Detroit GHG17 Heavy Duty Troubleshooting Manual PDF

Detroit Diesel
GHG17 Heavy Duty Troubleshooting Manual
farmconstructionmanuals.com
1 GHG17 Heavy Duty Troubleshooting Manual (DDC-SVC-MAN-0191)
California Proposition 65 Warning and Engine Idle Notice
1
Troubleshooting Manual Introduction

Detroit™ is the world leader in diesel engines and diesel engine electronics. Detroit™ has made technological
leaps in engine performance and fuel economy. Today, we build the most dependable electronically controlled
diesel engine in the industry.
EPA07, EPA10, and GHG14 Electronic Controls, DDEC VI, DDEC10, and DDEC13, provide industry standard
serial data links: SAE Standards J1587 and J1939. SAE Standard J1587 provides two way communications for
the diagnostic equipment and vehicle displays. SAE Standard J1939 provides control data to other vehicle
systems such as transmissions and traction control devices.
As the leader in engine computer systems and technology, Detroit™ remains focused on providing excellence in
products, service support and training. As products become more and more advanced, today's technicians must
become specialized in multiple areas. This manual is designed with that thought in mind.
Our goal at Detroit™ is to be the most customer focused and most responsive engine manufacturer in the world.
1
Scope and Use of This Troubleshooting Manual

Note : Be aware that troubleshooting in this manual is mostly concerned with DDEC related codes. Codes
associated with other components, e.g. transmissions, ECUs, ABS, etc. can be found in the proper manufacturers
publications.
Note : Service Information Bulletins are issued via the Detroit™ website. Visit https://ddcsn-ddc.freightliner.com
The first half of the manual contain mechanical troubleshooting procedures. The second half contains instructions
for troubleshooting the electronic controls. This manual is divided into numbered chapters. Each chapter begins
with a table of contents. Pages and illustrations are numbered consecutively within each chapter. Information can
be located by using the table of contents at the front of the manual or the table of contents at the beginning of
each chapter.
Instructions to "Contact Detroit™ Customer Support Center" indicate that at the time of this publication, all known
troubleshooting checks have been included. Review any recent Service Information Bulletins (SIB) or Service
Information letters before calling. It is also suggested that other Detroit™ outlets be contacted. E.g. if you are a
dealer or user, contact your closest DDC Distributor. Ensure you have the engine serial number when you call.
The phone number for the Detroit™ Customer Support Center is 800-445-1980.
Instructions in this manual may suggest replacing a non Detroit™ component. It may be required to contact the
supplier of the component, e.g. truck manufacturer for a TPS concern, to obtain approval to replace the
component.
3.1 Mechanical Troubleshooting

Each chapter has a fault as the title (i.e. Excessive White Smoke). The next level within the chapter is the
probable cause/symptom of the fault. Following this are the resolution and verification of the resolution. The
mechanical troubleshooting should be used before the electronic troubleshooting.
1
GHG17 Heavy Duty Troubleshooting Manual (DDC-SVC-MAN-0191) 3
3.2 Electronic Troubleshooting

The Electronic Control system allows for an increased processor speed and increased memory.
Instructions for repair in this manual are generic. For example, "Repair Open" is used to advise the technician that
a particular wire has been determined to be broken. In some cases it may not be best to try and locate the open. It
may be that the best repair technique is to replace a complete harness. Instructions to check terminals and
connectors should include checking for proper contact tension. Using a mating terminal, a modest force should be
required to remove a terminal from its mate. Replace terminals with poor tension. The technician should make the
determination of the proper repair, with the best interest of the customer in mind. After completing any repair,
always clear fault codes that may have been generated during the troubleshooting process.
2
Safety Precautions
The following safety measures are essential when working on any Detroit™ engine.
4.1 Exhaust (Start/Run Engine)

Before starting and running an engine, adhere to the following safety precautions:
WARNING
PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a
level surface, parking brake is set, and the wheels are blocked.
WARNING
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
1
4.2 Stands
Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either the jack or the hoist
to carry the load. When lifting an engine, ensure the lifting device is fastened securely. Ensure the item to be lifted
does not exceed the capacity of the lifting device.
2
4.3 Glasses
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when using tools
such as hammers, chisels, pullers or punches.
WARNING
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye
protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
3
4.4 Welding
Wear welding goggles and gloves when welding or using an acetylene torch.
WARNING
PERSONAL INJURY
To avoid injury from arc welding, gas welding, or cutting, wear required safety equipment
such as an arc welder's face plate or gas welder's goggles, welding gloves, protective
apron, long sleeve shirt, head protection, and safety shoes. Always perform welding or
cutting operations in a well ventilated area. The gas in oxygen/acetylene cylinders used in
gas welding and cutting is under high pressure. If a cylinder should fall due to careless
handling, the gage end could strike an obstruction and fracture, resulting in a gas leak
leading to fire or an explosion. If a cylinder should fall resulting in the gage end breaking
off, the sudden release of cylinder pressure will turn the cylinder into a dangerous
projectile. Observe the following precautions when using oxygen/acetylene gas cylinders:
WARNING
FIRE
To avoid injury from fire, check for fuel or oil leaks before welding or carrying an open
flame near the engine.
NOTICE
Use proper shielding around hydraulic lines when welding to prevent hydraulic line
damage.
Ensure that a metal shield separates the acetylene and oxygen tanks. (Tanks must be chained to a cart).
4
4.5 Work Place
5
4.6 Clothing
Safe work clothing fits and is in good repair. Work shoes are sturdy and rough-soled. Bare feet, sandals or
sneakers are not acceptable foot wear when adjusting and/or servicing an engine. Do not wear the following when
working on an engine.
WARNING
PERSONAL INJURY
To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.
Any of these items could catch on moving parts causing serious injury:
• Rings
• Wrist watches
• Loose fitting clothing
6
4.7 Power Tools

Do not use defective portable power tools. Check for frayed cords prior to using the tool. Be sure all electric tools
are grounded. Defective electrical equipment can cause severe injury. Improper use of electrical equipment can
cause severe injury.
WARNING
ELECTRICAL SHOCK
To avoid injury from electrical shock, follow OEM furnished operating instructions prior to
usage.
7
4.8 Air
Recommendations regarding the use of compressed air are indicated throughout the manual.
WARNING
EYE INJURY
8
4.9 Fluids and Pressure

Be extremely careful when dealing with fluids under pressure. Fluids under pressure can have enough force to
penetrate the skin. These fluids can infect a minor cut or opening in the skin. If injured by escaping fluid, see a
doctor at once. Serious infection or reaction can result without immediate medical treatment.
WARNING
PERSONAL INJURY
To avoid injury from penetrating fluids, do not put your hands in front of fluid under
pressure. Fluids under pressure can penetrate skin and clothing.
9
4.10 Fuel
Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank when refueling to
avoid the possibility of an electric spark igniting the fuel.
WARNING
FIRE
To avoid injury from fire caused by heated diesel-fuel vapors:
WARNING
GASOLINE VAPOR IGNITION
To avoid injury from possible gasoline vapor ignition when refueling, keep the hose,
nozzle, funnel, or container in contact with the metal opening of the fuel tank. This will
reduce the likelihood of a dangerous spark.
The following cautions should be followed when filling a fuel tank:
CAUTION
PERSONAL INJURY
To avoid injury from fuel spills, do not overfill the fuel tank.
WARNING
FIRE
To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including
open flames, sparks, and electrical resistance heating elements. Do not smoke when
refueling.
10
4.11 Batteries
Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to do so for some
time after receiving a steady charge.
WARNING
Battery Explosion and Acid Burn
To avoid injury from battery explosion or contact with battery acid, work in a well ventilated
area, wear protective clothing, and avoid sparks or flames near the battery. If you come in
contact with battery acid:
Always disconnect the battery cable before working on the electrical system.
WARNING
PERSONAL INJURY
To avoid injury from accidental engine startup while servicing the engine,
disconnect/disable the starting system.
Disconnect the batteries or disable an air starter when working on the engine (except DDEC) to prevent accidental
starting.
CAUTION
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
Use care when connecting battery cables to avoid electrical shock.
11
4.12 Fire
Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher for the situation.
The correct fire extinguisher types for specific working environments are listed in the following table.
Fire Extinguisher Work Environment

Type A Wood, Paper, Textile and Rubbish
Type B Flammable Liquids
Type C Electrical Equipment
12
4.13 Cleaning Agent

Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it releases. Ensure
the work area is adequately ventilated. Use protective gloves, goggles or face shield, and apron.
WARNING
PERSONAL INJURY
To avoid injury from harmful vapors or skin contact, do not use carbon tetrachloride as a
cleaning agent.
Exercise caution against burns when using oxalic acid to clean the cooling passages of the engine.
13
4.14 Working on a Running Engine

When working on an engine that is running, accidental contact with the hot exhaust manifold can cause severe
burns.
CAUTION
PERSONAL INJURY
To avoid injury from unguarded rotating and moving engine components, check that all protective
devices have been reinstalled after working on the engine.
WARNING
PERSONAL INJURY
To avoid injury, use care when working around moving belts and rotating parts on the
engine.
14
4.15 Turbocharger Compressor Inlet Shield

A turbocharger compressor inlet shield, is available and must be used anytime the engine is operated with the air
inlet piping removed. The shield helps to prevent foreign objects from entering and damaging the turbocharger
and will prevent the mechanic from accidentally touching the turbocharger impeller.
WARNING
PERSONAL INJURY
To avoid injury from contact with rotating parts when an engine is operating with the air
inlet piping removed, install an air inlet screen shield over the turbocharger air inlet. The
shield prevents contact with rotating parts.
Use of this shield does NOT preclude any other safety practices contained in this manual.
15
4.16 Fluoroelastomer (VITON®) Caution

Under normal design conditions, fluoroelastomer (VITON®) parts, such as O-rings and seals, are perfectly safe to
handle.
WARNING
CHEMICAL BURNS
To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves
when handling fluoroelastomer O-rings or seals that have been degraded by excessive
heat. Discard gloves after handling degraded fluoroelastomer parts.
However, a potential hazard may occur if these components are raised to a temperature above 316°C (600°F),
such as during a cylinder failure or engine fire. At temperatures above 316°C (600°F) fluoroelastomer will
decompose (indicated by charring or the appearance of a black, sticky mass) and produce hydrofluoric acid. This
is extremely corrosive and, if touched by bare skin, may cause severe burns, sometimes with symptoms delayed
for several hours.
16
Electrical System
5.1 Detroit Diesel Electronic Control System
The Detroit Diesel Electronic Control System (DDEC) controls fuel injection timing and output by the common rail
fuel injector on the engine. The system also monitors several engine functions using electrical sensors which send
electrical signals to the Motor Control Module (MCM). The MCM then computes the incoming data and determines
the correct fuel output and timing for optimum power, fuel economy and emissions. The MCM also has the ability
to display warnings or shut down the engine completely (depending on option selection) in the case of damaging
engine conditions, such as low oil pressure, low coolant, or high oil temperature.
The DDEC system also has a cab-mounted control unit for vehicle engine management, the Common Powertrain
Controller (CPC). The connection to the vehicle is made via a CAN interface which digitally transmits the nominal
values (e.g. torque, engine speed specifications, etc.) and the actual values (e.g. engine speed, oil pressure, etc.).
The Exhaust Gas Recirculation (EGR) engines will use the sixth generation of the DDEC system, DDEC10®
Motor Control Module (MCM).
The replacement of DDEC components is based on indicated diagnostic codes leading to faulty components.
5.1.1 Harnesses
There are two major harness: the Engine Harness (EH) and the Vehicle Interface Harness (VIH). The Engine
Harness is installed at the factory and is delivered connected to all engine sensors, the fuel injection system, and
the MCM. The Original Engine Manufacturer (OEM) supplied VIH connects the CPC to other vehicle systems.
1
5.2 Motor Control Module

The engine mounted Motor Control Module (MCM) includes control logic to provide overall engine management.
1. 21–pin Connector (OEM Responsibility)

2. 120–pin Connector (Detroit™ Responsibility)
Fig 5.1, Motor Control Module
The following is a summary of the tasks the MCM monitors:

• Exhaust gas recirculation (EGR)
• Intake air preheating system
• Turbocharger
• Diesel Particulate Filter (DPF) (EPA07 ONLY - for EPA10 the Aftertreatment Control Module (ACM)
monitors the DPF)
• Instrument cluster
• Engine brake
• Amplified Pressure Common Rail System (APCRS)
• Thermal management
DDEC VI/10 provides an indication of engine and vehicle malfunctions. The MCM continually monitors the DDEC
VI/10 system.
Any faults that occur are stored as codes. These codes can be accessed in any of three ways:
• A DiagnosticLink® Standard for DDEC VI/10 can be used to read the codes.
• A personal computer (PC) connected to the Motor Control Module (MCM) through a translator device using
SAE J1939 Data Link+, are used as the communication link, to Common Powertrain Controller (CPC) and
CAN link to Motor Control Module (MCM).
• The Amber Warning Lamp (AWL) (check engine) or the Red Stop Lamp (RSL) is illuminated.
The AWL (check engine) (panel mounted yellow indicator light) illuminated diagnose condition as soon as
convenient, lights are CPC controlled. The RSL (panel mounted red indicator light) and AWL (check engine)
illuminated, a major fault occurred and immediate attention required to avoid engine damage. Automatic engine
2
shutdown or ramp down is available as an option. A shutdown override switch is required to allow the vehicle to
be moved to a safe location during automatic shutdown or ramp down. The MCM tells the light when to activate.
5.2.1 MCM 21–pin Connector

The wiring for the VIH 21–pin to the MCM listed in the following table. The side of the connector shown is looking
into the pins.
MCM 21–pin Connector

Pin Signal Type Function Pin Signal Type Function
Battery (+)
1 CAN2L Not Used 12 KL30 (current demand
40A)
Powertrain CAN
2 CAN2GND Not Used 13 CAN1H High
Battery (+)
3 CAN2H Not Used 14 KL30 (current demand
40A)
Battery (+)
4 CAN2GND Not Used 15 KL30 (current demand
40A)
Battery (-) Powertrain CAN
5 KL31 (current demand 16 CAN1GND Ground
40A)
Battery (-)
6 KL31 (current demand 17 Not Used Not Used
40A)
7 KL15 IGN 18 KDiag_S Not Used
Battery (-) Powertrain CAN
8 KL31 (current demand 19 CAN1L Low
40A)
Battery (-)
9 KL31 (current demand 20 KL50 Crank Start Input
40A)
IES Motor CAN Start Enable
10 CAN1GND 21 START_B
HF Ground Output
Battery (+)
11 KL30 (current demand
40A)
5.2.2 DD13 120-Pin Connector Pin-Out

The following tables show the 120-pin connector pin-outs for the DD13 MCM.
3
MCM Connector – DD13 (1 of 2)

IMV / FMU
Highside supply
1 RPU_H 31 PWM_5 Not Used
metering unit
(PWM)
IMV / FMU
Lowside supply
2 RPU_L 32 PWM_7 Jake brake low
metering unit (S
/ W)
3 H_OUT1 Not Used 33 PWM_6 Actuator fan 2
APCRS:
Amplifier; Bosch
4 MV_B5F 34 PWM_8 Not Used
PLD; E3: Spill
valve
5 MV_B5 Not Used 35 PWM_10 Wastegate
APCRS:
Amplifier; Bosch
6 MV_B5D 36 PWM_09 Not Used
PLD; E3: Spill
valve
Spill control
7 MV_B5 valve / Amplifier 37 PWM_11 Not Used
/ PLD (EUP)
APCRS:
Amplifier; Bosch
8 MV_B5B 38 PV_M Wastegate GND
PLD; E3: Spill
valve
9 MV_B5 Not Used 39 HSW2 Not Used
APCRS:
Amplifier; Bosch
10 MV_B4E 40 PCV_H Not Used
PLD; E3: Spill
valve
APCRS:
Amplifier; Bosch
12 MV_B4C 42 LSU_LS Not Used
PLD; E3: Spill
valve
Input for
inductive sensor
Spill control crankshaft
13 MV_B4 valve / Amplifier 43 DYN3_S [analysis of the
/ PLD (EUP) falling edge from
the sensor
signal]
APCRS:
Amplifier; Bosch
14 MV_B4A 44 LSU_V Not Used
PLD; E3: Spill
valve
Input for
inductive sensor
camshaft
(2PINs) or hall
15 MV_B4 Not Used 45 DYN2_S sensor (3PINs)
[analysis of the
falling edge from
the sensor
signal]
EvoBus
Needle control
16 MV_B2F 46 D3_V Start/Stop rear
valve switch
Sensor fan
17 MV_B2 Not Used 47 DYN4_S speed (hall
sensor)
Cam Sensor
Needle control
18 MV_B2D 48 DYN2_M Signal ground
valve GND
4
Needle control
19 MV_B2 49 DYN5_S Not Used
valve
Needle control Turbo Speed
20 MV_B2B 50 SGND
valve GND
21 MV_B2 Not Used 51 DYN1_S Turbo Speed
Needle control
22 MV_B1E 52 SGND_P Sensor ground
valve
23 MV_B1 Not Used 53 A23_S Not Used
Needle control Oil pressure
24 MV_B1C 54 A09_S
valve switch
Needle control
25 MV_B1 55 SGND_P Sensor ground
valve
Needle control
26 MV_B1A 56 KN2_2 Not Used
valve
Water level fuel
27 MV_B1 Not Used 57 A05_S filter
Sensor Power
28 START_B Not Used 58 SENS1_V Supply 1
29 KN1_1 Not Used 59 KN1_2 Not Used
30 A01_S Not Used 60 A02_S Not Used
5

SW and PWM
Power Supply
61 PWM_1 Not Used 91 PV_B1 Output (high
side)
SW and PWM
Power Supply
62 PV_B2 92 PWM_3 Not Used
Output (high
side)
Wastegate
63 H_OUT2 Not Used 93 PV_B1 Power Supply
SW and PWM
Power Supply
Output (high
side)
65 PWM_12 HC dosing valve 95 PV_M Not Used
66 PWM_13 Jake brake high 96 PWM_2 Not Used
Prop Valve
67 PV_M 97 PWM_15 Not Used
Group Ground
68 PCV_L Not Used 98 PWM_14 Not Used
Fuel cut off valve
69 PWM_18 HC Metering 99 PWM_17 Not Used
Unit
H-bridge output
70 PWM_16 Not Used 100 H_OUT1 for intake air
throttle
12V Power
supply (Vbatt-
71 LIN_V 101 H_OUT2 Sensor ground
0.25V max.15V)
for LIN sensors
72 LIN Not Used 102 SGND Sensor ground
Crank Position
73 DYN3_M Signal ground 103 SGND Sensor ground
GND
Actuator CAN:
74 CAN3L 104 SGND Sensor ground
CAN-Low
Actuator CAN:
75 CAN3H 105 SGND Sensor ground
CAN-High
Intake manifold
EvoBus temperature
76 D3_S Start/Stop rear 106 A30_S [EGR and fresh
switch signal in air mixed]
Fuel
77 A29_S 107 D2_S Not Used
temperature
Engine oil
78 A15_S Rail pressure 108 A28_S temperature
Differential
79 D1_S Not Used 109 A14_S pressure EGR
Coolant inlet Coolant outlet
80 A27_S 110 A26_S
temperature temperature
HC doser fuel
81 A13_S Not Used 111 A12_S pressure out
82 SENS2_V Sensor Supply 2 112 A25_S Not Used
HC doser fuel
84 A10_S 114 SGND Sensor ground
pressure in
Sensor Supply
85 SENS2_V 115 A22_S Not Used
2/10 way
6
Charge air
pressure Sensor Power
87 A06_S [directly after 117 SENS1_V Supply 1
intake air
throttle]
88 SGND Not Used 118 A07_S Not Used
Charge air
temperature
89 KN2_1 Not Used 119 A19_S [directly after
intercooler]
Position intake
90 A03_S 120 A04_S Not Used
air throttle

7

IMV / FMU
Highside supply
metering unit
(PWM)
IMV / FMU
Lowside supply
metering unit (S
/ W)
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
5 MV_B5 Not Used 35 PWM_10 Not Used
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Spill control
/ PLD (EUP)
APCRS:
Amplifier; Bosch
8 MV_B5B 38 PV_M Not Used
PLD; E3: Spill
valve
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Input for
inductive sensor
the sensor
signal]
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Input for
inductive sensor
camshaft
(2PINs) or hall
[analysis of the
falling edge from
the sensor
signal]
Needle control
16 MV_B2F 46 D3_V Not Used
valve
Sensor fan
sensor)
Cam Sensor
Needle control
valve GND
8
Needle control Electrostatic Oil

19 MV_B2 49 DYN5_S
valve Separator Speed
Needle control
20 MV_B2B 50 SGND Not Used
valve
21 MV_B2 Not Used 51 DYN1_S Not Used
Needle control
valve
24 MV_B1C 54 A09_S
valve switch
Needle control
valve
Needle control
valve
Water level fuel
Sensor Power
9

