessory drive belt tensioner. Torque bolt to 43 N·m (32 ft. Ibs.) torque.
15. Install the cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN INSTALLATION).
16. Install the radiator upper hose and clamps.
17. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
18. Connect the battery cables.
19. Start engine and inspect for leaks.

535ed7fa 7712 4fea A4af 21970782f11c Ram 6.7 Disel Electrico

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535ed7fa 7712 4fea A4af 21970782f11c Ram 6.7 Disel Electrico

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DR - - - - - - - - - ENGINE .. ELECTRICAL DIAGNOSTICS· 6.

ENGINE· ELECTRICAL DIAGNOSTICS· 6.7L DIESEL

ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L P0102-MASS AIR FLOW SENSOR "A"

P0304-CYLINDER 4 MiSFIRE .............. 1896 P0516-BATTERY TEMPERATURE SENSOR

P0633-SKIM SECRET KEY NOT STORED IN P141 A-EXHAUST GAS TEMPERATURE

P0700-TRANSMISSION CONTROL SYSTEM P2033-EXHAUST GAS TEMPERATURE

PERFORMANCE. ........................ 2159 P2080·EXHAUST GAS TEMP SENSOR

P125A-POWER ENABLE CONTROL P2084-EXHAUST GAS TEMP SENSOR

HIGH ................................... 2172 P2123-ACCELERATOR PEDAL POSITION

OPEN (TIPM) ............................ 2187 P2227-BAROMETERIC PRESSURE SENSOR

HIGH (TIPM) ............................ 2195 P2262-TURBOCHARGER BOOST

P2267-WATER IN FUEL SENSOR CIRCUIT P268D-CYLINDER 2 INJECTOR DATA

ENGINE - ELECTRICAL DIAGNOSTICS - 6.7L DIESEL

3. VEHICLE HISTORY AND

4. WIRE HARNESS INSPECTION

For a complete wiring diagram Refer to Section 8W.

PRESSURE LIMITING VALVE

1 a PRESSURE LIMITING VALVE

3. HIGH PRESSURE PUMP PERFORMANCE

4. HIGH PRESSURE PUMP RETURN

5. FUEL INJECTOR RETURN FLOW

6. PRESSURE LIMITING VALVE

K44 K916 F855 K824 K24 K925

For a complete wiring diagram Refer to Section 8W.

DAMAGE TO THE ESS OR EPS

1.. DAMAGE TO THE ESS OR EPS

2. MECHANICAL MISALIGNMENT OF THE ESS OR EPS

3. MECHANICAL MISALIGNMENT OF THE CAMSHAFT AND CRANKSHAFT GEARS

I FUSED IGNITION 11iTI-LOCI F960

02111 02111 02111 02112 02112 021n

For a complete wiring diagram Refer to Section 8W.

HEATER CIRCUIT IN 02 SENSOR

Perlorm POWERTRAIN VERIFICATION TEST - 6.7L.

2. OXYGEN SENSOR AND SMART MODULE

02111 02111 02111 02112 02lfl 0211'2

10'( 1'( 14 T lOT 1'( 15 T 61 ~ T 12 T 8 T 2 T 13 T T 4

02111 02111 02111 02111 02 111

For a complete wiring diagram Reter to Section 8W.

HEATER CIRCUIT IN 02 SENSOR

1. AFTERTREATMENT WIRING HARNESS

2. OXYGEN SENSOR AND SMART MODULE

491 C2 50 1C2 601 C2 42 C1 43 Ct 33 Ct 38 Ct 39 C1

ACTUATOR·VQT SEll lOR.

INCORRECT ACTUATOR INSTALLATION

2. INCORRECT ACTUATOR INSTALLATION

For a complete wiring diagram Refer to Section 8W.

INTERMITTENT J1939 CONNECTION

For a complete wiring diagram Refer to Section 8W.

3. TURBOCHARGER SPEED SENSOR

4. TURBOCHARGER SPEED SENSOR

7. CIRCUITS SHORTED TOGETHER

P006E-TURBOCHARGER BOOST CONTROL MODULE SUPPLY VOLTAGE CIRCUIT

49lci 50lci 60lci 42 Ct 43 Ct 33 Ct 38 C1 39 C1

For a complete wiring diagram Refer to Section 8W.

1. DTC P006F PRESENT

P0071-INLET AIR TEMP SENSOR RATIONAI.lTY - ECM

1. INLET AIR TEMPERATURE SENSOR

2. INLET AIR TEMPERATURE SENSOR

(G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

2. (G31) AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

3. AAT SENSOR VOLTAGE ABOVE 4.6 VOLTS

5. (G31) AAT SIGNAL CIRCUIT OPEN

6. (G930) SENSOR GROUND CIRCUIT OPEN