SW and PWM
Power Supply
side)
SW and PWM
Power Supply
Output (high
side)
63 H_OUT2 Not Used 93 PV_B1 Not Used
SW and PWM
Power Supply
Output (high
side)
Prop Valve
Group Ground
Fuel cut off valve
Unit
70 PWM_16 Not Used 100 H_OUT1
12V Power H-bridge output
supply (Vbatt- for intake air
71 LIN_V 101 H_OUT2 throttle
0.25V max.15V)
for LIN sensors
72 LIN Not Used 102 SGND
Signal ground
73 DYN3_M 103 SGND
GND
Actuator CAN: Sensor ground
74 CAN3L 104 SGND
CAN-Low
Actuator CAN:
75 CAN3H 105 SGND
CAN-High
Intake manifold
temperature
76 D3_S Not Used 106 A30_S [EGR and fresh
air mixed]
Fuel
temperature
Engine oil
Differential
80 A27_S 110 A26_S
HC doser fuel
HC doser fuel
pressure in
Sensor Supply
2/10 way
Charge air
intake air
throttle]
10

Charge air
temperature
intercooler]
Position intake
air throttle

11

IMV / FMU
Highside supply
metering unit
(PWM)
IMV / FMU
Lowside supply
metering unit (S
/ W)
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
5 MV_B5 Not Used 35 PWM_10 Not Used
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Spill control
/ PLD (EUP)
APCRS:
Amplifier; Bosch
8 MV_B5B 38 PV_M Not Used
PLD; E3: Spill
valve
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Input for
inductive sensor
the sensor
signal]
APCRS:
Amplifier; Bosch
PLD; E3: Spill
valve
Input for
inductive sensor
camshaft
(2PINs) or hall
[analysis of the
falling edge from
the sensor
signal]
Needle control
16 MV_B2F 46 D3_V Not Used
valve
Sensor fan
sensor)
Cam Sensor
Needle control
valve GND
12
Needle control Electrostatic Oil

19 MV_B2 49 DYN5_S
valve Separator Speed
Needle control
20 MV_B2B 50 SGND Not Used
valve
21 MV_B2 Not Used 51 DYN1_S Not Used
Needle control
valve
24 MV_B1C 54 A09_S
valve switch
Needle control
valve
Needle control
valve
Water level fuel
Sensor Power
13

SW and PWM
Power Supply
side)
SW and PWM
Power Supply
Output (high
side)
63 H_OUT2 Not Used 93 PV_B1 Not Used
SW and PWM
Power Supply
Output (high
side)
Prop Valve
Group Ground
Fuel cut off valve
Unit
70 PWM_16 Not Used 100 H_OUT1
12V Power H-bridge output
supply (Vbatt- for intake air
71 LIN_V 101 H_OUT2 throttle
0.25V max.15V)
for LIN sensors
72 LIN Not Used 102 SGND
Signal ground
73 DYN3_M 103 SGND
GND
Actuator CAN: Sensor ground
74 CAN3L 104 SGND
CAN-Low
Actuator CAN:
75 CAN3H 105 SGND
CAN-High
Intake manifold
temperature
76 D3_S Not Used 106 A30_S [EGR and fresh
air mixed]
Fuel
temperature
Engine oil
Differential
80 A27_S 110 A26_S
HC doser fuel
HC doser fuel
pressure in
Sensor Supply
2/10 way
Charge air
intake air
throttle]
14

Charge air
temperature
intercooler]
Position intake
air throttle
5.2.1 Removal of the Motor Control Module

Remove as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Open the hood.
CAUTION
ELECTRICAL SHOCK
3. Disconnect batteries. Refer to Original Equipment Manufacturer (OEM) procedures.
4. Remove the 120-pin electrical connector retaining bolts.
5. Release the latch on the harness connector to remove the 21-pin and the 120-pin electrical connectors
from the Motor Control Module (MCM).
6. On a rear sump oil pan, disconnect the oil dipstick tube from the MCM.
7. Remove the four bolts holding the MCM to the engine and remove the MCM.
5.2.2 Inspection of the Motor Control Module

Inspect as follows:
1. Inspect the Motor Control Module (MCM) for damage and replace if required.
2. Inspect the ISO mounts for damage and replace if required.
5.2.3 Installation of the Motor Control Module

Install as follows:
15
NOTICE
Ensure the MCM metal housing does not come in contact with the chassis.
Note : Do not ground the MCM housing. This can result in false codes being logged.
1. Confirm that vehicle battery power is disconnected and the ignition is in the OFF position.
2. Install the MCM to the cylinder block with four bolts and eight isolators. Torque the MCM-to-cylinder block
bolts to 15 N·m (11 lb·ft).
3. Connect the 21-pin and 120-pin engine harness connectors to the MCM. Close and lock the latch on the
connectors.
4. Install the 120-pin electrical connector retaining bolts. Torque to 15 N·m (11 lb·ft).
CAUTION
ELECTRICAL SHOCK
5. Connect the batteries. Refer to Original Equipment Manufacturer (OEM) procedures.
6. Is the MCM being installed a replacement MCM?
6.a Yes; using DiagnosticLink , program the MCM to the correct configuration. After programming, perform
an Accumulated Fuel Mass Sync. For more information, refer to the DiagnosticLink help menu.
Afterwards, Go to step 7.
6.b No; Go to step 7.
7. Turn the ignition ON (key ON, engine OFF). Observe DiagnosticLink for any diagnostic code(s). If any
code(s) are logged, refer to the proper code diagnostics.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-
ventilated area. Engine exhaust is toxic.
8. Start the engine.

9. Close the hood.
16
5.3 Common Powertrain Controller

The Common Powertrain Controller (CPC) has three 18-pin connectors and one 21-pin connector. The following
sections contain the connector pin-outs for truck. vocational, transit bus and crane applications.
The CPC is the interface between the MCM and the vehicle/equipment for engine control and manages other
vehicle/equipment functions.
Fig 5.2, Common Powertrain Controller
The OEM is responsible for mounting this part in an enclosed, protected environment. The mounting bracket is the
responsibility of the OEM. There must be maximum physical separation of the VIH from other vehicle/equipment
electrical systems. Other electrical system wires should ideally be at least three feet away from the VIH and
should not be parallel to the VIH. This will eliminate coupling electromagnetic energy from other systems into the
VIH.
17
Fig 5.3, Common Powertrain Controller Dimensions
Note : The CPC should be mounted with the connectors pointing down.
The CPC communicates over the J1587 and J1939 Data Links to the vehicle.
Fig 5.4, NAFTA Architecture On-highway
Within the CPC, sets of data for specific applications are stored. These include idle speed, maximum running
speed, and speed limitation. Customer programmable parameters are also stored here.
The CPC receives data from the operator (accelerator pedal position, switches, various sensors) and other
electronic control units (for example, synchronization controllers for more than one genset, air compressor
controls).
18
From this data, instructions are computed for controlling the engine and transmitted to the MCM via the
proprietary data link.
19
Connector #1 Pin Assignments

Pin Signal Type Function
1 Digital Input_FLEX_01 Multiple Applications
2 Digital Input_FLEX_02 Park Brake Interlock
3 Digital Input_SFP_05 Idle Validation Switch 2 (throttle active)
4 Digital Output_LP_LS_02 Throttle Position Sensor Ground
5 Digital Output_LP_LS_01 DPF Regeneration Lamp
6 Digital Input_SFP_06 Idle Validation Switch 1 (idle active)
7 SFP_08 Throttle Position Sensor
8 SFP_07 Throttle Position Sensor Supply
9 PWM_FPO_02 Tachometer
11 Digital Input_FLEX_08 Limiter 0
12 Digital Input_FLEX_03 Set / Coast Enable
13 Digital Output_LP_FLEX_01 MIL Lamp
14 Digital Input_FLEX_04 Cruise Control Enable
15 Digital Input_FLEX_05 Stop Engine Override
16 Digital Input_FLEX_06 Resume / Accel Enable
18 SFP_01 Run Start
20
21

1 Battery (+) PSU (KL_30) Main Battery +12 V
2 Battery (-) PSU (KL_31) Main Battery Ground
3 Battery (+) Switched PSU Ignition
4 K_DIAG_C K-line
5 J 1708_A Not Used
6 J 1708_B Not Used
10 Digital Output_LP_FLEX_03 Amber Warning Lamp
11 Digital Input_FLEX_10 Limiter 1
12 Digital Input_FLEX_11 A/C Status
16 VCAN_L_C J1939 (-)
17 VCAN_GND_C J1939 Shield
18 VCAN_H_C J1939 (+)
22
23

1 Analog_In_01 Multiple Applications
2 Analog_GND Sensor Return
3 Analog__SUP_5V Sensor Supply
4 Analog_In_02 PTO
5 Analog_Out_01 Multiple Applications
6 Analog_Out_02 Multiple Applications
7 Digital Output_HP_HS_01 Multiple Applications
9 Digital Output_HP_LS_01 Multiple Applications
10 Digital Output_LP_FLEX_02 DEF Low Lamp
11 SFP_14 Low Coolant Level Sensor
12 Digital Output_LP_FLEX_04 Multiple Applications
13 SFP_09 Vehicle Speed (+)
14 SF_VGND Vehicle Speed (-)
15 Analog_In_SFP_13 Ambient Air Temp Sensor
16 Digital Output_LP_FLEX_05 Red Stop Lamp
17 Digital Output_HP_FLEX_02 Multiple Applications
18 Digital Input_SFP_02 Multiple Applications
19 PTCAN_L 5V Powertrain CAN (-)
20 PTCAN_GND 5V Powertrain CAN Shield
21 PTCAN_H 5V Powertrain CAN (+)
24
25

1 C_ECAN_L Not Used
2 C_ECAN_GND Not Used
3 C_ECAN_H Not Used
4 Digital Input_SFP_11 Not Used
6 Digital Output_LP_FLEX_06 Wait to Start Lamp
7 Digital Output_HP_LS_02 High Exhaust Temperature Lamp
8 Digital Input_FLEX_E1 Multiple Applications
9 Digital Output_HP_FLEX_01 Multiple Applications
11 Frequency_SFP_10 Not Used
12 PWM_FPO_01 Multiple Applications
13 Digital Input__FLEX_19 DPF Inhibit Switch
17 Digital Input_FLEX_21 DPF Regeneration Switch
26
27
5.4 Description and Operation of the 1-BOX™

Aftertreatment Contol Module
The Aftertreatment Control Module (ACM) controls all aftertreatment functions. It is mounted on the 1-BOX™
configuration. Temperature, pressure, and NOx sensors connect to the ACM in addition to aftertreatment
components. The ACM uses the inputs from the sensors to control the aftertreatment systems. Vehicle electrical
harnesses run throughout the vehicle to connect the ACM to all aftertreatment components and sensors.
1. 120-Pin Connector
2. 21-Pin Connector
Fig 5.5, Aftertreatment Control Module (ACM) Components
5.4.1 Removal of the 1-BOX™ Aftertreatment Control Module

Note : The Aftertreatment Control Module (ACM) is mounted on the rear of the 1-BOX assembly.
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
CAUTION
ELECTRICAL SHOCK
2. Disconnect the batteries. Refer to Original Equipment Manufacturer (OEM) procedures.
3. If necessary, remove the passenger side fairing. Refer to OEM procedures.
28
4. Remove the lower ACM cover mounting bolts (1) and remove the cover (2).
5. Note the location of the zip ties mounting the ATS harness to the ACM.
6. Remove the zip ties mounting the Aftertreatment System (ATS) harness to the ACM.
7. Release latch on harness connector to remove the 21-pin (1) and the 120-pin (4) electrical connectors from
the ACM.
29
8. Disconnect the Soot Sensor Control Unit (SCU) electrical connector (5).
9. Remove the Soot SCU mounting bolts (2) and remove the SCU (6).
Note : If replacing the ACM, remove the Soot SCU, mounting bracket and bolts.
10. Remove the four mounting bolts (3) securing the ACM; remove ACM along with the isolators.
5.4.2 Installation of the 1-BOX™ Aftertreatment Control Module

1. Install the Aftertreatment Control Module (ACM) with four mounting bolts (3) and eight isolators. Torque the
bolts to 15 N·m (11 lb·ft).
30
Note : If replacing the ACM, install the Soot Sensor Control Unit (SCU) mounting bracket with new bolts.
2. Install the Soot SCU (6) and torque the mounting bolts (2) to 12 N·m (9 lb·ft).
3. Connect the Soot SCU electrical connector (5).
4. Connect the 21-pin (1) and 120-pin (4) electrical connectors to the ACM. Close and lock the latch on the
connectors.
5. Install the zip ties that mount the Aftertreatment System (ATS) harness to the ACM.
6. Install the lower ACM cover (2) with the six mounting bolts (1). See graphic below. Torque the bolts to 10
N·m (7 lb·ft).
31
CAUTION
ELECTRICAL SHOCK
7. Connect the batteries. Refer to OEM procedures.
8. If removed, install the passenger side fairing. Refer to Original Equipment Manufacturer (OEM) procedures.
an Accumulated Fuel Mass Sync. For more information, reft to the DiagnosticLink help menu.
10. Turn the ignition ON (key ON, engine OFF). Observe DiagnosticLink® for any diagnostic code(s). If any
32
5.5 Description and Operation of the Two-BOX (2V2)

Aftertreatment Control Module
The Aftertreatment Control Module (ACM) controls all aftertreatment functions. It is mounted on the vehicle
chassis in a protected area. Temperature, pressure, and NOx sensors connect to the ACM in addition to
aftertreatment components. The ACM uses the inputs from the sensors to control the aftertreatment systems.
Vehicle electrical harnesses run throughout the vehicle to connect the ACM to all aftertreatment components and
sensors.
1. Mounting Bolts
2. 120-Pin Connector
3. 21-Pin Connector
Fig 5.6, Aftertreatment Control Module
5.5.1 Removal of the Two-BOX (2V2) Aftertreatment Control Module

Note : Typically the Aftertreatment Control Module (ACM) is mounted just behind the driver’s side fender.
CAUTION
ELECTRICAL SHOCK
1. Disconnect the batteries. Refer to OEM procedures
2. If necessary, remove the driver's side fairing.
33
3. Remove the two bolts securing the ACM cover and remove cover.
4. Release latch on harness connector to remove the 21-pin (3) and the 120-pin (2) connectors from the ACM.
5. Remove the four mounting bolts (1) securing the ACM; remove ACM along with the isolators.
5.5.2 Installation of the Two-BOX (2V2) Aftertreatment Control Module

1. Confirm that vehicle battery power is disconnected and the ignition is in the OFF position.
2. Install the ACM with four bolts (1) and isolators. Torque the bolts to 15 N·m (11 lb·ft).
3. Connect the 21-pin (3) and 120-pin (2) harness connectors to the ACM. Close and lock the latch on the
connectors.
34
4. Install the ACM cover with the two bolts. Torque the bolts to 18 N·m (13 lb·ft).
CAUTION
ELECTRICAL SHOCK
5. Connect the batteries. Refer to OEM procedures
6. If removed, install the driver side fairing. Refer to OEM procedures.
an Accumulated Fuel Mass Sync. For more information, reft to the DiagnosticLink help menu.
8. Turn the ignition ON (key ON, engine OFF). Observe the DiagnosticLink® for any diagnostic code(s). If any
35
5.6 Instrument Panel Lamps

5.6.1
The instrument panel lamps are explained below:
5.6.2 Amber Warning Lamp
Lamp Lamp Name Description Result

Amber Warning Lamp (AWL) Indicates a fault with the engine Vehicle can be driven to end of shift.
controls. Call for service.
Lamp Solid Lamp Flashing
5.6.3 Red Stop Lamp

Red Stop Lamp (RSL) Indicates a major engine fault that Move the vehicle to the nearest safe
may result in engine damage. Engine location and shut down the engine.
derate and/or shutdown sequence will Call for service.
be initiated.
5.6.4 Diesel Particulate Filter Regeneration Lamp

Diesel Particulate Filter Regeneration Solid yellow indicates a regeneration Lamp Solid - regeneration is required.
Lamp is required. Blinking yellow, derate Lamp Flashing- regeneration is
and/or shutdown are possible as soot required immediately.
load continues to increase. Lamp will
shut off during parked regeneration.
5.6.5 High Exhaust System Temperature Lamp
36

High Exhaust System Temperature Lamp is yellow. Indicates exhaust Vehicle can be driven. Lamp solid for
(HEST) Lamp temperature is above a preset limit an extended period (Longer than 40
and unit is operating at low vehicle Minutes) - call for service.
speed (below 5 mph [8 kph]). When
the engine speed is elevated for a
parked regeneration, lamp will flash
once every 10 seconds.
5.6.6 Malfunction Indicator Lamp

Malfunction Indicator Lamp (MIL) Yellow lamp Indicates a failure of an Vehicle can be driven to end of the
Emission Control device. May shift. Call for service.
illuminate at the same time as the
Amber Warning Lamp.
5.6.7 Fuel Filter Restriction Sensor Lamp: Fuel Filter Failed

Fuel Filter Restriction Sensor (FFRS) Yellow lamp Indicates that the fuel Service soon.
Lamp filter is restricted and needs to be
serviced. May illuminate at the same
time as the Malfunction Indicator
Lamp (MIL) and Amber Warning Lamp
(AWL).
5.6.8 Water-In-Fuel Lamp (WIF)

Water-In-Fuel (WIF) Lamp Yellow lamp indicates that the fuel Engine water separator must be
water separator has reached its drained or an engine derate will occur.
capacity and needs to be drained.
37
GHG17 Heavy Duty Troubleshooting Manual (DDC-SVC-MAN-0191)
6.1 GHG17 SCR Circuit Diagram
1
1. DEF Tank Screen

2. DEF Line Tank to DEF Pump
3. Pump Electric Motor
4. Ventilation Membrane
5. Freeze Protection Element
6. DEF Pump Suction Port
7. DEF Pump Pressure Port
8. DEF Pump Coolant Inlet Port
9. DEF Pump Coolant Outlet Port
10. Pressure Relief Valve
11. Filter Screen
12. Dosing Valve
13. Pressure Sensor
14. Heating Element
15. Backflow Orifice
16. Atomizer
17. Filter Screen
18. Doser Inlet Port
19. Doser Outlet Port
20. DEF Doser Return Line to Tank
21. Coolant Valve
22. DEF Tank Header
23. Coolant Heating Circuit Inside DEF Tank
24. DEF Level Sensor
25. DEF Tank Temperature Sensor
26. Coolant Line Engine to Control Valve
27. Coolant Line Tank to DEF Pump
28. Coolant Line DEF Pump to Engine
29. DEF Line to DEF Pump to Dosing Unit
30. Engine
31. DEF Tank
32. DEF Pump Module
33. DEF Dosing Unit
2
Fig 0.1, GHG17 SCR Circuit Diagram
3
Aftertreatment SCR Circuit Diagrams
4
7.6 Aerated Fuel Test – Two-Filter Fuel System

Service Tools Used in the Procedure
Tool Number Description
J-48708 Fuel Flow Tool
J-48709 Sight Glass Tools
W470589209100 Fuel Flow/Aeration Test Adapters
W470589039100 Fuel System Tool Update Kit w/o MCM cooler
ESOC 350 Fuel Priming Unit
DDDL 7.09 or later
1. Disconnect the chassis side fuel supply and return lines from the fuel filter module.
2. Using the appropriate adaptors from the W470589039100 Fuel System Tool Update Kit, install the two J-
48709 Sight Glass Tools onto the fuel filter module. Connect the other end of the sight glass lines to the
chassis side fuel supply and return lines.
3. Prime the fuel system using the hand priming pump or the ESOC 350 fuel priming pump.
Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"
4. Connect the DDDL to the vehicle, access the Service Routines section and select the Fuel System Integrity
Check (FSIC) tab.
1
WARNING
ENGINE EXHAUST
Note : Use a flashlight behind the sight glass lens to make any air bubbles more visible.
5. Carry out the FSIC routine and watch the fuel inlet and outlet flow through the sight glasses for air bubbles.
6. Is the fuel aerated in the fuel supply line?

6.a Yes; repair the fuel supply chassis lines from the fuel tank(s) to the fuel filter module.
7. Is the fuel aerated in the fuel return line?
7.a Yes; Go to step 8.
7.b No; return to initial diagnostics that referred you to this procedure "Aerated Fuel Test - Two-Filter Fuel
System."
8. Carry out a low pressure leak test. Refer to section "FIS Low Pressure Leak Test" Refer to section "FIS Low
Pressure Leak Test". Does the low pressure leak test pass?
8.a Yes, Go to step 9.
8.b No, repair the leak(s) as necessary.
9. Install the W470589209100 Fuel Flow/Aeration Test Adapters for the needle and amplifier return lines flow
test. Refer to Tool Letter 12 TL-7 for installation instructions.
10. Carry out the FSIC routine and observe the fuel flow from the amplifier and needle return circuits through
the clear lines.
10.a If there is any air coming out of the needle or amplifier return lines, Go to step 12.
2
10.b If there is no air coming out of the needle or amplifier return lines, Go to step 11.
Note : If there is no air coming out of the needle or amplifier return lines, the initial concern may have been caused
by a loose line, cylinder head fitting or damaged cylinder head fitting sealing washer.
11. Remove the special service tools, install the cylinder head fittings with new sealing washers, reconnect the
fuel return lines, then Go to step 1. to verify if the fuel is still aerated. Refer to Tool Letter 12 TL-7 for the needle
and amplifier return lines flow test tool removal instructions.
12. Perform a cranking compression test using DDDL. Is any cylinder below 90% compression?
12.b No; contact the Customer Support Center at (800) 445-1980.
13. Remove the injector for the cylinder(s) found with compression below 90%. Refer to section "Removal of the Fuel
Injector - Two-Filter System" .
14. Remove and discard the fuel injector cup(s). Refer to section "Removal of the Fuel Injector Cup" .
15. Install new injector cup(s). Refer to section "Installation of the Fuel Injector Cup" .
16. Install the injector(s) removed with new hold down bolt(s), O-ring seals and copper washer(s). Refer to section
"Installation of the Fuel Injector - Two-Filter System" .
17. Repeat the cranking compression test using DDDL. Contact the Customer Support Center at (800) 445-
1980 if any of the cylinder compression is below 90%.
3
7.7 Amplifier Return Flow Test - Two-Filter Fuel System

Test as follows:
1. Install the W470589209100 Fuel Flow/Aeration Test Adaptors. Refer to Tool Letter 12 TL-7 for the injector
amplifier and needle return flow test adaptors installation.
2. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System" for fuel system priming.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : When measuring amplifier return flow, the needle return line MUST be removed from the fuel module and
put into a separate container to equalize pressure in the fuel gallery in the cylinder head. Only the amplifier return
fuel is measured.
3. Start engine and allow it to run at base idle.
4. Measure and record the amplifier return flow from the clear return line (J-48708-2) to the J-48708-1
container.
5. The maximum allowable amplifier return rate at idle is 15 liters per hour (250 mL per minute).
5.a If the fuel return flow rate is within specifications, the system passed. Return system to original
condition. Refer to section "Verify Repairs" .
5.b If the fuel return flow rate is out of specification, Go to step 6.
6. Using DDDL 7.09 or higher, read the “Idle Speed Balance Values” parameters under “Instrumentation”
section for all six cylinders. Refer to section "Checking Idle Speed Balance" . Did the Idle Speed Balance (ISB) test
identify a bad injector?
6.a Yes; replace bad injector. Refer to section "Removal of the Fuel Injector - Two-Filter System" . After replacing the
fuel injector, repeat the amplifier return flow test; Go to step 5.
Note : The system may contain residual high pressure when engine is turned off. Allow the residual pressure to
bleed off for ten minutes.
7. Turn engine OFF and wait ten minutes.
WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has
been shut down for a minimum of 10 minutes before servicing any component within the
high pressure circuit. Residual high fuel pressure may be present within the circuit.
4
8. Disconnect the #1 fuel injector high pressure line.

9. Install J-48704 rail plug on to the fuel rail and torque to 40 N·m (30 lb·ft).
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

11. Measure the amplifier flow from the clear return line (J-48708-2) to the container (J-48708-1) during a one
minute time frame and note the flow rate in the following chart.
12. Repeat steps 7 through 11 for the remaining injectors, one at the time.
5
Amplifier Leakage Rate Worksheet

Total Leakage Rate (from step 4) mL per minute
Capped Cylinder Leakage Rate Was a drop of more than 50mL (1.7 ounces) compared to
the Total Leakage Rate noted?
Cylinder #1 mL per minute YES NO
13. Replace any fuel injector causing a drop of more than 50 mL (1.7 ounces) compared to the “Total Leakage
Rate” value. Refer to section "Removal of the Fuel Injector - Two-Filter System" . After replacing the fuel injector,
recheck the system; Go to step 4.
6
7.8 Fuel Filter Pressure Test – Two-Filter Fuel System

The fuel filtration system consists of two filters, the prefilter and coalescer/final filter. The prefilter has the task of
filtering material down to 100 micron. The coalescer/final filter has two tasks. The first task is to separate out
emulsified water from the fuel. The second task is to filter material down to 3-5 micron. Generally, the
coalescer/final filter is the filter that reaches the pressure limit first. With the current configuration, both filters are
changed at the same time. The pressure limits when both fuel filters are to be replaced are listed in the following
table below.
Filter Pressure Limits using LPPO Fuel Pressure (DDDL)

RPM New Filter Pressures Replace Filters
600 RPM 80-90 PSI Greater than 97 psi
7.8.1 Checking Fuel Filter Restriction - Two-Filter Fuel System

1. Install and connect DDDL 7.X.
2. Click on the “Service Routines” tab.
3. Click on the “Fuel System Integrity Check” tab.
7
4. Click on the “Run Test” tab.
8
Note : Once the Fuel System Integrity Check routine has completed, the engine will shut down.
5. Review the fuel pressure at 600 rpm. Is the fuel pressure within the specification listed in the Filter Pressure
Limits using LPPO Fuel Pressure (DDDL) table?
5.b No, replace the fuel filters.
For prefilter replacement, Refer to section "Removal of the Fuel Prefilter" .
For coalescer/final filter replacement, Refer to section "Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter
System" .
6. Review the fuel pressure at 1800 rpm. Is the fuel pressure within the specification listed in the Filter
Pressure Limits using LPPO Fuel Pressure (DDDL) table?
6.a Yes, fuel filters have passed.
System" .
9
7.9 Fuel System Integrity Check Routine -Two-Filter Fuel

System
Note : Note: Most fuel system troubleshooting procedures will include performing a Fuel System Integrity Check
(FSIC) routine.
The FSIC test runs the fuel system through several operational states and records important information which a
technician can use to determine a failed system or component without removing any components from the engine.
The following will give a good explanation of what the technician can expect and look for during the FSIC routine
or log file review.
When the FSIC routine is first activated, the fuel cutoff valve in the doser block will open allowing the fuel
compensation pressure sensor to read the regulated fuel pressure that is going into the doser block. At 0 rpm, the
fuel compensation pressure sensor will be at atmospheric pressure. When the engine starts to rotate, the fuel
compensation pressure sensor will increase in fuel pressure. Once the fuel compensation pressure reads 35 psi,
there will be enough supplied fuel pressure to build rail pressure. For KM59 GEN1 fuel systems, fuel pressure test
plug W470589099100 is installed in place of the doser pressure regulator; the actual fuel pressure available at the
high pressure pump inlet can be measured using the fuel compensation pressure sensor.
7.9.1 Fuel System Integrity Check Routine Operation Overview - Two-

Filter Fuel System
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if at any time unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the FISC routine
immediately by turning the ignition OFF and contact the Detroit™ Customer Support
Center for further assistance at 800-445-1980.
Using DiagnosticLink 8.06 or newer, the Automatic FSIC routine runs the engine through a routine that starts at
600 rpm, then goes to 850 rpm, 950 rpm, 1100 rpm, 1500 rpm and 1800 rpm. After 1800 rpm the engine will:
• return to 600 rpm
• ramp the rail pressure to 800 bar for 60 seconds
• request the ignition be turned off and back on
• perform a Fuel System Leak Detection routine
On occasion, the Motor Control Module (MCM) may not allow the rail pressure to ramp to 800 bar, at this point the
routine will substitute the rail pressure ramp with an idle speed adjustment to 1400 rpm.
Note : If the fuel mass is over 50 mg/st at 600 RPM (engine at operating temperature), abort the FSIC routine and
contact the Detroit™ Customer Support Center for further assistance at (800-445-1980).
Refer to section "Normal Fuel System Pressures - Two-Filter System"
7.9.2 How to Run a Fuel System Integrity Check Routine - Two-Filter

Fuel System
10

Tool Number Description Graphic
W470589099100 Fuel Pressure Test Plug
DiagnosticLink 8.06 or later
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if there are any unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the routine
immediately by turning the ignition OFF.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Connect to the vehicle with DiagnosticLink 8.06 or later.

2. Navigate in DiagnosticLink to “Actions.”
11
3. Select "Fuel System" and then “Fuel System Integrity Check” in the drop-down menu.
12
4. Select "FSIC Automatic Test" from the drop-down menu.
5. Follow the instructions on screen. Allow the routine to complete.
6. Once the routine completes, review the dialog box for the high pressure leak test results.
13
7. Return to the initial diagnostics that directed you to the FSIC Routine.
7.9.3 FSIC Leak Test

The FSIC Leak Test will allow a technician to identify a leak in the high pressure fuel system. The panel will
calculate if there is an acceptable pressure bleed-down rate. A leak in one of the following locations will show a
fast bleed-down rate over time:
• High pressure fuel pump (pumping elements)
• High pressure fuel rail feed lines
• High pressure fuel injector lines
• Fuel rail pressure sensor
• Pressure limiting valve
• Internal injector amplifier or needle leakage to the return
• Internal injector amplifier or needle leakage into the cylinder
1. Using DiagnosticLink , go to the "Actions" menu and click on the "Fuel System" menu option and then the
"Fuel System Integrity Check" option.
14
2. In the dropdown menu, select "FSIC Leak Test."
WARNING
PERSONAL INJURY
15
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Start engine and allow Fuel System Integrity Check (FSIC) Leak Test routine to run. The test will instruct
when to cycle the ignition to complete the test
4. Once the FSIC Leak Test routine has completed, review the results of the test in the dialog box of the test
panel.
16
5. Did the panel result in a "System Leaking" message?

5.a Yes; Refer to section "High Pressure Fuel System - Leak Test - Two-Filter System" .
5.b No; return to original troubleshooting.
17
7.10 Pressure Limiting Valve Flow Test – Two-Filter Fuel

System
J-48708 Fuel Flow Tool, Amp/Needle Valve, HDE
W470589209100 Fuel Flow/Aeration Test Adaptors
DiagnosticLink
Test as follows:
1. Install the Pressure Limiting Valve (PLV) flow test adaptor included in the W470589209100 Fuel
Flow/Aeration Test Adaptors kit. Refer to the installation instructions in tool letter 12 TL-7 .
2. Is the vehicle in for an engine starting complaint?
3. Connect DiagnosticLink to the vehicle and turn the ignition on. From the “Service Routines,” open the “Fuel
System Integrity Check” tab.
4. Start the Fuel System Integrity Check routine and follow the instructions in DiagnosticLink.
5. Monitor the PLV return flow into a suitable container. Container should be able to hold at least 200 mL
(6.75 oz.) of fuel. Was fuel flow out of the PLV during the Fuel System Integrity Check routine greater than
160 mL (5.4 oz.)?
5.a Yes; replace the Pressure Limiting Valve (PLV) and reset the PLV counter to 0. Refer to section "Removal of
the Pressure Limiting Valve - Two-Filter System" .
5.b No; the PLV is not out of spec. Return to initial diagnostics that referred you to this procedure.
6. Crank the engine for at least 10 seconds and monitor the flow into a suitable container. Container should
be able to hold at least 200 mL (6.75 oz.) of fuel. Was fuel flow out of the PLV greater than 20 mL (0.7 oz.)?
the Pressure Limiting Valve - Two-Filter System"
6.b No; the PLV is not out of spec. Return to the ignition diagnostics that referred you to this procedure.
18
7.11 Fuel Cooler Leak Test Procedure - Two-Filter Fuel

System
Test as follows:
Service Tools Used in This Test

J-45982-7 Air Pressure Regulator
W470589139100 Fuel Cooler Leak Test Plate
WARNING
PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.
1. Remove the fuel cooler from the fuel filter module. Refer to section "Removal of the Fuel Cooler - Two Filter System" .
2. Thoroughly clean the surface of the fuel cooler.
3. Install W470589139100 Fuel Cooler Leak Test Plate (1) onto the fuel cooler using supplied mounting bolts.
19
4. Gradually tighten bolts in a cross pattern until a torque of 3.5 N·m (30 lb·in.) is achieved.
5. Connect J-45982-7 air pressure regulator to W470589139100 Fuel Cooler Leak Test Plate and turn the
regulator counter-clockwise until regulator stops.
20
WARNING
PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure
test.
6. Attach shop air supply to the J-45982-7 air pressure regulator and turn the regulator clockwise until the
gauge on the tool reads 68 KPa (10 psi).
7. Close the shut-off valve on the J-45982-7 air pressure regulator and disconnect the shop air supply.
Note : If air bubbles are present between the fuel cooler leak test plate and the fuel cooler, it may be necessary to
tighten the mounting bolts. Only tighten enough to prevent air from escaping between the fuel cooler and the fuel
cooler leak test plate.
21
8. Submerge the fuel cooler into a tank filled with warm water and verify no leaks are present between the fuel
cooler and the fuel cooler leak test plate.
Note : Air can get trapped in the fuel cooler when the cooler is placed in the warm water.
9. Soak the fuel cooler in the warm water for two minutes to remove any air that may be trapped in the cooler.
10. Continue to monitor the fuel cooler for one minute and observe if air bubbles escape continuously from the
fuel cooler.
10.a If no air bubbles are present, reinstall the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
10.b If air bubbles are present, replace the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
22
Diagnostic Tests - Two-Filter Fuel System
7.1 Chassis Fuel System Isolation Test

This test is used to determine if the cause of a hard start or no start condition is on the engine side or the chassis
side.

Detroit Approved Fuel Priming Unit
DiagnosticLink™
1. Prime the fuel system using a Detroit-approved priming unit.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System" .
Note : It is important that the road test is performed to purge the remaining air from the system after priming.
2. Disconnect the chassis-side fuel supply and return lines from the fuel filter module.
48708 Fuel Flow test lines onto the fuel filter module. Connect the other end of the test lines to the J-48708
fuel flow container. Container should have enough fuel to run a Fuel System Integrity Check (FSIC) and still
have at least two liters (2.11 qt.) of fuel remaining.
Note : Do not move or otherwise disturb the Fuel System Update kit and the lines during the next two steps to
ensure the ends of the lines remain submerged in fuel.
23
4. Prime the fuel system using the hand-priming pump.

5. Connect DiagnosticLink to the vehicle, access the Service Routines section, select the Fuel System
Integrity Check (FSIC) tab and run the Automatic FSIC.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
6. Wait 15 minutes and then restart engine to ensure there is not a hard start/no start condition.
7. Was there a starting issue?
7.a Yes; verify all connections are tight and ensure that end of fuel lines remain submerged in fuel. Restart
from step 4.
8. Allow engine to sit long enough for previous hard start/no start complaint to be verified.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
24
WARNING
ENGINE EXHAUST
9. Start engine.
10. Was there a starting issue?
10.a Yes; the cause of the hard start/no start is on the engine side. Refer to section "Hard Start/No Start - Two-Filter
Fuel System (This Test Must Be Done First)" to continue the diagnostics on the engine side.
10.b No; the cause of the hard start/no start is on the chassis side. Check chassis fuel system lines per
OEM procedures.
25
7.2 FIS Low Pressure Leak Test

Tool Number Tool Description Tool Graphic
J-48710 Air Pressure Test Kit, Fuel System
W470589039100 Fuel System Tool Update Kit without an

MCM (Motor Control Module) cooler
DiagnosticLink
Note : Please review 13 TL-11REV to ensure changes to essential tool J-48710 have been made to improve the
accuracy of detecting low pressure fuel system leaks.
Test as follows:
1. With the engine OFF, apply the parking brake, chock the wheels and perform any other applicable safety
steps.
2. Remove the fuel tank fill caps.
3. Remove the fuel feed line from the fuel filter module.
WARNING
PRESSURIZED AIR AND FLYING PARTICLES
test.
4. Install J-48710 tool (1) on to the fuel filter module.
26
5. Connect an air supply to J-48710 tool.

6. Pressurize the fuel system to 517 kPa (75 psi) for six minutes.
7. Close the ball valve on J-48710 tool.
8. Wait two minutes.
9. Remove the return line from the fuel filter module and install J-48710 cap tool (1) on the fuel filter module
return line fitting.
27
10. Install the fuel tank fill caps.

11. Ignition ON, engine OFF, connect to the MCM using DiagnosticLink.
12. Click the “service routines” tab in DiagnosticLink.
28
13. Click the “FIS Low Pressure Leak Test” tab in DiagnosticLink.
29
WARNING
test.
14. Using J-48710 tool, pressurize the fuel system to 517 kPa (75 psi) for four minutes.
15. Close the ball valve and disconnect the air supply from J-48710 tool.
Note : The fuel compensation pressure will increase after the “Start” button has been pressed.
Note : The fuel compensation pressure sensor reads in absolute pressure, therefore the pressure should read
about 100 kPa (14.5 psi) (depending on elevation) more than the fuel pressure gauge on the J-48710 tool. The
fuel compensation sensor will read close to 620 kPa (90 psi) of pressure when the J-48710 tool is reading 517
kPa (75 psi).
16. Press the “Start” button on DiagnosticLink.
17. Once the test is complete, review the DiagnosticLink log file test results.
18. Did the fuel system pass the FIS Low Pressure Leak Test?
18.a Yes; slowly remove the J-48710 cap tool from the fuel filter module. Remove the J-48710 tool from the
fuel filter module. Install the fuel feed line and return line on to the fuel filter module. Return to the initial
diagnostics that directed you to the FIS Low Pressure Leak Test.
30
WARNING
test.
19. Connect an air supply to the J-48710 tool.

20. Open the ball valve and pressurize the fuel system to 517 kPa (75 psi).
21. Locate leak by using a soapy solution, spray connectors, fittings and hoses shown in the "Potential Fuel
Leak Points-Two-Filter Fuel System" procedure. Refer to section "Potential Fuel Leak Points - Two-Filter Fuel System" .
31
7.3 Low Pressure Fuel System – Measuring Fuel Pressure

Using Fuel System Integrity Check – Two-Filter Fuel
System
Tool Number Description KM59 Gen 1 KM63 Gen 2
W470589099100 Fuel Pressure Test Plug X N/A
(doser regulator)
W470589149100 Pre-Filter Cap (with test port) X X
DiagnosticLink 8.x X X
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
This procedure is used to measure and record fuel pressures in the low pressure side of the fuel system at given
locations and rpm. Once completed, it will provide electronic results that can be viewed in a DDDL log file.
Note : Step 1 only applies to the KM59 Gen 1 fuel system. For a KM63 Gen 2 fuel system, begin the test with step
2.
Check as follows:
1. For KM59 Gen 1 systems only , install tool number W470589099100 Fuel Pressure Test Plug into the high
pressure flange. Refer to Tool Letter 11 TL-9 for installation instructions.
2. For KM59 Gen 1 fuel systems and KM63 Gen 2 fuel systems, install tool number W470589149100 Filter
Cap w/Test Port. Refer to Tool Letter 12 TL-8 for installation instructions. Inspect the pre-filter at this time. If
the filter is plugged, clean or replace only this filter as needed.
3. Connect the DDDL to the vehicle and turn the ignition on. From the “Service Routines,” open the Fuel
System Integrity Check tab.
4. Start the Fuel System Integrity Check routine and follow the instructions in DDDL.
5. Monitor the low pressure pump outlet (LPPO) fuel pressure, the fuel compensation pressure and the low
pressure pump inlet (LPPI) fuel pressure while the Fuel System Integrity Check routine is running.
32
6. Add the LPPI fuel pressure values as a user event into the log file. Press CTRL, SHIFT, and space bar at
the same time, and add the pressure reading from the gauge.
33
7. Compare the recorded fuel pressure values with the normal fuel pressures. Refer to section "Normal Fuel System
Pressures - Two-Filter System" .
8. Return to original troubleshooting. Remove the special tools from the engine after troubleshooting is
completed.
34
7.4 Low Pressure Fuel System - Pressure Measurement –

Two-Filter Fuel System
PLV return line.
The low pressure side of the fuel system can be measured using either DDDL or a manual pressure gauge.
Suction pressure is now measured using a prefilter cap with a test port (W470589149100). Some tests (KM59
Gen1 system only) will also require the use of fuel pressure test plug (W470589099100). The following section
explains the correct way to identify how pressures are going to be measured on each variation of fuel filter
module.
7.1.1 KM59 GEN1 Fuel Filter Module
1. Priming port fitting

2. Low pressure fuel sensor
3. Pre-filter cap w/ test port - W470589149100
4. Fuel pressure test plug - W470589099100
Fig 7.1, KM59 GEN1 Fuel Filter Module Pressure Measurement Points
35
Pressure Measured Measurement Point Measurement Method

LP pump outlet
LP pump outlet
LP pump inlet
HP pump inlet
7.1.2 KM63 GEN2 Fuel Filter Module
1. Priming port fitting

2. Low pressure fuel sensor
3. Pre-filter cap w/ test port - W470589149100
Fig 7.2, KM63 GEN2 Fuel Filter Module Pressure Measurement Points
Pressure Measured Measurement Point Measurement Method

LP pump outlet
LP pump outlet
LP pump inlet
HP pump inlet
36
7.5 High Pressure Fuel System - Leak Test - Two-Filter

System
High pressure fuel system leaks can cause a variety of problems including fault codes, difficulty starting, fuel in oil,
rough running, low power, and several other issues. If there is a suspected leak in the high pressure fuel system,
follow these steps to find the leak.
WARNING
PERSONAL INJURY
To avoid injury from fire caused by heated diesel-fuel vapors:

• Keep those people who are not directly involved in servicing away from the engine.
• Stop the engine immediately if a fuel leak is detected.
• Do not smoke or allow open flames when working on an operating engine.
• Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).
• To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.
PLV return line.
WARNING
FIRE HAZARD
Do not power wash or steam clean the engine bay in the area of vehicle electrical
components, unless specified by vehicle manuals or service literature. Power
washing/steam cleaning can permanently damage these components, which could result
in fire, personal injury, or property damage.
1. Steam clean the entire fuel system prior to inspecting for leaks. If there are obvious external leaks, repair
the leak(s). Go to step 2.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
2. Start engine and allow it to reach operating temperature 60°C (140°F ).
37
3. Perform a Fuel System (FSIC) Leak Test. Refer to section "FSIC Leak Test" . Did the test detect a leak? If the
diagnostic that led you here already had you perform one, Go to step 4.
4. Inspect the high pressure pump to rail feed fittings at the rail and the pump (2) for leakage. KM63 GEN2
shown, KM59 GEN1 similar. Are any leaks found? Are the line fittings loose?
4.a Yes; replace the lines (1). Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System" .
5. Inspect fuel injector fuel line rail connections (1) for external leaks. Are leaks found or are there any loose
lines?
5.a Yes; torque the fuel line rail connections, start the engine and recheck. If leaks are still found, replace
the lines. Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System" .
38
6. Inspect the fuel rail pressure sensor (3) for leakage. Is the sensor leaking or is it loose?
6.a Yes; torque the fuel rail pressure sensor, start the engine and recheck. If leaks are still found, replace
the fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
39
7. Inspect Pressure Limiting Valve (PLV) (2) for leakage. Is the PLV leaking externally or is it loose?
7.a Yes; torque the PLV, start the engine and recheck. If leaks are still found, replace the Pressure Limiting
Valve (PLV). Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" .
8. Inspect the high pressure fuel pump for external leaks at the pressure relief valve/two-stage valve (1), low
pressure pump (2), Quantity Control Valve (QCV) (3), high pressure pump elements (4) and high pressure
pump element fittings (5) (KM59 GEN1). Are there any leaks coming from the high pressure pump?
8.a Yes; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter
System"
40
8.c KM59 GEN1 High Pressure Fuel Pump shown below:
8.d KM63 GEN2 High Pressure Fuel Pump shown below:
41
Note : It will take a few minutes for the dye in the test bottle to make its way into the high pressure system and up
to the fuel injectors.
9. Install fuel test bottle kit (J-48708). Fill one container with ultra-low sulfur diesel fuel and add fuel dye to the
fuel in the bottle per the fuel dye manufacturer’s recommendation. Connect the hoses to the fitting on the
top of the cap. This will isolate the engine from the chassis fuel system.
10. Prime the fuel system.
11. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" Install tool (W470589009800) Cam Gear
Cover onto the rear of the cam frame.
WARNING
HOT OIL
To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.
WARNING
PERSONAL INJURY
42
WARNING
PERSONAL INJURY
12. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine
at 950 rpm. Using the black light, inspect the fuel injectors and fuel lines for signs of leakage. Are there any
leaks coming from any of the fuel injectors (1) or lines (2)?
12.a Yes; replace any leaking fuel injector(s) or replace any leaking fuel line(s).
13. Using the black light, inspect the entire high pressure system for leaks. Repair as necessary. If no leaks are
found, Go to step 14.
43
14. Perform amplifier/needle return flow test and measurements. Refer to section "Amplifier Return Flow Test - Two-Filter
Fuel System" .
14.a If the amplifier/needle return flow test passes, Go to step 15.

14.b If the amplifier/needle return flow test fails, repair as necessary.
15. Cap the rail at all six injector feed connections using J-48704 injector rail caps and attempt to start the
engine. Does the ASL001 Rail Pressure reach AS098 Desired Rail Pressure?
15.b No; replace high pressure fuel pump. Refer to section "Installation of the High Pressure Fuel Pump - Two Filter System"
.
16. Does the rail pressure bleed down under a 100 bar in less than five minutes?
16.a Yes; replace the High Pressure Fuel Pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter
System" .
16.b No; replace all six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
44
7.6 Normal Fuel System Pressures

Check as follows:
1.
45
7.7 Aerated Fuel Test – Two-Filter Fuel System

J-48709 Sight Glass Tools
W470589209100 Fuel Flow/Aeration Test Adapters
ESOC 350 Fuel Priming Unit
DDDL 7.09 or later
1. Disconnect the chassis side fuel supply and return lines from the fuel filter module.
48709 Sight Glass Tools onto the fuel filter module. Connect the other end of the sight glass lines to the
chassis side fuel supply and return lines.
3. Prime the fuel system using the hand priming pump or the ESOC 350 fuel priming pump.
4. Connect the DDDL to the vehicle, access the Service Routines section and select the Fuel System Integrity
Check (FSIC) tab.
46
WARNING
ENGINE EXHAUST
Note : Use a flashlight behind the sight glass lens to make any air bubbles more visible.
5. Carry out the FSIC routine and watch the fuel inlet and outlet flow through the sight glasses for air bubbles.
6. Is the fuel aerated in the fuel supply line?

6.a Yes; repair the fuel supply chassis lines from the fuel tank(s) to the fuel filter module.
7. Is the fuel aerated in the fuel return line?
7.b No; return to initial diagnostics that referred you to this procedure "Aerated Fuel Test - Two-Filter Fuel
System."
8. Carry out a low pressure leak test. Refer to section "FIS Low Pressure Leak Test" Refer to section "FIS Low
Pressure Leak Test". Does the low pressure leak test pass?
8.b No, repair the leak(s) as necessary.
9. Install the W470589209100 Fuel Flow/Aeration Test Adapters for the needle and amplifier return lines flow
test. Refer to Tool Letter 12 TL-7 for installation instructions.
10. Carry out the FSIC routine and observe the fuel flow from the amplifier and needle return circuits through
the clear lines.
10.a If there is any air coming out of the needle or amplifier return lines, Go to step 12.
47
10.b If there is no air coming out of the needle or amplifier return lines, Go to step 11.
Note : If there is no air coming out of the needle or amplifier return lines, the initial concern may have been caused
by a loose line, cylinder head fitting or damaged cylinder head fitting sealing washer.
11. Remove the special service tools, install the cylinder head fittings with new sealing washers, reconnect the
fuel return lines, then Go to step 1. to verify if the fuel is still aerated. Refer to Tool Letter 12 TL-7 for the needle
and amplifier return lines flow test tool removal instructions.
12. Perform a cranking compression test using DDDL. Is any cylinder below 90% compression?
12.b No; contact the Customer Support Center at (800) 445-1980.
13. Remove the injector for the cylinder(s) found with compression below 90%. Refer to section "Removal of the Fuel
14. Remove and discard the fuel injector cup(s). Refer to section "Removal of the Fuel Injector Cup" .
15. Install new injector cup(s). Refer to section "Installation of the Fuel Injector Cup" .
16. Install the injector(s) removed with new hold down bolt(s), O-ring seals and copper washer(s). Refer to section
"Installation of the Fuel Injector - Two-Filter System" .
17. Repeat the cranking compression test using DDDL. Contact the Customer Support Center at (800) 445-
1980 if any of the cylinder compression is below 90%.
48
7.8 Amplifier Return Flow Test - Two-Filter Fuel System

Test as follows:
1. Install the W470589209100 Fuel Flow/Aeration Test Adaptors. Refer to Tool Letter 12 TL-7 for the injector
amplifier and needle return flow test adaptors installation.
2. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System" for fuel system priming.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : When measuring amplifier return flow, the needle return line MUST be removed from the fuel module and
put into a separate container to equalize pressure in the fuel gallery in the cylinder head. Only the amplifier return
fuel is measured.
4. Measure and record the amplifier return flow from the clear return line (J-48708-2) to the J-48708-1
container.
5. The maximum allowable amplifier return rate at idle is 15 liters per hour (250 mL per minute).
5.a If the fuel return flow rate is within specifications, the system passed. Return system to original
condition. Refer to section "Verify Repairs" .
5.b If the fuel return flow rate is out of specification, Go to step 6.
6. Using DDDL 7.09 or higher, read the “Idle Speed Balance Values” parameters under “Instrumentation”
section for all six cylinders. Refer to section "Checking Idle Speed Balance" . Did the Idle Speed Balance (ISB) test
identify a bad injector?
6.a Yes; replace bad injector. Refer to section "Removal of the Fuel Injector - Two-Filter System" . After replacing the
fuel injector, repeat the amplifier return flow test; Go to step 5.
Note : The system may contain residual high pressure when engine is turned off. Allow the residual pressure to
bleed off for ten minutes.
7. Turn engine OFF and wait ten minutes.
WARNING
PERSONAL INJURY
49
8. Disconnect the #1 fuel injector high pressure line.

9. Install J-48704 rail plug on to the fuel rail and torque to 40 N·m (30 lb·ft).
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

11. Measure the amplifier flow from the clear return line (J-48708-2) to the container (J-48708-1) during a one
minute time frame and note the flow rate in the following chart.
12. Repeat steps 7 through 11 for the remaining injectors, one at the time.
50
Amplifier Leakage Rate Worksheet

Total Leakage Rate (from step 4) mL per minute
Capped Cylinder Leakage Rate Was a drop of more than 50mL (1.7 ounces) compared to
the Total Leakage Rate noted?
13. Replace any fuel injector causing a drop of more than 50 mL (1.7 ounces) compared to the “Total Leakage
Rate” value. Refer to section "Removal of the Fuel Injector - Two-Filter System" . After replacing the fuel injector,
recheck the system; Go to step 4.
51
7.9 Fuel Filter Pressure Test – Two-Filter Fuel System

The fuel filtration system consists of two filters, the prefilter and coalescer/final filter. The prefilter has the task of
filtering material down to 100 micron. The coalescer/final filter has two tasks. The first task is to separate out
emulsified water from the fuel. The second task is to filter material down to 3-5 micron. Generally, the
coalescer/final filter is the filter that reaches the pressure limit first. With the current configuration, both filters are
changed at the same time. The pressure limits when both fuel filters are to be replaced are listed in the following
table below.
Filter Pressure Limits using LPPO Fuel Pressure (DDDL)

RPM New Filter Pressures Replace Filters
7.9.1 Checking Fuel Filter Restriction - Two-Filter Fuel System

1. Install and connect DDDL 7.X.
2. Click on the “Service Routines” tab.
3. Click on the “Fuel System Integrity Check” tab.
52
4. Click on the “Run Test” tab.
53
Note : Once the Fuel System Integrity Check routine has completed, the engine will shut down.
5. Review the fuel pressure at 600 rpm. Is the fuel pressure within the specification listed in the Filter Pressure
Limits using LPPO Fuel Pressure (DDDL) table?
System" .
6. Review the fuel pressure at 1800 rpm. Is the fuel pressure within the specification listed in the Filter
Pressure Limits using LPPO Fuel Pressure (DDDL) table?
6.a Yes, fuel filters have passed.
System" .
54
7.10 Fuel System Integrity Check Routine -Two-Filter Fuel

System
Note : Note: Most fuel system troubleshooting procedures will include performing a Fuel System Integrity Check
(FSIC) routine.
The FSIC test runs the fuel system through several operational states and records important information which a
technician can use to determine a failed system or component without removing any components from the engine.
The following will give a good explanation of what the technician can expect and look for during the FSIC routine
or log file review.
When the FSIC routine is first activated, the fuel cutoff valve in the doser block will open allowing the fuel
compensation pressure sensor to read the regulated fuel pressure that is going into the doser block. At 0 rpm, the
fuel compensation pressure sensor will be at atmospheric pressure. When the engine starts to rotate, the fuel
compensation pressure sensor will increase in fuel pressure. Once the fuel compensation pressure reads 35 psi,
there will be enough supplied fuel pressure to build rail pressure. For KM59 GEN1 fuel systems, fuel pressure test
plug W470589099100 is installed in place of the doser pressure regulator; the actual fuel pressure available at the
high pressure pump inlet can be measured using the fuel compensation pressure sensor.
7.10.1 Fuel System Integrity Check Routine Operation Overview - Two-

Filter Fuel System
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if at any time unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the FISC routine
immediately by turning the ignition OFF and contact the Detroit™ Customer Support
Center for further assistance at 800-445-1980.
Using DiagnosticLink 8.06 or newer, the Automatic FSIC routine runs the engine through a routine that starts at
600 rpm, then goes to 850 rpm, 950 rpm, 1100 rpm, 1500 rpm and 1800 rpm. After 1800 rpm the engine will:
• return to 600 rpm
• ramp the rail pressure to 800 bar for 60 seconds
• request the ignition be turned off and back on
• perform a Fuel System Leak Detection routine
On occasion, the Motor Control Module (MCM) may not allow the rail pressure to ramp to 800 bar, at this point the
routine will substitute the rail pressure ramp with an idle speed adjustment to 1400 rpm.
Note : If the fuel mass is over 50 mg/st at 600 RPM (engine at operating temperature), abort the FSIC routine and
contact the Detroit™ Customer Support Center for further assistance at (800-445-1980).
7.10.2 How to Run a Fuel System Integrity Check Routine - Two-Filter

Fuel System
55

Tool Number Description Graphic
W470589099100 Fuel Pressure Test Plug
DiagnosticLink 8.06 or later
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if there are any unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the routine
immediately by turning the ignition OFF.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Connect to the vehicle with DiagnosticLink 8.06 or later.

2. Navigate in DiagnosticLink to “Actions.”
56
3. Select "Fuel System" and then “Fuel System Integrity Check” in the drop-down menu.
57
4. Select "FSIC Automatic Test" from the drop-down menu.
5. Follow the instructions on screen. Allow the routine to complete.
6. Once the routine completes, review the dialog box for the high pressure leak test results.
58
7. Return to the initial diagnostics that directed you to the FSIC Routine.
7.10.3 FSIC Leak Test

The FSIC Leak Test will allow a technician to identify a leak in the high pressure fuel system. The panel will
calculate if there is an acceptable pressure bleed-down rate. A leak in one of the following locations will show a
fast bleed-down rate over time:
• High pressure fuel pump (pumping elements)
• High pressure fuel rail feed lines
• High pressure fuel injector lines
• Fuel rail pressure sensor
• Pressure limiting valve
• Internal injector amplifier or needle leakage to the return
• Internal injector amplifier or needle leakage into the cylinder
1. Using DiagnosticLink , go to the "Actions" menu and click on the "Fuel System" menu option and then the
"Fuel System Integrity Check" option.
59
2. In the dropdown menu, select "FSIC Leak Test."
WARNING
PERSONAL INJURY
60
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Start engine and allow Fuel System Integrity Check (FSIC) Leak Test routine to run. The test will instruct
when to cycle the ignition to complete the test
4. Once the FSIC Leak Test routine has completed, review the results of the test in the dialog box of the test
panel.
61
5. Did the panel result in a "System Leaking" message?

62
7.11 Pressure Limiting Valve Flow Test – Two-Filter Fuel

System
J-48708 Fuel Flow Tool, Amp/Needle Valve, HDE
W470589209100 Fuel Flow/Aeration Test Adaptors
DiagnosticLink
Test as follows:
1. Install the Pressure Limiting Valve (PLV) flow test adaptor included in the W470589209100 Fuel
Flow/Aeration Test Adaptors kit. Refer to the installation instructions in tool letter 12 TL-7 .
2. Is the vehicle in for an engine starting complaint?
3. Connect DiagnosticLink to the vehicle and turn the ignition on. From the “Service Routines,” open the “Fuel
System Integrity Check” tab.
4. Start the Fuel System Integrity Check routine and follow the instructions in DiagnosticLink.
5. Monitor the PLV return flow into a suitable container. Container should be able to hold at least 200 mL
(6.75 oz.) of fuel. Was fuel flow out of the PLV during the Fuel System Integrity Check routine greater than
160 mL (5.4 oz.)?
the Pressure Limiting Valve - Two-Filter System" .
5.b No; the PLV is not out of spec. Return to initial diagnostics that referred you to this procedure.
6. Crank the engine for at least 10 seconds and monitor the flow into a suitable container. Container should
be able to hold at least 200 mL (6.75 oz.) of fuel. Was fuel flow out of the PLV greater than 20 mL (0.7 oz.)?
the Pressure Limiting Valve - Two-Filter System"
6.b No; the PLV is not out of spec. Return to the ignition diagnostics that referred you to this procedure.
63
7.12 Fuel Cooler Leak Test Procedure - Two-Filter Fuel

System
Test as follows:
Service Tools Used in This Test

J-45982-7 Air Pressure Regulator
W470589139100 Fuel Cooler Leak Test Plate
WARNING
PERSONAL INJURY
1. Remove the fuel cooler from the fuel filter module. Refer to section "Removal of the Fuel Cooler - Two Filter System" .
2. Thoroughly clean the surface of the fuel cooler.
3. Install W470589139100 Fuel Cooler Leak Test Plate (1) onto the fuel cooler using supplied mounting bolts.
64
4. Gradually tighten bolts in a cross pattern until a torque of 3.5 N·m (30 lb·in.) is achieved.
5. Connect J-45982-7 air pressure regulator to W470589139100 Fuel Cooler Leak Test Plate and turn the
regulator counter-clockwise until regulator stops.
65
WARNING
PRESSURIZED FUEL
test.
6. Attach shop air supply to the J-45982-7 air pressure regulator and turn the regulator clockwise until the
gauge on the tool reads 68 KPa (10 psi).
7. Close the shut-off valve on the J-45982-7 air pressure regulator and disconnect the shop air supply.
Note : If air bubbles are present between the fuel cooler leak test plate and the fuel cooler, it may be necessary to
tighten the mounting bolts. Only tighten enough to prevent air from escaping between the fuel cooler and the fuel
cooler leak test plate.
66
8. Submerge the fuel cooler into a tank filled with warm water and verify no leaks are present between the fuel
cooler and the fuel cooler leak test plate.
Note : Air can get trapped in the fuel cooler when the cooler is placed in the warm water.
9. Soak the fuel cooler in the warm water for two minutes to remove any air that may be trapped in the cooler.
10. Continue to monitor the fuel cooler for one minute and observe if air bubbles escape continuously from the
fuel cooler.
10.a If no air bubbles are present, reinstall the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
10.b If air bubbles are present, replace the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
67
8.1 Idle Speed Balance Test

Incorporated into the MCM is the Idle Speed Balance (ISB) software which monitors the crankshaft speed
variation per cylinder power stroke and compensates each fuel injector to allow for a smoother running engine at
idle. The compensation values can be learned and stored in the EEPROM. ISB values are the percentage of
adjustment that the MCM can make to a fuel injector to adjust for idle stability. It does not represent the total
amount of available fuel per cylinder.
For diagnostic purposes, these values can be used to pinpoint a cylinder which is getting close to or at its
maximum/minimum limit. The limit values are set to positive (+100) and negative (-100). A value above or below
the acceptable limit indicates that the MCM software is compensating for a crankshaft speed variation. On a
common rail system this can be caused by internal engine damage, fuel injector fueling issue or failure of a high
pressure supply to a particular fuel injector.
If the ISB values are 0, this indicates no fueling compensation is needed. Values of +40 and -40 are not
uncommon for a new fuel system. If values reach +70 or -70, injection quantities are reaching their limits and
should be noted. If values are at +100 or -100, the respective cylinders should be checked for a failed component.
For example, for a low injection rate (low fueling from fuel injector), the software will try to compensate for this fuel
injector by increasing its pulse width to smooth out the engine. The value will go positive until the engine is
performing properly. If the value reaches (+100), no more compensation can occur. The fuel injector should only
be replaced after a visual inspection of the fuel supply to the fuel injector is checked. If the value reaches (-100),
this would indicate that the fuel injector is over-fueling to the point that the software cannot take out any more fuel.
Note : Mechanical failure can also cause a +100 or a -100 reading of ISB. Follow all of the troubleshooting
procedures for the particular system to determine the root cause of the failure.
8.1.1 Checking Idle Speed Balance

Check as follows:
Note : Fuel temp must be at least 10°C (50°F) and coolant temp must be at least 70°C (158°F).
1. Using DDDL 7.X, go to the "Service Routines" window and click on the "Idle Speed Balance" tab.
1
2. If there are any cylinders with a +100 or -100 Idle Speed Balance (ISB) value, run a compression test with
DDDL 7.X. Refer to section "Relative Cylinder Compression Test".
2.a If all cylinders pass the compression test, Go to step 3.
2.b If any cylinder(s) fail, inspect for mechanical failure.
3. Run the engine at idle and monitor ISB parameters, making note of each cylinder that is showing a positive
or negative 100% value.
Note : During the learning process, some cylinders may reach the positive or negative 100% limit, but will only
stay there for a short period of time. Looking at the parameters using the chart function can help determine
between an injector that is stuck at the 100% limit compared to an injector that has reached the limit for a short
time.
4. Click on “RUN TEST” to reset the values for all cylinders to zero. If all cylinders have not updated within
three minutes, run the engine to 1200 RPM for one minute and return to idle. This will cause the MCM
software to relearn the ISB values.
2
Fill in the following chart with the ISB values. These can be used at a later date or may be required for
another procedure.
3
ISB Worksheet
Cylinder # ISB Value
Cylinder # 1
Cylinder # 2
Cylinder # 3
Cylinder # 4
Cylinder # 5
Cylinder # 6
5. Continue to monitor any cylinder(s) that have reached a positive or negative 100%. If the suspect cylinder
is stuck at the limit of positive or negative 100%, check the following components:
• Fuel line from fuel rail to fuel injector (kinked or plugged). Repair as necessary. Refer to section "Verify
Repairs". Go to step 6.
• Fuel line connection at fuel injector or fuel rail (leaking). Repair as necessary. Refer to section "Verify
• Compression test; Refer to section "Relative Cylinder Compression Test". Repair as necessary. Refer to
section "Verify Repairs". Go to step 6.
6. If a cylinder is constantly higher than +70% or lower than -70% and there are no other mechanical concerns
with the engine, replace the fuel injector. Refer to section "Verify Repairs" .
7. If Idle Speed Balance values (ISB) are out of range after performing repairs, contact Customer Support
Center at 800-445-1980.
4
8.2 Diesel Exhaust Fluid Quantity Test - GHG17

The Diesel Exhaust Fluid (DEF) Quantity Test will check that the correct amount of DEF fluid is delivered in a
certain period of time. A fault code will normally accompany this procedure.
Note : Using DiagnosticLink®:
• A properly operating system will deliver between 108 and 132mL of DEF once the test has completed.
• New doser bolts and gasket are required after running this procedure.
Doser Bolts x 3 A0019907103

Doser Gasket A0001421180
Test as follows:
1. Remove the vehicle side fairing to gain better access to the dosing unit.
2. Remove the three bolts securing the DEF dosing unit to the mounting plate and discard bolts. Do not
disconnect the DEF lines or electrical connector.
3. Use the graduated cylinder from DEF kit W060589001900 to measure the DEF dispensed during the test.
4. Place the doser on top of the graduated cylinder with the nozzle facing downward into the cylinder.
5. Turn the ignition ON (key ON, engine OFF).

6. Connect to DiagnosticLink®.
7. From "Actions" drop-down menu, select "Aftertreatment", then "DEF Quantity Test."
8. Click the "Start" button to begin the "DEF Quantity Test."
5
9. The test will run for four minutes; once completed, verify the amount of DEF dispensed.
6
8.3 GHG17 Perform Parked SCR Efficiency Test

This test validates Selective Catalytic Reduction (SCR) system integrity from engine warm-up through NOx
efficiency.
You would normally run this test to detect:
• SCR catalyst efficiency concerns
• DEF concentration concerns
NOTICE
The total time for the test is between 60 and 85 minutes.
Note : The engine must be at operating temperature for accurate results (Coolant temperature greater than 71°C
(160°F).
This routine will bring the engine operating temperature and aftertreatment temperatures up to enable dosing
conditions where NOx conversion efficiency can be verified.
Before starting the routine, if the DPF lamp is illuminated, run a parked regeneration.
To run the Parked SCR Efficiency test:
1. Go to the SCR System tab in the Service Routines window.
2. Select Perform Parked SCR Efficiency Test from the drop-down menu.
3. Press the Start button.

A CAUTION dialog box will be displayed:
7
4. Ensure the transmission is in park or neutral and the parking brake is applied; press Yes to continue or No
to exit.
5. Hold DPF Switch to the ON position for five seconds and then release (engine speed will increase
indicating the routine has started).
8
6. The test will be carried out with the current status shown in the progress box:
9
NOTE: If the test aborts at any point, the progress box will show a description of where the test has failed in
the cycle.
The test is not a passed or failed test; the progress box will show the status "nox concentration not high
enough" at the end of the test, after one hour of stabilizing.
NOTICE: If the progress box shows the status "routine not started" or "stopping the routine," please check
the following:
a. High idle safety conditions: Park brake, neutral switch, clutch state, vehicle speed, engine idle states.
Please set them as requested in the service document.
b. Check for the component failure codes in the SCR system (DEF pump and DEF doser valve faults not
active) and troubleshoot them first.
c. After performing (a) & (b), if the routine still doesn't run, then perform an ignition cycle and make sure the
communication from all the modules is disabled before turning the ignition ON again and starting the
routine.
d. After performing (c), if the routine still doesn't run, then complete a parked regeneration before starting
the routine.
NOTICE: If 520372/16 - SCR closed loop at maximum limit fault is active/ confirmed ( and not
"permanent") and if any of the following codes below are not active/ confirmed , run a parked regen and
idle the system for 30 minutes then cycle the ignition before starting the service routine
10
8.4 GHG17 Perform Performance Check - Low

Temperature ATD
To run the routine:
1. Navigate to the DPF System Panel, under Service Routines. Open the drop-down window and select the
Perform Performance Check - Low Temp ATD.
2. Start the service routine. The engine speed will increase to 1250 rpm for this routine.
11
3. Once the engine coolant temperature reaches 50°C (126°F), the engine brake will activate (100% PWM).
12
4. The system will continue to warm up. Once the DOC inlet temperature reaches 270°C (518°F), the HC
dosing system will turn on. The HC dosing system will perform its safety check with no HC dosing. The Fuel
Doser Injection Status (in yellow) will go to 100%, then back to 0% for the remainder of the routine.
5. Navigate to the SCR Service Routines Panel. The DOC Inlet, DOC Outlet, DPF Outlet, SCR Inlet
(calculated value based on DPF outlet and SCR outlet on the 1-BOX) and SCR Outlet temperatures should
stabilize in the mid-to-upper 375°C (700°F) range.
13
6. Once the temperatures stabilize (should occur within 25 to 30 minutes into the service routine), compare all
temperature sensor values. They should read within 27°C (45°F) of each other. If the values are outside the
27°C (45°F) range, the temperature sensor has possibly drifted high or low.
7. The service routine will automatically stop after 30 minutes.
14
8.5 GHG17 Diesel Oxidation Catalyst Face Cleaning

The Diesel Oxidation Catalyst (DOC) Face Plug Cleaning service routine can be run to unclog the front face of the
Diesel Oxidation Catalysts. It can be used on a 1-Box™ emissions package or Two-box option.
Before performing this service routine, the cause of the DOC plugging should be found and corrected. Typical
causes are vehicle duty cycles that are stop-and-go, have excessive idle time, have stationary PTO operation, or
have a hardware issue with the engine or vehicle. Perform the "ATD Checklist" to review these items and correct
them before running this service routine.
The following engine conditions must be met before this routine can be performed:
• Engine is at base idle speed
NOTICE
Do not run the service routine if the DOC inlet pressure is greater than 20 kPa (2.9 psi). If
the pressure is above that, use the DOC air cleaning tool P/N: W470589239100. Refer to
section "Diesel Oxidation Catalyst Air Cleaning". This is to protect the engine and
turbocharger from excessive exhaust temperatures.
This service routine will run for approximately 4 hours and 45 minutes. You MUST remain with the vehicle for the
entire procedure.
If possible and safe to do so, warm up the engine to operating temperature before running the service routine.
To improve the chances of a successful procedure, engine load needs to be as low as possible. Turn off all
unnecessary accessories in the truck such as the air conditioner, extra lighting, PTO, etc. Note that setting the
HVAC system on Defrost typically turns on the air conditioner, so turn off the HVAC system or select a different
setting.
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1. Start the engine and allow it to idle at base (600 rpm) idle speed.
2. Connect DiagnosticLink 8.3 with Service Pack 1 (or higher).
3. Navigate to the Actions menu (1) / Aftertreatment (2) / DOC Face Plug Cleaning (3).
15
4. Once the panel opens, click on the Start button (1) in the bottom right hand corner to start the routine.
16
5. Once the Start button is clicked ’On’, the Actual DPF zone will shift in to zone 2 (1).
6. Read the dialog prompt message in the bottom left hand corner. Press and hold the regeneration dash
switch located on the dash for five seconds (2). See figure above.
7. For a New Cascadia, use the steering wheel controls, locate the PDF menu, and press OK; press OK again
to start the routine.
17
18
8. When the regeneration dash switch is depressed, the DPF Regen Switch Status Box will turn green.
9. Once the switch has been depressed for five seconds, the engine rpm will ramp up to about 1250 rpm.
10. The Intake Throttle Valve (ITV) (if applicable) and Jake Brake 1 (PWM13) may begin cycling (temperature
dependent) to raise DOC Inlet Temperature. This will cause engine rpm to fluctuate. The engine will run
and sound abnormal during this transition point but this condition is COMPLETELY NORMAL.
19
11. After the engine warms up, the ITV (if applicable) should become steady. The Jake Brake 1 (PWM13) will
be steady at 100%. Engine rpm should then become stable about 1250 rpm.
12. Monitor DOC inlet temperature (1). The DOC inlet temperature should be greater than 400°C (750°F).
Ambient temperature will have a large impact on DOC inlet temperature. If it is not above 400°C (750°F),
block off part of the radiator. Be careful that coolant temperature does not go high enough to cause a
Check Engine Light. If 400°C (750°F) DOC inlet temperature is not reached, the service routine will abort.
See Figure below. Note the DOC inlet temperature (1) is too low in this picture.
20
13. After four hours of run time, the engine rpm will change to 1100 - 1250 rpm (2) and a standard DPF Parked
Regeneration will occur automatically. The Parked Regeneration process will take about 45 minutes.
21
14. If the DOC inlet pressure ((1) see above figure) is within the expected range, the routine will complete. If
not, the service routine will abort.
15. After the DPF Parked Regeneration has completed, the engine will ramp down to 600 rpm to cool down.
16. The service routine is complete when actual engine speed is at 600 rpm (1).
17. Examine the DPF Parked Regeneration portion of the log file. Confirm DOC inlet pressure has dropped
from the previous level and is less than these approximate values.
1-Box Two-box
DD16 TC 6 kPa (0.9 psi) 13 kPa (1.9 psi)
DD15AT 7.5 kPa (1.1 psi) 13 kPa (1.9 psi)
DD13 5 kPa (0.7psi) 13 kPa (1.9 psi)
Note : A full DPF (end-of-life use) can replicate a plugged DOC (10kPa for a 1-Box and 13 kPa for a Two-box
option). This may be an issue on higher mileage units.
18. Confirm the original complaint (noisy ATS, Check Engine Light, etc.) has been resolved.
22
8.6 Diesel Oxidation Catalyst Air Cleaning

DOC plugging causes are vehicle duty cycles that are: stop-and-go, have excessive idle time, have stationary
PTO operation, or have a hardware issue with the engine or vehicle. Perform the "ATD Checklist" to review these
possible causes and correct them before running this service routine.
The Diesel Oxidation Catalyst (DOC) air cleaning will remove soot that has built up on the face of the DOC. Air
cleaning the DOC will reduce the aftertreatment inlet pressure, allowing for a parked regeneration to safely run
without damaging the engine.
DOC air cleaning kit DSN0ATZ16002 is compatible for use on EPA10 1-Box, GHG14 1-Box and 2016-2018
MDEG 1-Box aftertreatment systems. You will also need an air gun with a six-inch tip and shop vacuum equipped
with a dust bag to capture soot removed from the aftertreatment. A shop vacuum with a 2 ½ inch diameter hose
will provide the best sealing around the inlet reduction cone.
KIT CONTENT
Call Out Number Part Description Quantity
1 DOC block-off plate 1
2 DOC cleaning cone 1
4 Inlet reduction cone 1
23
Check as follows:
WARNING
PERSONAL INJURY
Use caution when handling and cleaning the Diesel Oxidation Catalyst (DOC). Personal
protective equipment and clothing in accordance with all applicable federal, state and local
laws or regulations should be used. Contents of the ash and soot removed from the DOC
may be classified as a hazardous waste under federal, state and/or local laws or
regulations. Hazardous wastes must be handled and disposed of in accordance with all
applicable federal, state and local laws or regulations.
1. Remove the 1-BOX™ aftertreatment from the vehicle. Refer to section "Removal of the 1-BOX™ from the Vehicle" .
2. Remove the outboard heat shield (1) from the 1-BOX™ configuration by disengaging the folded flange on
the top of the outboard heat shield.
24
3. Remove the four mounting bolts (2) from the inboard heat shield (1). Slide the inboard heat shield down
allowing better access to the inboard Diesel Particulate Filter (DPF), V-band and flat band clamp.
25
Note : Record the orientation of the bands and clamps. These components need to be installed in the same
location.
4. Loosen the outboard V-band and flat band clamps on the outboard DPF.
5. Slide the outboard flat band clamp inward and the V-band clamp outward on the outboard DPF.
6. Remove the outboard DPF assembly (2) from the 1-BOX™ configuration and discard the flat band gasket
(1).
26
7. Loosen the V-band and flat band clamps on the inboard DPF.
27
8. Slide the inboard flat band clamp inward and the V-band clamp outward on the inboard DPF.
9. Remove the inboard DPF (2) from the 1-BOX™ configuration and discard the flat band gasket (1).
28
10. Using DOC face cleaning kit W470589239100, slide the inlet reduction cone (3) over the aftertreatment
inlet. See graphic below.
29
11. Install the DOC block-off plate (2) over the inboard DOC and hand-tighten clamp.
12. Attach the DOC cleaning cone (1) to the outboard DOC and hand-tighten clamp.
13. Attach the shop vacuum hose to the aftertreatment reduction cone (3).
CAUTION
EYE INJURY
To avoid injury from flying debris, wear a face shield or goggles.
14. Turn on the shop vacuum; you should be able to feel suction if you place your hand momentarily over the
DOC cleaning cone opening.
NOTICE
Regulate air pressure to a maximum of 120 psi to prevent damage to the substrate.
15. Place the air gun nozzle inside the cleaning cone and keep the air gun tip 25 mm (1 in.) away from the
DOC to prevent damage to the brick.
16. Start blowing compressed air into the DOC cleaning cone. Move the air nozzle in a circular pattern, starting
from the outer edge and work your way inward to center of the DOC. Continue this motion for several
minutes.
30
17. Remove the DOC cleaning cone.
31
18. Continue blowing air into the DOC using a slow sweeping motion, making sure to cover 100% of the DOC
surface. Keep the air gun tip 25mm (1 in.) away from the DOC to prevent damage to the brick.
19. Move the block-off plate to the outboard DOC and install the cleaning cone onto the inboard DOC.
20. Place the air gun nozzle inside the cleaning cone, keep the air gun tip 25 mm (1 in.) away from the DOC to
prevent damage to the brick. Start blowing compressed air into the DOC cleaning cone. Move the air
nozzle in a circular pattern, starting from the outer edge and work your way inward to the center of the
DOC. Continue this motion for several minutes.
21. Remove the inboard DOC cleaning cone.
22. Continue blowing air into the inboard DOC using a slow sweeping motion making sure to cover 100% of the
DOC surface. Keep the air gun tip 25 mm (1 in.) away from the DOC to prevent damage to the brick.
23. Disconnect the vacuum and remove the inlet reduction cone and DOC block-off plate.
24. After each DOC has been air cleaned, reinstall both Diesel Particulate Filters (DPF) using new flat band
clamps and V-band gaskets.
25. Reinstall the aftertreatment.
26. Run a Parked Regen to verify DOC inlet pressure and check for proper NOx conversion.
32
8.7 Relative Cylinder Compression Test

The relative compression test runs during engine cranking. DiagnosticLink prevents the engine from starting while
it uses engine speed to calculate the test results. The best cylinder will show a result of 100%. A difference of
more than 15% suggests there is a compression issue. If there are any cylinders showing less than 85%, perform
a manual compression test to confirm the presence of any compression issues.
Note : The relative compression test can only be performed once per ignition cycle.
Note : After performing the relative compression test the ignition must be cycled off and then on before the engine
can be started.
Check as follows:
1. Connect to DiagnosticLink .
2. Turn the ignition ON, (key ON, engine OFF).
3. Click on the "Actions" tab in the top menu and select "Relative Compression Test" in the drop down menu.
4. DiagnosticLink will open a second window with no test results. Click the "Run Test" button in the lower right
hand corner of the screen.
33
5. Comply with the caution warning and click "Yes" to continue.
34
6. Crank the engine until the starter stops. Then click "OK".
7. Check the results. Are any of the cylinders reading lower than 85%?
7.a Yes; Refer to section "Mechanical Cylinder Compression Test" and perform the manual compression test.
7.b No; all of the cylinders read 85% or higher. Select "Close" and return to the previous troubleshooting
that directed you to perform the Relative Compression test.
35
36
8.8 Mechanical Cylinder Compression Test

Note : This test should be performed only if directed here by a diagnostic procedure.
Special Service Tools Used in the Procedure

Tool Number Tool Name Tool Graphic
J-47411 Compression Test Adaptor
J-48704 or W470589129100 High Pressure Fuel Rail Test Caps
Perform the following steps for a mechanical compression test on a GHG17Heavy Duty DD Platform Engine:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.
Note : First perform the Relative Cylinder Compression Test using DiagnosticLink. Refer to section "Relative Cylinder
Compression Test" . If results indicate a weak cylinder, perform this mechanical compression test.
37
1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to
205°F).
CAUTION
ELECTRICAL SHOCK
2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover" .
4. Remove the fuel injector harness.
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
5. Disconnect electrical contacts at the fuel injectors.
6. Disconnect the two wiring terminals going to the Jake Brake solenoids.
7. Disconnect the 14-pin fuel injector harness connector.
8. Remove the spring clip holding the fuel injector harness connectors to camshaft frame.
9. Remove the fuel injector wiring harness(es).
10. Remove the high pressure fuel line from the suspect cylinder. Refer to section "Removal of the High Pressure Fuel
Injector Lines - Two-Filter System" .
11. Remove the fuel injector. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
12. Remove excess fuel from cylinder using a vacuum pump.
13. Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder head.
14. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) + 90 degrees.
15. Install the fuel rail plug (J-48704 or W470589129100).
16. Install a hold-down bolt onto the Jake-Brake solenoid and snug the bolt.
CAUTION
ELECTRICAL SHOCK
17. Reconnect the batteries; keep the battery charger plugged into the batteries.
Note : Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
voltage.
18. Using DiagnosticLink start the Mechanical Compression Test routine, this will disable fuel from the Quantity
Control Valve.
19. With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater using
the starter motor. Record the compression reading on the gauge.
20. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If
compression readings are below specifications, repeat step 13 with a different gauge to be certain of the
reading.
Note : Fuel injector hold-down bolts are a one-time use item.
21. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test
adaptors.
22. Repeat steps for all suspect cylinders.
38
23. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression" .
39
8.9 Crankcase Pressure Test

Check the engine crankcase pressure as follows:
Tool Number Tool Name Graphic

W651589029100 Crankcase Pressure Test Adaptor
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

2. Run the engine and bring the engine coolant temperature to normal operating range, 88º to 96°C (19º to
205°F).
3. Install the crankcase pressure test adapter (W651589029100) on to the oil fill opening. Attach a water
manometer, calibrated to read pressure as inches of H2O, on to the adaptor.
4. Run the vehicle to full load and rated speed with a loaded trailer or dyno.
5. Measure and record crankcase pressure.
6. Shut down the engine.
7. Remove the adaptor from the oil fill opening.
Note : Any tubing used to feed the manometer will artificially increase the crankcase pressure results.
40
8. The correct crankcase pressure should be less than 5 inches of H2O at full load. If the engine crankcase
pressure is greater than 5 in. H2O, Refer to section "High Crankcase Pressure" .
41
8.10 Power Verification With Chassis Dynamometer

The chassis dynamometer is a device for applying specific loads to a vehicle to determine if the vehicle will
perform to published specifications and to permit a physical inspection for leaks of any kind. It can be used for
detecting improper tune-up, misfiring fuel injectors, low compression, and other malfunctions.
8.2.1 Chassis Dynamometer Room Ventilation Recommendations

For safe and accurate dynamometer readings, the chassis dynamometer room must be properly ventilated.
WARNING
ENGINE EXHAUST
CAUTION
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface,
parking brake is set, and the wheels are blocked.
If a vehicle is tested on a dynamometer located in an area without proper ventilation, the engine will be subject to
high ambient air temperatures. High air inlet temperatures can result in false low power readings on the
dynamometer.
To help ensure accurate horsepower readings, the dynamometer room should have a ceiling-mounted fan with an
850 to 1133 m³ /min (30,000 to 40,000 ft³ /min) capacity. This will provide proper ventilation of exhaust gases and
heat radiated by the operating engine.
8.2.2 Chassis Dynamometer Test and Run-in Procedure

The function of the dynamometer is to absorb and measure the engine output after it has been transmitted
through the vehicle transmission and driveline to the drive tires.
The vehicle is connected to the dynamometer through the roller absorption unit. The load on the vehicle may be
varied from zero to maximum by decreasing or increasing the resistance in the unit. The amount of power
absorbed in a water brake-type dynamometer, as an example, is governed by the volume of fluid within the
working system. The fluid offers resistance to a rotating motion. By controlling the volume of water in the
absorption unit, the load may be increased or decreased as required.
42
8.11 Minimum Acceptable Wheel Horsepower

The minimum acceptable wheel horse power is 80% of the maximum horse power at rated speed.
Wheel horsepower is a measurement of engine output minus the parasitic losses associated with engine
accessories (alternator, fan, A/C, etc) and driveline losses (transmission, driveshaft, axles, etc.). A total parasitic
loss of 15-20% is not uncommon, depending on how a particular vehicle is configured. Refer to " Engine Performance
Curves " for horsepower specifications.
43
8.12 Perform Output Component Test

Note : This test can only run once per ignition cycle - If you need to run the test more than once, the ignition must
be cycled between tests.
The Perform Output Component Test can be used as a sanity check for components related to the Aftertreatment
System (ATS).
The Selective Catalyst Reduction (SCR) heaters, Pressure Limiting Unit (PLU), Coolant Valve, Intake Throttle
Valve (ITV), Fuel Cutoff Valve, and HC Doser are commanded ON for a brief period and individual fault codes will
be set during the test if a component fails.
To run this test:
3. Go to the "Service Routines" work window and select the "SCR System" tab. Select the "Perform
Output Component Test" from the drop-down list.
4. Press the "Start" button.

Note : You can view the instruments in the Chart tab in the "Instrumentation" work window to ensure the
instruments are turning ON as commanded.
5. The following examples illustrates successful completion of the routine.
5.a All relative instruments were commanded ON, no faults were set.
44
5.b The progress box in the SCR System panel shows complete.
6. The following example illustrates unsuccessful completion of the routine.
6.a All relative instruments were commanded ON, but Line Heater 3 failed and the fault code was set.
45
6.b The progress box in the SCR tab shows that the test failed.
46
8.13 Piston Protrusion Measurement Procedure
1. Setscrew Slot for MDEG

2. Setscrew Slot for HDEP
3. Setscrew
4. Sleeve
5. HDEP Use
6. MDEG Use
7. Tool Set for Use with HDEP
8. Setscrew
Check as follows:
1. Remove all of the injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
2. Set the piston protrusion tool upper collar for HDEP engines.
3. Install the piston protrusion tool into cylinder #1.
47
4. Install and torque the injector hold down clamp to 20 N·m (14.8 lb·ft).
5. Ensure that the dowel is at the bottom of the tool.
48
Note : If the dowel is not at the bottom of the tool, bar the engine over by hand until the dowel is at the bottom of
the tool.
6. Set the dial indicator to zero.
7. Bar the engine over by hand while watching the dowel pin and the dial indicator. If there is no measurement
on the dial indicator and the dowel pin does not rise, the dial indicator must be set further down into the tool
collar.
NOTICE
Once the first measurement has been recorded, the dial indicator should not be adjusted.
Adjusting the dial indicator after measurement can lead to inaccurate measurement
comparison.
8. Bar the engine over by hand and record the maximum height for cylinder #1.
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6

in. in. in. in. in. in.
9. Remove the piston protrusion tool and install the tool into cylinder #2.
13. Bar the engine over and record the maximum height for cylinder #2.
14. Repeat steps 9 through 13 for the remaining cylinders. Once the measurements are recorded for each
cylinder, proceed to step 15.
Note : The lower the measurement, the shorter the piston connecting rod.
15. Compare the measurements for each cylinder. A difference of 0.017 in. for HDEP engines from the highest
cylinder measurement indicates that the piston is not reaching top dead center and further investigation is
needed to determine the cause of the concern.
If the measurements are within specification, reinstall the injectors. Refer to section "Installation of the Fuel Injector -
Two-Filter System" . Return to the originating diagnostic procedure.
49
8.14 Cylinder Leak-Down Test

Service Tools Used in this Procedure
OTC 5609 or equivalent Cylinder Leakage Tester
J-47411 Adapter, Compression Test HDE
J-45982-7 Regulator and gauge set (part of J-45982, Head and Block
Leak Tester)
Test as follows:
1. Remove the intake and exhaust rocker arm shafts.
Refer to section "Removal of the Intake Rocker Shaft Assembly"
Refer to section "Removal of the Exhaust Rocker Shaft Assembly"
2. Remove the six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
Note : Make sure the seal at the tip of the J-47411 Compression Test Adapter is installed and it does not fall out
while installing the tool into the fuel injector cup.
Note : Note: The original fuel injector hold-down clamp bolt can be re-used to install and secure the J-47411
Compression Test Adapter in place. Use new fuel injector hold-down clamp bolts when installing the new fuel
injectors.
3. Using a fuel injector hold-down clamp and bolt, install J-47411 Compression Test Adapter in the in the fuel
injector cup for cylinder number one.
4. Torque the fuel injector hold-down clamp bolt to 20 N•m (15 lb•ft) + 90 degree.
5. Connect a short air hose (2) to the J-47411 Compression Test Adapter (1).
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6. Connect the other end of the short air hose (2) to the output side of the Cylinder Leakage Tester (1).
7. Connect the output side of the J-45982-7 Regulator and Gauge Set (3) to the input side of the Cylinder
Leakage Tester (1).
Note : The shop air must be capable to continuously supply 689 kPa (100 psi) of air pressure.
8. Connect shop air to the input side of the J-45982-7 Regulator and Gauge Set.
9. Open the air shut-off valve and adjust the J-45982-7 Regulator and Gauge output to 689 kPa (100 psi).
10. Adjust the air regulator on the Cylinder Leakage Tester so the left side gauge on the Cylinder Leakage
Tester indicates 620 kPa (90 psi).
11. Record the pressure indicated on the right side gauge of the Cylinder Leakage Tester.
12. Subtract the pressure recorded on the right side gauge from the pressure shown on the left gauge.
Note : The pressure difference between the two Cylinder Leakage Tester gauges indicates the pressure loss on
that respective cylinder. A pressure loss greater than 103 kPa (15 psi) on any one cylinder, or a difference in
pressure loss greater than 68 kPa (10 psi) from cylinder to cylinder, indicates a potential issue and further
investigation to identify the source of leak is needed.
13. Repeat steps 3 through 12 for the remaining cylinders.
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8.15 Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel

System
Note : This test is only to be performed if a fuel leak is present and a visual inspection of the engine did not
pinpoint a fuel leak path.
J-48710 Fuel system air pressure tool
W470589039100 Fuel System Update kit
J-48708 Fuel Flow tool
J-48707 FFM in and outlet hose
ESOC 350 Fuel Priming Pump
J-28431-B (recommended) Fluorescent Fuel Dye that is diesel compatible
52
Check as follows:
Note : When diagnosing an engine fuel leak, the source and location of the leak MUST be positively identified
prior to repair.
steps.
WARNING
test.

7. Remove the J-48710 tool.
Note : When configuring the amount of dye to be added. Consider this procedure will be run with approximately
two gallons of fuel.
53
8. Add diesel fuel compatible fuel dye, per manufacturer’s recommendation, to the two fitting container on the
Fuel flow tool J-48708.
9. Remove the OEM Fuel return line off the fuel filter module.
10. Connect Fuel System Update Kit W470589039100 connectors to Fuel Filter Module supply and return
fittings.
11. Install the FFM in and outlet Hoses J-48707 to Fuel System Update kit W470589039100.
12. Connect the other end of the FFM in and outlet hoses J-48707 to the Fuel Flow tool J-48708.
Note : 0.8 L of fuel is in the module after the above draining is performed. This amount is compensated for when
priming.
13. Measure 6.8 L of Diesel fuel into the single fitting container of the Fuel Flow tool J-48708.
14. Add fuel from the single fitting container of the Fuel Flow tool J-48708 to the ESOC 350.
15. Prime the fuel system until the ESOC 350 is empty.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
at 900 rpm.
17. Using the black light, inspect the fuel system for the source of the fuel leak. Refer to section "Potential Fuel Leak
Points - Two-Filter Fuel System" .
54
8.16 Air Compressor Unloader Leakage Test

Check as follows:
1. Park vehicle on a level surface and chock the wheels.
2. Remove the governor and install a fitting to the unloader port.
3. Add a section of air hose (minimum 1 foot long for ½-in. diameter line) and a calibrated test gauge to the
unloader port on the air compressor.
4. Install a shut-off valve and an air source (shop air or small tank).
5. Open shut-off valve and charge the unloader port by allowing air pressure to enter the hose and unload the
compressor.
6. Shut off the air supply and observe the gauge.
7. A steady reading indicates no leakage at the unloader port. If pressure drops, the unloader valve is leaking
and needs to be replaced.
55
8.17 Air Brake System and Accessory Leakage Test

Test as follows:
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : The following is a general procedure for isolating leaks in different areas of the air brake system. Refer to
vehicle service literature for more specific tests and information.
2. Build system pressure to governor cut-out, stop the engine, and allow the pressure to stabilize for one
minute.
3. Observe the dash gauges for two minutes without applying the service brake.
4. Does the system hold pressure?
4.b No; follow OEM troubleshooting for air leaks in the air brake system.
Note : A block of wood may be used to hold the brake pedal in position.
5. Apply the service brakes and allow the pressure to stabilize for two minutes.
6. Observe the dash gauges for two minutes.
7. Does the system lose more than 27 kPa (4 psi) [plus 14 kPa (2 psi) for each additional trailer] of pressure?
7.a Yes; follow OEM troubleshooting for air leaks in brake chambers and lines/components associated with
brake application.
8. Install a test gauge on the supply reservoir or wet tank.
9. Observe the test gauge for two minutes.
10. Does the system lose more than 6 kPa (1 psi) per minute?
10.a Yes; follow OEM troubleshooting for the air dryer and the inlet check valves of the primary and
secondary reservoirs, then perform the "Governor System Leakage and Function" test. Refer to section
"Governor System Leakage and Function Test"
10.b No; the air system is performing properly.
56
8.18 Governor System Leakage and Function Test

Test as follows:
2. Verify that the air lines on the governor are connected to the correct ports on the governor.
3. Inspect for blockage, kinks or folds, or leakage in all air lines and fittings to the governor, air compressor
unloader port, and air dryer purge control port, and repair as needed.
NOTICE
Use caution not to drop any hardware or debris into the air compressor or severe damage
can occur.
4. Test for internal leakage within the air compressor unloader port. Refer to section "Air Compressor Unloader Leakage
Test" .
5. Test for internal leakage within the purge control port of the air dryer. Refer to OEM troubleshooting.
6. Test for a large continuous air leak using soapy water at the governor exhaust port during governor cut-out
and governor cut-in. A small leak is normal.
Note : Air leaks within the governor system must be identified and repaired before performing this test.
7. Verify governor cut-in and cut-out pressure set points as follows:
7.a Install a calibrated test gauge on the supply reservoir or wet tank.
7.b Install a second test gauge into the governor control line or an unused governor control port.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
7.c Run the engine, and operate the brakes or otherwise bleed air to allow the governor to go into cut-in
and cut-out while observing the two test gauges. Make the following checks:
i. View the test gauges to ensure the reservoir pressures at the times of governor cut-in and cut-out are
within vehicle OEM specifications.
ii. Ensure that the change in governor control line pressure during a governor shift is nearly
instantaneous (less than 3 seconds).
7.d Perform repair, replacement, or adjustment of the governor according to vehicle OEM or governor
manufacturer service literature.
57
8.19 Priming of the Lubrication System to Check for Leaks

in the Upper Portion of the Engine
Detroit Diesel Tools Needed to Perform This Procedure
J-49181 Oil System Priming Adapter
J-45299 Oil System Priming Pump
1. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port on the oil coolant module.
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2. If equipped with an oil sample valve, remove the valve and washer.
Note : Tool J-49181 is used to adapt the J-45299 priming pump.
3. Install oil system priming adaptor tool (J-49181) into the oil priming port (1) in the oil coolant module.
59
NOTICE
If chassis application prevents access, a 90-degree or a 45-degree pipe fitting (1/4" NPT)
can be used (if needed) for access.
4. Install the engine pre-lube kit (J-45299) to the fitting adaptor (1).
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5. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" .
6. Fill the canister with four quarts of oil.
7. Open the valve on the primer and start pumping.
8. Inspect the rockers and engine brake solenoids for excessive oil. If leaks are present, repair the leaks as
necessary.
9. Install the rocker cover; Refer to section "Installation of the Rocker Cover" .
10. Close the valve on the priming tool and loosen the fitting; do not completely remove it from the adaptor.
11. Remove the priming adaptor from the oil coolant module with the line attached to keep the oil from flowing
out of the module.
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12. Install the Allen head plug or oil sample valve to the module and torque to 70 to 80 N·m (51 to 59 lb·ft).
62
8.20 Cylinder Head Pressure Test
1. Cup Plug Caps

2. Nut
3. Washer
4. Reinforcement Plate
5. Cylinder Head Sealing Plate
6. Manifold Opening Covers
7. Air Connector Quick Coupling
8. Washer
9. Bolt
10. Cylinder Head Bolt
DD13 Engines use tool number: W470589012500 DD15 and DD16 engines use tool number: W470589002500
Check as follows:
1. Remove the cylinder head.
Refer to section "Removal of the DD13 Cylinder Head Assembly"
Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly"
2. Thoroughly clean the cylinder head. Refer to section "Cleaning of the Cylinder Head" .
3. Inspect the sealing surfaces of the cylinder head and the tool. If damage is found, repair as necessary.
Note : The leak test plates have gaskets that seal to the deck surface of the cylinder head and the exhaust side of
63
the head. These gaskets can prevent pressure from escaping if there is a leak around the valves or a leak inside
of an exhaust port. For this reason, Detroit recommends drilling small relief holes in the gaskets at the valve areas
and the exhaust ports.
4. Install the leak test tool using the original head bolts along with the supplied hardware onto the head gasket
surface of the cylinder head with the rubber side toward the head. Torque to 13 N·m (10 lb·ft) or until the
rubber starts to bulge out from in between the tool and the head.
5. Install the water manifold opening covers with the supplied hardware in the same fashion. Tighten the bolts
to 13 N·m (10 lb·ft). The rubber should be starting to bulge from between the tool and the cylinder head.
6. Install the cup plug caps onto the cup plugs using the supplied hardware with the cutout side facing the cup
plug. Torque to 15 N·m (11 lb·ft).
7. Attach the air pressure gauge and regulator J-45982-7 or equivalent.
8. Turn regulator counterclockwise until it stops.
WARNING
EYE INJURY
9. Connect shop air to the regulator and turn it clockwise until the gauge reads 206.8 kPa (30 psi).
10. Allow the air pressure to stabilize for one minute.
11. Close the ball valve on the regulator and disconnect the shop air hose.
12. Allow the head to remain pressurized for thirty minutes. There should be no pressure loss over a 30-minute
time period.
13. If the pressure drops, use a soap and water solution to determine where the possible leak is coming from.
Once the leak has been identified, repair as necessary.
64
Diagnostic Tests
8.1 Idle Speed Balance Test

Incorporated into the MCM is the Idle Speed Balance (ISB) software which monitors the crankshaft speed
variation per cylinder power stroke and compensates each fuel injector to allow for a smoother running engine at
idle. The compensation values can be learned and stored in the EEPROM. ISB values are the percentage of
adjustment that the MCM can make to a fuel injector to adjust for idle stability. It does not represent the total
amount of available fuel per cylinder.
For diagnostic purposes, these values can be used to pinpoint a cylinder which is getting close to or at its
maximum/minimum limit. The limit values are set to positive (+100) and negative (-100). A value above or below
the acceptable limit indicates that the MCM software is compensating for a crankshaft speed variation. On a
common rail system this can be caused by internal engine damage, fuel injector fueling issue or failure of a high
pressure supply to a particular fuel injector.
If the ISB values are 0, this indicates no fueling compensation is needed. Values of +40 and -40 are not
uncommon for a new fuel system. If values reach +70 or -70, injection quantities are reaching their limits and
should be noted. If values are at +100 or -100, the respective cylinders should be checked for a failed component.
For example, for a low injection rate (low fueling from fuel injector), the software will try to compensate for this fuel
injector by increasing its pulse width to smooth out the engine. The value will go positive until the engine is
performing properly. If the value reaches (+100), no more compensation can occur. The fuel injector should only
be replaced after a visual inspection of the fuel supply to the fuel injector is checked. If the value reaches (-100),
this would indicate that the fuel injector is over-fueling to the point that the software cannot take out any more fuel.
Note : Mechanical failure can also cause a +100 or a -100 reading of ISB. Follow all of the troubleshooting
procedures for the particular system to determine the root cause of the failure.
8.1.1 Checking Idle Speed Balance

Check as follows:
Note : Fuel temp must be at least 10°C (50°F) and coolant temp must be at least 70°C (158°F).
1. Using DDDL 7.X, go to the "Service Routines" window and click on the "Idle Speed Balance" tab.
65
2. If there are any cylinders with a +100 or -100 Idle Speed Balance (ISB) value, run a compression test with
DDDL 7.X. Refer to section "Relative Cylinder Compression Test".
2.a If all cylinders pass the compression test, Go to step 3.
2.b If any cylinder(s) fail, inspect for mechanical failure.
3. Run the engine at idle and monitor ISB parameters, making note of each cylinder that is showing a positive
or negative 100% value.
Note : During the learning process, some cylinders may reach the positive or negative 100% limit, but will only
stay there for a short period of time. Looking at the parameters using the chart function can help determine
between an injector that is stuck at the 100% limit compared to an injector that has reached the limit for a short
time.
4. Click on “RUN TEST” to reset the values for all cylinders to zero. If all cylinders have not updated within
three minutes, run the engine to 1200 RPM for one minute and return to idle. This will cause the MCM
software to relearn the ISB values.
66
Fill in the following chart with the ISB values. These can be used at a later date or may be required for
another procedure.
67
ISB Worksheet
Cylinder # ISB Value
Cylinder # 1
Cylinder # 2
Cylinder # 3
Cylinder # 4
Cylinder # 5
Cylinder # 6
5. Continue to monitor any cylinder(s) that have reached a positive or negative 100%. If the suspect cylinder
is stuck at the limit of positive or negative 100%, check the following components:
• Fuel line from fuel rail to fuel injector (kinked or plugged). Repair as necessary. Refer to section "Verify
• Fuel line connection at fuel injector or fuel rail (leaking). Repair as necessary. Refer to section "Verify
• Compression test; Refer to section "Relative Cylinder Compression Test". Repair as necessary. Refer to
section "Verify Repairs". Go to step 6.
6. If a cylinder is constantly higher than +70% or lower than -70% and there are no other mechanical concerns
with the engine, replace the fuel injector. Refer to section "Verify Repairs" .
7. If Idle Speed Balance values (ISB) are out of range after performing repairs, contact Customer Support
Center at 800-445-1980.
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8.2 Diesel Exhaust Fluid Quantity Test - GHG17

The Diesel Exhaust Fluid (DEF) Quantity Test will check that the correct amount of DEF fluid is delivered in a
certain period of time. A fault code will normally accompany this procedure.
Note : Using DiagnosticLink®:
• A properly operating system will deliver between 108 and 132mL of DEF once the test has completed.
• New doser bolts and gasket are required after running this procedure.
Doser Bolts x 3 A0019907103

Doser Gasket A0001421180
Test as follows:
1. Remove the vehicle side fairing to gain better access to the dosing unit.
2. Remove the three bolts securing the DEF dosing unit to the mounting plate and discard bolts. Do not
disconnect the DEF lines or electrical connector.
3. Use the graduated cylinder from DEF kit W060589001900 to measure the DEF dispensed during the test.
4. Place the doser on top of the graduated cylinder with the nozzle facing downward into the cylinder.

7. From "Actions" drop-down menu, select "Aftertreatment", then "DEF Quantity Test."
8. Click the "Start" button to begin the "DEF Quantity Test."
69
9. The test will run for four minutes; once completed, verify the amount of DEF dispensed.
70
8.3 GHG17 Perform Parked SCR Efficiency Test

This test validates Selective Catalytic Reduction (SCR) system integrity from engine warm-up through NOx
efficiency.
You would normally run this test to detect:
• SCR catalyst efficiency concerns
• DEF concentration concerns
NOTICE
The total time for the test is between 60 and 85 minutes.
Note : The engine must be at operating temperature for accurate results (Coolant temperature greater than 71°C
(160°F).
This routine will bring the engine operating temperature and aftertreatment temperatures up to enable dosing
conditions where NOx conversion efficiency can be verified.
Before starting the routine, if the DPF lamp is illuminated, run a parked regeneration.
To run the Parked SCR Efficiency test:
1. Go to the SCR System tab in the Service Routines window.
2. Select Perform Parked SCR Efficiency Test from the drop-down menu.
3. Press the Start button.

A CAUTION dialog box will be displayed:
71
4. Ensure the transmission is in park or neutral and the parking brake is applied; press Yes to continue or No
to exit.
5. Hold DPF Switch to the ON position for five seconds and then release (engine speed will increase
indicating the routine has started).
72
6. The test will be carried out with the current status shown in the progress box:
73
NOTE: If the test aborts at any point, the progress box will show a description of where the test has failed in
the cycle.
The test is not a passed or failed test; the progress box will show the status "nox concentration not high
enough" at the end of the test, after one hour of stabilizing.
NOTICE: If the progress box shows the status "routine not started" or "stopping the routine," please check
the following:
a. High idle safety conditions: Park brake, neutral switch, clutch state, vehicle speed, engine idle states.
Please set them as requested in the service document.
b. Check for the component failure codes in the SCR system (DEF pump and DEF doser valve faults not
active) and troubleshoot them first.
c. After performing (a) & (b), if the routine still doesn't run, then perform an ignition cycle and make sure the
communication from all the modules is disabled before turning the ignition ON again and starting the
routine.
d. After performing (c), if the routine still doesn't run, then complete a parked regeneration before starting
the routine.
NOTICE: If 520372/16 - SCR closed loop at maximum limit fault is active/ confirmed ( and not
"permanent") and if any of the following codes below are not active/ confirmed , run a parked regen and
idle the system for 30 minutes then cycle the ignition before starting the service routine
74
8.4 GHG17 Perform Performance Check - Low

Temperature ATD
To run the routine:
1. Navigate to the DPF System Panel, under Service Routines. Open the drop-down window and select the
Perform Performance Check - Low Temp ATD.
2. Start the service routine. The engine speed will increase to 1250 rpm for this routine.
75
3. Once the engine coolant temperature reaches 50°C (126°F), the engine brake will activate (100% PWM).
76
4. The system will continue to warm up. Once the DOC inlet temperature reaches 270°C (518°F), the HC
dosing system will turn on. The HC dosing system will perform its safety check with no HC dosing. The Fuel
Doser Injection Status (in yellow) will go to 100%, then back to 0% for the remainder of the routine.
5. Navigate to the SCR Service Routines Panel. The DOC Inlet, DOC Outlet, DPF Outlet, SCR Inlet
(calculated value based on DPF outlet and SCR outlet on the 1-BOX) and SCR Outlet temperatures should
stabilize in the mid-to-upper 375°C (700°F) range.
77
6. Once the temperatures stabilize (should occur within 25 to 30 minutes into the service routine), compare all
temperature sensor values. They should read within 27°C (45°F) of each other. If the values are outside the
27°C (45°F) range, the temperature sensor has possibly drifted high or low.
7. The service routine will automatically stop after 30 minutes.
78
8.5 GHG17 Diesel Oxidation Catalyst Face Cleaning

The Diesel Oxidation Catalyst (DOC) Face Plug Cleaning service routine can be run to unclog the front face of the
Diesel Oxidation Catalysts. It can be used on a 1-Box™ emissions package or Two-box option.
causes are vehicle duty cycles that are stop-and-go, have excessive idle time, have stationary PTO operation, or
have a hardware issue with the engine or vehicle. Perform the "ATD Checklist" to review these items and correct
them before running this service routine.
The following engine conditions must be met before this routine can be performed:
• Engine is at base idle speed
NOTICE
Do not run the service routine if the DOC inlet pressure is greater than 20 kPa (2.9 psi). If
the pressure is above that, use the DOC air cleaning tool P/N: W470589239100. Refer to
section "Diesel Oxidation Catalyst Air Cleaning". This is to protect the engine and
turbocharger from excessive exhaust temperatures.
This service routine will run for approximately 4 hours and 45 minutes. You MUST remain with the vehicle for the
entire procedure.
If possible and safe to do so, warm up the engine to operating temperature before running the service routine.
To improve the chances of a successful procedure, engine load needs to be as low as possible. Turn off all
unnecessary accessories in the truck such as the air conditioner, extra lighting, PTO, etc. Note that setting the
HVAC system on Defrost typically turns on the air conditioner, so turn off the HVAC system or select a different
setting.
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1. Start the engine and allow it to idle at base (600 rpm) idle speed.
2. Connect DiagnosticLink 8.3 with Service Pack 1 (or higher).
3. Navigate to the Actions menu (1) / Aftertreatment (2) / DOC Face Plug Cleaning (3).
79
4. Once the panel opens, click on the Start button (1) in the bottom right hand corner to start the routine.
80
5. Once the Start button is clicked ’On’, the Actual DPF zone will shift in to zone 2 (1).
6. Read the dialog prompt message in the bottom left hand corner. Press and hold the regeneration dash
switch located on the dash for five seconds (2). See figure above.
7. For a New Cascadia, use the steering wheel controls, locate the PDF menu, and press OK; press OK again
to start the routine.
81
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8. When the regeneration dash switch is depressed, the DPF Regen Switch Status Box will turn green.
9. Once the switch has been depressed for five seconds, the engine rpm will ramp up to about 1250 rpm.
10. The Intake Throttle Valve (ITV) (if applicable) and Jake Brake 1 (PWM13) may begin cycling (temperature
dependent) to raise DOC Inlet Temperature. This will cause engine rpm to fluctuate. The engine will run
and sound abnormal during this transition point but this condition is COMPLETELY NORMAL.
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11. After the engine warms up, the ITV (if applicable) should become steady. The Jake Brake 1 (PWM13) will
be steady at 100%. Engine rpm should then become stable about 1250 rpm.
12. Monitor DOC inlet temperature (1). The DOC inlet temperature should be greater than 400°C (750°F).
Ambient temperature will have a large impact on DOC inlet temperature. If it is not above 400°C (750°F),
block off part of the radiator. Be careful that coolant temperature does not go high enough to cause a
Check Engine Light. If 400°C (750°F) DOC inlet temperature is not reached, the service routine will abort.
See Figure below. Note the DOC inlet temperature (1) is too low in this picture.
84
13. After four hours of run time, the engine rpm will change to 1100 - 1250 rpm (2) and a standard DPF Parked
Regeneration will occur automatically. The Parked Regeneration process will take about 45 minutes.
85
14. If the DOC inlet pressure ((1) see above figure) is within the expected range, the routine will complete. If
not, the service routine will abort.
15. After the DPF Parked Regeneration has completed, the engine will ramp down to 600 rpm to cool down.
16. The service routine is complete when actual engine speed is at 600 rpm (1).
17. Examine the DPF Parked Regeneration portion of the log file. Confirm DOC inlet pressure has dropped
from the previous level and is less than these approximate values.
1-Box Two-box
DD16 TC 6 kPa (0.9 psi) 13 kPa (1.9 psi)
DD15AT 7.5 kPa (1.1 psi) 13 kPa (1.9 psi)
DD13 5 kPa (0.7psi) 13 kPa (1.9 psi)
Note : A full DPF (end-of-life use) can replicate a plugged DOC (10kPa for a 1-Box and 13 kPa for a Two-box
option). This may be an issue on higher mileage units.
18. Confirm the original complaint (noisy ATS, Check Engine Light, etc.) has been resolved.
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8.6 Diesel Oxidation Catalyst Air Cleaning

DOC plugging causes are vehicle duty cycles that are: stop-and-go, have excessive idle time, have stationary
PTO operation, or have a hardware issue with the engine or vehicle. Perform the "ATD Checklist" to review these
possible causes and correct them before running this service routine.
The Diesel Oxidation Catalyst (DOC) air cleaning will remove soot that has built up on the face of the DOC. Air
cleaning the DOC will reduce the aftertreatment inlet pressure, allowing for a parked regeneration to safely run
without damaging the engine.
DOC air cleaning kit DSN0ATZ16002 is compatible for use on EPA10 1-Box, GHG14 1-Box and 2016-2018
MDEG 1-Box aftertreatment systems. You will also need an air gun with a six-inch tip and shop vacuum equipped
with a dust bag to capture soot removed from the aftertreatment. A shop vacuum with a 2 ½ inch diameter hose
will provide the best sealing around the inlet reduction cone.
KIT CONTENT
Call Out Number Part Description Quantity
1 DOC block-off plate 1
2 DOC cleaning cone 1
4 Inlet reduction cone 1
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Check as follows:
WARNING
PERSONAL INJURY
Use caution when handling and cleaning the Diesel Oxidation Catalyst (DOC). Personal
protective equipment and clothing in accordance with all applicable federal, state and local
laws or regulations should be used. Contents of the ash and soot removed from the DOC
may be classified as a hazardous waste under federal, state and/or local laws or
regulations. Hazardous wastes must be handled and disposed of in accordance with all
applicable federal, state and local laws or regulations.
1. Remove the 1-BOX™ aftertreatment from the vehicle. Refer to section "Removal of the 1-BOX™ from the Vehicle" .
2. Remove the outboard heat shield (1) from the 1-BOX™ configuration by disengaging the folded flange on
the top of the outboard heat shield.
88
3. Remove the four mounting bolts (2) from the inboard heat shield (1). Slide the inboard heat shield down
allowing better access to the inboard Diesel Particulate Filter (DPF), V-band and flat band clamp.
89
Note : Record the orientation of the bands and clamps. These components need to be installed in the same
location.
4. Loosen the outboard V-band and flat band clamps on the outboard DPF.
5. Slide the outboard flat band clamp inward and the V-band clamp outward on the outboard DPF.
6. Remove the outboard DPF assembly (2) from the 1-BOX™ configuration and discard the flat band gasket
(1).
90
7. Loosen the V-band and flat band clamps on the inboard DPF.
91
8. Slide the inboard flat band clamp inward and the V-band clamp outward on the inboard DPF.
9. Remove the inboard DPF (2) from the 1-BOX™ configuration and discard the flat band gasket (1).
10. Using DOC face cleaning kit W470589239100, slide the inlet reduction cone (3) over the aftertreatment
inlet. See graphic below.
11. Install the DOC block-off plate (2) over the inboard DOC and hand-tighten clamp.
12. Attach the DOC cleaning cone (1) to the outboard DOC and hand-tighten clamp.
13. Attach the shop vacuum hose to the aftertreatment reduction cone (3).
CAUTION
EYE INJURY
To avoid injury from flying debris, wear a face shield or goggles.
14. Turn on the shop vacuum; you should be able to feel suction if you place your hand momentarily over the
DOC cleaning cone opening.
NOTICE
Regulate air pressure to a maximum of 120 psi to prevent damage to the substrate.
15. Place the air gun nozzle inside the cleaning cone and keep the air gun tip 25 mm (1 in.) away from the
DOC to prevent damage to the brick.
16. Start blowing compressed air into the DOC cleaning cone. Move the air nozzle in a circular pattern, starting
from the outer edge and work your way inward to center of the DOC. Continue this motion for several
minutes.
17. Remove the DOC cleaning cone.
92
18. Continue blowing air into the DOC using a slow sweeping motion, making sure to cover 100% of the DOC
surface. Keep the air gun tip 25mm (1 in.) away from the DOC to prevent damage to the brick.
19. Move the block-off plate to the outboard DOC and install the cleaning cone onto the inboard DOC.
20. Place the air gun nozzle inside the cleaning cone, keep the air gun tip 25 mm (1 in.) away from the DOC to
prevent damage to the brick. Start blowing compressed air into the DOC cleaning cone. Move the air
nozzle in a circular pattern, starting from the outer edge and work your way inward to the center of the
DOC. Continue this motion for several minutes.
21. Remove the inboard DOC cleaning cone.
22. Continue blowing air into the inboard DOC using a slow sweeping motion making sure to cover 100% of the
DOC surface. Keep the air gun tip 25 mm (1 in.) away from the DOC to prevent damage to the brick.
23. Disconnect the vacuum and remove the inlet reduction cone and DOC block-off plate.
24. After each DOC has been air cleaned, reinstall both Diesel Particulate Filters (DPF) using new flat band
clamps and V-band gaskets.
25. Reinstall the aftertreatment.
26. Run a Parked Regen to verify DOC inlet pressure and check for proper NOx conversion.
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8.7 Relative Cylinder Compression Test

The relative compression test runs during engine cranking. DiagnosticLink prevents the engine from starting while
it uses engine speed to calculate the test results. The best cylinder will show a result of 100%. A difference of
more than 15% suggests there is a compression issue. If there are any cylinders showing less than 85%, perform
a manual compression test to confirm the presence of any compression issues.
Note : The relative compression test can only be performed once per ignition cycle.
Note : After performing the relative compression test the ignition must be cycled off and then on before the engine
can be started.
Check as follows:
3. Click on the "Actions" tab in the top menu and select "Relative Compression Test" in the drop down menu.
4. DiagnosticLink will open a second window with no test results. Click the "Run Test" button in the lower right
hand corner of the screen.
5. Comply with the caution warning and click "Yes" to continue.
6. Crank the engine until the starter stops. Then click "OK".
7. Check the results. Are any of the cylinders reading lower than 85%?
7.a Yes; Refer to section "Mechanical Cylinder Compression Test" and perform the manual compression test.
7.b No; all of the cylinders read 85% or higher. Select "Close" and return to the previous troubleshooting
that directed you to perform the Relative Compression test.
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8.8 Mechanical Cylinder Compression Test

Note : This test should be performed only if directed here by a diagnostic procedure.
Special Service Tools Used in the Procedure

Tool Number Tool Name Tool Graphic
J-47411 Compression Test Adaptor J-48704 or W470589129100
Perform the following steps for a mechanical compression test on a GHG17Heavy Duty DD Platform Engine:
Note : First perform the Relative Cylinder Compression Test using DiagnosticLink. Refer to section "Relative Cylinder
Compression Test" . If results indicate a weak cylinder, perform this mechanical compression test.
1. Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to
205°F).
CAUTION
ELECTRICAL SHOCK
2. Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.
3. Remove rocker cover. Refer to section "Removal of the Rocker Cover" .
4. Remove the fuel injector harness.
5. Disconnect electrical contacts at the fuel injectors.
6. Disconnect the two wiring terminals going to the Jake Brake solenoids.
7. Disconnect the 14-pin fuel injector harness connector.
8. Remove the spring clip holding the fuel injector harness connectors to camshaft frame.
9. Remove the fuel injector wiring harness(es).
10. Remove the high pressure fuel line from the suspect cylinder. Refer to section "Removal of the High Pressure Fuel
Injector Lines - Two-Filter System" .
11. Remove the fuel injector. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
12. Remove excess fuel from cylinder using a vacuum pump.
13. Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder head.
14. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) + 90 degrees.
15. Install the fuel rail plug (J-48704 or W470589129100).
16. Install a hold-down bolt onto the Jake-Brake solenoid and snug the bolt.
CAUTION
ELECTRICAL SHOCK
17. Reconnect the batteries; keep the battery charger plugged into the batteries.
Note : Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking
speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery
95
voltage.
18. Using DiagnosticLink start the Mechanical Compression Test routine, this will disable fuel from the Quantity
Control Valve.
19. With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater using
the starter motor. Record the compression reading on the gauge.
20. At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If
compression readings are below specifications, repeat step 13 with a different gauge to be certain of the
reading.
Note : Fuel injector hold-down bolts are a one-time use item.
21. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test
adaptors.
22. Repeat steps for all suspect cylinders.
23. Repair engine as necessary. Refer to section "Symptom Diagnostics - Low Engine Compression" .
96
8.9 Crankcase Pressure Test

Check the engine crankcase pressure as follows:
Tool Number Tool Name Graphic

2. Run the engine and bring the engine coolant temperature to normal operating range, 88º to 96°C (19º to
205°F).
3. Install the crankcase pressure test adapter (W651589029100) on to the oil fill opening. Attach a water
manometer, calibrated to read pressure as inches of H2O, on to the adaptor.
4. Run the vehicle to full load and rated speed with a loaded trailer or dyno.
5. Measure and record crankcase pressure.
6. Shut down the engine.
7. Remove the adaptor from the oil fill opening.
Note : Any tubing used to feed the manometer will artificially increase the crankcase pressure results.
8. The correct crankcase pressure should be less than 5 inches of H2O at full load. If the engine crankcase
pressure is greater than 5 in. H2O, Refer to section "High Crankcase Pressure" .
97
8.10 Power Verification With Chassis Dynamometer

The chassis dynamometer is a device for applying specific loads to a vehicle to determine if the vehicle will
perform to published specifications and to permit a physical inspection for leaks of any kind. It can be used for
detecting improper tune-up, misfiring fuel injectors, low compression, and other malfunctions.
8.2.1 Chassis Dynamometer Room Ventilation Recommendations

For safe and accurate dynamometer readings, the chassis dynamometer room must be properly ventilated.
CAUTION
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface,
parking brake is set, and the wheels are blocked.
If a vehicle is tested on a dynamometer located in an area without proper ventilation, the engine will be subject to
high ambient air temperatures. High air inlet temperatures can result in false low power readings on the
dynamometer.
To help ensure accurate horsepower readings, the dynamometer room should have a ceiling-mounted fan with an
850 to 1133 m³ /min (30,000 to 40,000 ft³ /min) capacity. This will provide proper ventilation of exhaust gases and
heat radiated by the operating engine.
8.2.2 Chassis Dynamometer Test and Run-in Procedure

The function of the dynamometer is to absorb and measure the engine output after it has been transmitted
through the vehicle transmission and driveline to the drive tires.
The vehicle is connected to the dynamometer through the roller absorption unit. The load on the vehicle may be
varied from zero to maximum by decreasing or increasing the resistance in the unit. The amount of power
absorbed in a water brake-type dynamometer, as an example, is governed by the volume of fluid within the
working system. The fluid offers resistance to a rotating motion. By controlling the volume of water in the
absorption unit, the load may be increased or decreased as required.
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8.11 Minimum Acceptable Wheel Horsepower

The minimum acceptable wheel horse power is 80% of the maximum horse power at rated speed.
Wheel horsepower is a measurement of engine output minus the parasitic losses associated with engine
accessories (alternator, fan, A/C, etc) and driveline losses (transmission, driveshaft, axles, etc.). A total parasitic
loss of 15-20% is not uncommon, depending on how a particular vehicle is configured. Refer to " Engine Performance
Curves " for horsepower specifications.
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8.12 Perform Output Component Test

Note : This test can only run once per ignition cycle - If you need to run the test more than once, the ignition must
be cycled between tests.
The Perform Output Component Test can be used as a sanity check for components related to the Aftertreatment
System (ATS).
The Selective Catalyst Reduction (SCR) heaters, Pressure Limiting Unit (PLU), Coolant Valve, Intake Throttle
Valve (ITV), Fuel Cutoff Valve, and HC Doser are commanded ON for a brief period and individual fault codes will
be set during the test if a component fails.
To run this test:
3. Go to the "Service Routines" work window and select the "SCR System" tab. Select the "Perform
Output Component Test" from the drop-down list.
4. Press the "Start" button.
5. The following examples illustrates successful completion of the routine.
5.a All relative instruments were commanded ON, no faults were set.
5.b The progress box in the SCR System panel shows complete.
6. The following example illustrates unsuccessful completion of the routine.
6.a All relative instruments were commanded ON, but Line Heater 3 failed and the fault code was set.
6.b The progress box in the SCR tab shows that the test failed.
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8.13 Piston Protrusion Measurement Procedure

Check as follows:
1. Remove all of the injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
2. Set the piston protrusion tool upper collar for HDEP engines.
3. Install the piston protrusion tool into cylinder #1.
Note : If the dowel is not at the bottom of the tool, bar the engine over by hand until the dowel is at the bottom of
the tool.
7. Bar the engine over by hand while watching the dowel pin and the dial indicator. If there is no measurement
on the dial indicator and the dowel pin does not rise, the dial indicator must be set further down into the tool
collar.
NOTICE
Once the first measurement has been recorded, the dial indicator should not be adjusted.
Adjusting the dial indicator after measurement can lead to inaccurate measurement
comparison.
8. Bar the engine over by hand and record the maximum height for cylinder #1.
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6

in. in. in. in. in. in.
9. Remove the piston protrusion tool and install the tool into cylinder #2.
13. Bar the engine over and record the maximum height for cylinder #2.
14. Repeat steps 9 through 13 for the remaining cylinders. Once the measurements are recorded for each
cylinder, proceed to step 15.
Note : The lower the measurement, the shorter the piston connecting rod.
15. Compare the measurements for each cylinder. A difference of 0.017 in. for HDEP engines from the highest
cylinder measurement indicates that the piston is not reaching top dead center and further investigation is
needed to determine the cause of the concern.
If the measurements are within specification, reinstall the injectors. Refer to section "Installation of the Fuel Injector -
Two-Filter System" . Return to the originating diagnostic procedure.
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8.14 Cylinder Leak-Down Test

Service Tools Used in this Procedure
OTC 5609 or equivalent Cylinder Leakage Tester
J-47411 Adapter, Compression Test HDE
J-45982-7 Regulator and gauge set (part of J-45982, Head and Block
Leak Tester)
Test as follows:
1. Remove the intake and exhaust rocker arm shafts.
Refer to section "Removal of the Intake Rocker Shaft Assembly"
2. Remove the six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
Note : Make sure the seal at the tip of the J-47411 Compression Test Adapter is installed and it does not fall out
while installing the tool into the fuel injector cup.
Note : Note: The original fuel injector hold-down clamp bolt can be re-used to install and secure the J-47411
Compression Test Adapter in place. Use new fuel injector hold-down clamp bolts when installing the new fuel
injectors.
3. Using a fuel injector hold-down clamp and bolt, install J-47411 Compression Test Adapter in the in the fuel
injector cup for cylinder number one.
4. Torque the fuel injector hold-down clamp bolt to 20 N•m (15 lb•ft) + 90 degree.
5. Connect a short air hose (2) to the J-47411 Compression Test Adapter (1).
6. Connect the other end of the short air hose (2) to the output side of the Cylinder Leakage Tester (1).
7. Connect the output side of the J-45982-7 Regulator and Gauge Set (3) to the input side of the Cylinder
Leakage Tester (1).
Note : The shop air must be capable to continuously supply 689 kPa (100 psi) of air pressure.
8. Connect shop air to the input side of the J-45982-7 Regulator and Gauge Set.
9. Open the air shut-off valve and adjust the J-45982-7 Regulator and Gauge output to 689 kPa (100 psi).
10. Adjust the air regulator on the Cylinder Leakage Tester so the left side gauge on the Cylinder Leakage
Tester indicates 620 kPa (90 psi).
11. Record the pressure indicated on the right side gauge of the Cylinder Leakage Tester.
12. Subtract the pressure recorded on the right side gauge from the pressure shown on the left gauge.
Note : The pressure difference between the two Cylinder Leakage Tester gauges indicates the pressure loss on
that respective cylinder. A pressure loss greater than 103 kPa (15 psi) on any one cylinder, or a difference in
pressure loss greater than 68 kPa (10 psi) from cylinder to cylinder, indicates a potential issue and further
investigation to identify the source of leak is needed.
13. Repeat steps 3 through 12 for the remaining cylinders.
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8.15 Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel

System
Note : This test is only to be performed if a fuel leak is present and a visual inspection of the engine did not
pinpoint a fuel leak path.
J-48710 Fuel system air pressure tool W470589039100

Fuel System Update kit J-48708 Fuel Flow tool
J-48707 FFM in and outlet hose ESOC 350
Fuel Priming Pump J-28431-B (recommended) Fluorescent Fuel
Dye that is diesel
compatible
Check as follows:
Note : When diagnosing an engine fuel leak, the source and location of the leak MUST be positively identified
prior to repair.
steps.
7. Remove the J-48710 tool.
Note : When configuring the amount of dye to be added. Consider this procedure will be run with approximately
two gallons of fuel.
8. Add diesel fuel compatible fuel dye, per manufacturer’s recommendation, to the two fitting container on the
Fuel flow tool J-48708.
9. Remove the OEM Fuel return line off the fuel filter module.
10. Connect Fuel System Update Kit W470589039100 connectors to Fuel Filter Module supply and return
fittings.
11. Install the FFM in and outlet Hoses J-48707 to Fuel System Update kit W470589039100.
12. Connect the other end of the FFM in and outlet hoses J-48707 to the Fuel Flow tool J-48708.
Note : 0.8 L of fuel is in the module after the above draining is performed. This amount is compensated for when
priming.
13. Measure 6.8 L of Diesel fuel into the single fitting container of the Fuel Flow tool J-48708.
14. Add fuel from the single fitting container of the Fuel Flow tool J-48708 to the ESOC 350.
15. Prime the fuel system until the ESOC 350 is empty.
at 900 rpm.
103
17. Using the black light, inspect the fuel system for the source of the fuel leak. Refer to section "Potential Fuel Leak
Points - Two-Filter Fuel System" .
104
8.16 Air Compressor Unloader Leakage Test

Check as follows:
2. Remove the governor and install a fitting to the unloader port.
3. Add a section of air hose (minimum 1 foot long for ½-in. diameter line) and a calibrated test gauge to the
unloader port on the air compressor.
4. Install a shut-off valve and an air source (shop air or small tank).
5. Open shut-off valve and charge the unloader port by allowing air pressure to enter the hose and unload the
compressor.
6. Shut off the air supply and observe the gauge.
7. A steady reading indicates no leakage at the unloader port. If pressure drops, the unloader valve is leaking
and needs to be replaced.
105
8.17 Air Brake System and Accessory Leakage Test

Test as follows:
Note : The following is a general procedure for isolating leaks in different areas of the air brake system. Refer to
vehicle service literature for more specific tests and information.
2. Build system pressure to governor cut-out, stop the engine, and allow the pressure to stabilize for one
minute.
3. Observe the dash gauges for two minutes without applying the service brake.
4. Does the system hold pressure?
4.b No; follow OEM troubleshooting for air leaks in the air brake system.
Note : A block of wood may be used to hold the brake pedal in position.
5. Apply the service brakes and allow the pressure to stabilize for two minutes.
6. Observe the dash gauges for two minutes.
7. Does the system lose more than 27 kPa (4 psi) [plus 14 kPa (2 psi) for each additional trailer] of pressure?
7.a Yes; follow OEM troubleshooting for air leaks in brake chambers and lines/components associated with
brake application.
8. Install a test gauge on the supply reservoir or wet tank.
9. Observe the test gauge for two minutes.
10. Does the system lose more than 6 kPa (1 psi) per minute?
10.a Yes; follow OEM troubleshooting for the air dryer and the inlet check valves of the primary and
secondary reservoirs, then perform the "Governor System Leakage and Function" test. Refer to section
"Governor System Leakage and Function Test"
10.b No; the air system is performing properly.
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8.18 Governor System Leakage and Function Test

Test as follows:
2. Verify that the air lines on the governor are connected to the correct ports on the governor.
3. Inspect for blockage, kinks or folds, or leakage in all air lines and fittings to the governor, air compressor
unloader port, and air dryer purge control port, and repair as needed.
NOTICE
Use caution not to drop any hardware or debris into the air compressor or severe damage
can occur.
4. Test for internal leakage within the air compressor unloader port. Refer to section "Air Compressor Unloader Leakage
Test" .
5. Test for internal leakage within the purge control port of the air dryer. Refer to OEM troubleshooting.
6. Test for a large continuous air leak using soapy water at the governor exhaust port during governor cut-out
and governor cut-in. A small leak is normal.
Note : Air leaks within the governor system must be identified and repaired before performing this test.
7. Verify governor cut-in and cut-out pressure set points as follows:
7.a Install a calibrated test gauge on the supply reservoir or wet tank.
7.b Install a second test gauge into the governor control line or an unused governor control port.
7.c Run the engine, and operate the brakes or otherwise bleed air to allow the governor to go into cut-in
and cut-out while observing the two test gauges. Make the following checks:
i. View the test gauges to ensure the reservoir pressures at the times of governor cut-in and cut-out are
within vehicle OEM specifications.
ii. Ensure that the change in governor control line pressure during a governor shift is nearly
instantaneous (less than 3 seconds).
7.d Perform repair, replacement, or adjustment of the governor according to vehicle OEM or governor
manufacturer service literature.
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8.19 Priming of the Lubrication System to Check for Leaks

in the Upper Portion of the Engine
Detroit Diesel Tools Needed to Perform This Procedure
J-49181 Oil System Priming Adapter J-45299
1. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port on the oil coolant module.
2. If equipped with an oil sample valve, remove the valve and washer.
Note : Tool J-49181 is used to adapt the J-45299 priming pump.
3. Install oil system priming adaptor tool (J-49181) into the oil priming port (1) in the oil coolant module.
NOTICE
If chassis application prevents access, a 90-degree or a 45-degree pipe fitting (1/4" NPT)
can be used (if needed) for access.
4. Install the engine pre-lube kit (J-45299) to the fitting adaptor (1).
6. Fill the canister with four quarts of oil.
7. Open the valve on the primer and start pumping.
8. Inspect the rockers and engine brake solenoids for excessive oil. If leaks are present, repair the leaks as
necessary.
9. Install the rocker cover; Refer to section "Installation of the Rocker Cover" .
10. Close the valve on the priming tool and loosen the fitting; do not completely remove it from the adaptor.
11. Remove the priming adaptor from the oil coolant module with the line attached to keep the oil from flowing
out of the module.
12. Install the Allen head plug or oil sample valve to the module and torque to 70 to 80 N·m (51 to 59 lb·ft).
108
8.20 Cylinder Head Pressure Test

DD13 Engines use tool number: W470589012500 DD15 and DD16 engines use tool number: W470589002500
Check as follows:
2. Thoroughly clean the cylinder head. Refer to section "Cleaning of the Cylinder Head" .
3. Inspect the sealing surfaces of the cylinder head and the tool. If damage is found, repair as necessary.
Note : The leak test plates have gaskets that seal to the deck surface of the cylinder head and the exhaust side of
the head. These gaskets can prevent pressure from escaping if there is a leak around the valves or a leak inside
of an exhaust port. For this reason, Detroit recommends drilling small relief holes in the gaskets at the valve areas
and the exhaust ports.
4. Install the leak test tool using the original head bolts along with the supplied hardware onto the head gasket
surface of the cylinder head with the rubber side toward the head. Torque to 13 N·m (10 lb·ft) or until the
rubber starts to bulge out from in between the tool and the head.
5. Install the water manifold opening covers with the supplied hardware in the same fashion. Tighten the bolts
to 13 N·m (10 lb·ft). The rubber should be starting to bulge from between the tool and the cylinder head.
6. Install the cup plug caps onto the cup plugs using the supplied hardware with the cutout side facing the cup
plug. Torque to 15 N·m (11 lb·ft).
7. Attach the air pressure gauge and regulator J-45982-7 or equivalent.
8. Turn regulator counterclockwise until it stops.
9. Connect shop air to the regulator and turn it clockwise until the gauge reads 206.8 kPa (30 psi).
10. Allow the air pressure to stabilize for one minute.
11. Close the ball valve on the regulator and disconnect the shop air hose.
12. Allow the head to remain pressurized for thirty minutes. There should be no pressure loss over a 30-minute
time period.
13. If the pressure drops, use a soap and water solution to determine where the possible leak is coming from.
Once the leak has been identified, repair as necessary.
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9.1 Fuel in Coolant/Coolant in Fuel

Service Tool Used in the Procedure
W470589012500 DD13 Cylinder Head Leak Tool
W470589002500 DD15/16 Cylinder Head Leak Tool
Note : DEF contamination in the fuel system can be mistaken for coolant in the fuel. When DEF is found to be a
contaminant of the fuel system, its appearance will be a brown or rusty color most notable in the fuel filter module.
steps.
2. Verify that fuel/coolant contamination is present.
3. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for
external coolant leaks. Are any leaks present?
3.a Yes; repair as necessary. Then, Go to step 9.
Note : The fuel injector O-rings and the fuel injector clamp hold-down bolts must be replaced each time they are
removed from the cylinder head.
4. Release the pressure from the cooling system.
5. Remove all six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
NOTICE
Failure to reinstall the fuel injector hold-down clamps may damage the cylinder head
coolant gallery plugs (1).
6. Reinstall the fuel injector hold-down clamps with old fuel injector bolts. Torque bolts to 20 N·m (15 lb·ft) +
90-degree torque turn.
1
7. Pressurize the cooling system per OEM specifications. Inspect for coolant leaks around the fuel injector
cups. Are any leaks present?
7.a Yes; clean the injector cups and replace all six injector cup O-rings. Refer to section "Removal of the Fuel
Injector - Two-Filter System" . Then Go to step 9.

8. Remove the cylinder head. Pressure test the cylinder head. For DD13 engines, use tool W470589012500.
For DD15 and DD16 engines, use tool W470589002500. Are there any leaks present?
For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly" .
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
8.a Yes; replace or repair as necessary. Then Go to step 9.
For the DD13: Refer to section "Installation of the DD13 Cylinder Head Assembly" .
For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly" .
2
8.b No; review the results of the above troubleshooting steps. Then Go to step 9.
9. If fuel has been identified as a contaminant in the coolant, replace the components listed below. All fuel
system repairs should now be complete. If the WIF Light is on refer to Power Service Literature for the fault
that is present.
Description Qty. Comments

Fuel Injector Cup Seals 1 This is a kit consisting of six seals.
Coolant Line - Air Compressor To Fuel 1
Filter Module
Coolant Line - Air Compressor To 1
Cylinder Block
Coolant Line - Fuel Filter Module To 1
Oil/Coolant Module
Gasket - Fuel Injector Jumper Lines 6
Fuel Injector O-Ring Seal Kit 6
Use applicable coolant filter. Note that
some engines may not have a coolant
Coolant Filter (if equipped) 1 filter if previously removed by the
customer.
Use applicable coolant as listed in the
Coolant NA "Coolant Selections" manual (DDC-SVC-
BRO-0002)
.. Refer to section "Installation of the Water
Water Pump 1 Pump" .
3
9.2 Fuel in Diesel Exhaust Fluid

If diesel fuel is suspected in the DEF system, there are three different methods to verify the issue.
1. A visual inspection of a DEF sample can be used to identify contamination. Diesel fuel will separate and
float on top of the DEF. Caution must be used when taking the sample; if the truck has been stationary for
some time and the sample is pulled from the bottom of the DEF tank it may not indicate contamination
because the fuel floats on the surface.
2. Smell can also be used to detect contamination. The DEF should have a slight ammonia smell. If a sweet
smell is noticed, check for coolant contamination. Diesel fuel in the DEF tank should be easily detected by
smell.
3. DEF test strip P/N: A0005850202 can be used to check for diesel fuel or oil contamination of the DEF fluid.
The DEF test strip will change to a darker color if the DEF is contaminated.
The table below identifies parts that must be replaced if the DEF system has been contaminated. Refer to
the Workshop Manual for proper repair procedures.
Parts to be Replaced for Diesel Fuel in the DEF System

Part Description Comment
DEF Tank Chassis OEM Part
DEF Tank Header Chassis OEM Part
DEF Supply Line From DEF Tank To DEF Pump Chassis OEM Part
DEF Line From DEF Pump To DEF Dosing Unit Chassis OEM Part
DEF Return Line From DEF Dosing Unit To Tank Chassis OEM Part
DEF Pump Detroit Diesel Part
DEF Dosing Unit Detroit Diesel Part
Notice: If diesel fuel has been added to the DEF tank and the system has not been turned on, the contamination is isolated
to the DEF tank. If so, the following components need replacing.

4
9.3 Fuel in Oil

J-48710 Air Pressure Test, Fuel System
DiagnosticLink® 7.10 or later
Check as follows:
WARNING
PERSONAL INJURY
1. Perform Low Pressure Leak Test. Refer to section "FIS Low Pressure Leak Test" . Was a leak detected?
Note : The high pressure pump weep hole (1) is located near the six o'clock position where the high pressure fuel
pump meets the flywheel housing.
WARNING
PRESSURIZED FUEL
test.
2. Pressurize the fuel system with shop air using tool J-48710 to 517 kPa (75 psi). Check for air leaks at the
weep hole (1) on the high pressure fuel pump. Is there an air leak present?
5
System" . Go to step 10.

3. Remove the rocker cover; pressurize the fuel system with shop air using tool J-48710 to 517 kPa (75 psi).
Inspect for leaks at the fuel injector bodies as show below. Was a leak detected?
6
Note : The fuel injector O-rings, the high pressure fuel injector line seal and the fuel injector clamp hold-down bolt
must be replaced each time a fuel injector is removed from the cylinder head.
4. Inspect for a loose fuel injector hold-down bolt at the leaking fuel injector. Is the hold-down bolt loose?
4.a Yes; replace the fuel injector and its fuel injector cup.
Refer to section "Removal of the Fuel Injector - Two-Filter System"
Refer to section "Removal of the Fuel Injector Cup - Two-Filter System"
Go to step 10.
4.b No; replace the fuel injector. Refer to section "Removal of the Fuel Injector - Two-Filter System" . Go to step 5.
7
WARNING
HOT OIL
5. Perform Fuel Dye Method; Refer to section "Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System" .
6. Inspect for dye at the weep hole on the high pressure fuel pump. Is dye present?

7. Remove the rocker cover. Inspect for dye at the fuel injector bodies. Was dye detected?
Refer to section "Removal of the Fuel Injector Cup"
Go to step 10.
9. Remove the oil pan and inspect for dye on the gear train. Is there dye present on the gear train?
System" .

10. Is SPN 100/FMI 1 Low Oil Pressure present?
10.a Yes; inspect the rod and main bearings for damage. Refer to section "Inspection of the Main and Connecting Rod
Bearings in Chassis" . Go to step 11.

11. Was a leak found and repaired that would have caused fuel to leak into the oil?
11.a Yes; change engine oil and release unit.
11.b No; advise the customer to change the oil and start to perform oil samples every 10,000 miles.
8
9.4 Coolant in Oil

Note : Appearance of oil will be brown and have a milky-like state. Oil may be above recommended level as well.
1. Verify the complaint.
2. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Does the
system hold pressure?
2.a Yes, the system holds pressure; Go to step 3.
2.b No; the system leaks down; Go to step 4.
3. Is fault code SPN 100/FMI 1 Low Engine Oil Pressure present?
3.a Yes; Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" . Make necessary repairs.
3.b No; verify that the contaminant in the oil is coolant. Question the driver about coolant consumption.
4. Remove the oil pan. Refer to section "Removal of the Oil Pan" . Pressurize the cooling system, per Original
Equipment Manufacturer (OEM) specifications. Is coolant leaking between the piston and liner?
4.a Yes; Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
5. Is coolant leaking between the liner and block?
6. Is coolant leaking from the gear train or an oil return passage?
6.b No, Go to step 9.
7. Remove the cylinder head and inspect for a failed cylinder kit; Refer to section "Inspection of the Cylinder Liner" .
Was a failed cylinder kit found?
7.a Yes; replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine
oil.
8. Remove the cylinder liner where the leak was found; Refer to section "Inspection of the Cylinder Liner" . Was
damage found?
oil.
8.b No; inspect the cylinder head gasket for torn or debonded grommets and make necessary repairs.
Replace the lower end bearing kit, flush the cooling system and change the oil.
9. Pressure test the oil cooler. Refer to section "Inspection and Pressure Testing of the Oil Cooler" . Were leaks found?
9.a Yes, replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine
oil.
9.b No, remove the cylinder head, inspect the cylinder head gasket for torn or debonded grommets and
make necessary repairs. Replace the lower end bearing kit, flush the cooling system and change the
oil.
9
9.5 Oil in Coolant

1. Verify that the contaminant in the coolant is oil. Combustion gas can darken the coolant appearance as well
and misdiagnose the issue.
2. Pressurize the transmission cooler, per Original Equipment Manufacturer (OEM) specifications. Inspect for
leaks. Are any leaks present?
2.a Yes; repair as necessary. Flush the cooling system prior to replacing any parts. Refer to section "Extended
Life Coolant Additive Maintenance Procedures" , and see "Drain, Flush, and Refill Procedure". Go to step 7.
WARNING
PERSONAL INJURY
3. Remove the oil coolant module. Refer to section "Removal of the Oil Coolant Module" .
4. Remove the oil cooler, paying close attention to the seal rings. Refer to section "Removal of the Oil Cooler " .
WARNING
test.
5. Pressure test the oil cooler. Refer to section "Inspection and Pressure Testing of the Oil Cooler" . Are any leaks present?

6. Inspect the cylinder head gasket for leaks.
For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly" .
For DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" . Are leaks present?
6.b No; verify that the contaminant in the coolant is oil. Combustion gas can darken the coolant
appearance as well. Question the driver about oil consumption. Contact the Detroit ™ Customer
Support Center (CSC).
7. If oil has been identified as a contaminant in the coolant, flush the cooling system prior to replacing any
parts. Refer to section "Extended Life Coolant Additive Maintenance Procedures" , and see "Drain, Flush, and Refill
Procedure". See Table 1 for a list of parts to be replaced.
10
Table 1 - Parts List

Filter Module
Oil/Coolant Module
Cylinder Block
Fuel Injector Cup Seal 6
Coolant Filter 1
Discard the coolant filter. Customers
may choose to eliminate the use of the
coolant filters,
Note some engines do not have a
coolant filter.
Coolant N/A Use applicable coolant as listed in the
"Coolant Selections" manual (DDC-SVC-
BRO-0002).
11
9.6 Checking Diesel Exhaust Fluid Quality

To determine if the Diesel Exhaust Fluid (DEF) quality is correct you will need to use the refractometer
W060589009101 in tool kit W060589001900 (DEF Test kit). Retrieve a sample of DEF from the DEF tank taking
the sample at the highest level. Put 2-3 drops on the refractometer and check the concentration level. Good
quality DEF should read between 31.8 – 33.2 if the reading is within specs then the next sample should be taken
at the metering unit. Disconnect the inlet to the metering unit and place the line in the graduated cylinder and
perform the SCR Pressure Test (60 seconds) and retest fluid again.
9.1.1 Checking for Contaminated Diesel Exhaust Fluid

To determine if the Diesel Exhaust Fluid (DEF) has been contaminated multiple things will need to be checked
from color, smell and the use of test strips.
9.1.2 Color
Diesel fuel and oil will float on the top of DEF after letting it set.
• Light blue exposed to copper or Brass
• Rusty color exposed to steel or Galvanized steel
9.1.3 SMELL
DEF can have a slight ammonia smell.
9.1.4 Checking for Diesel Fuel/Oil In Diesel Exhaust Fluid

If diesel fuel/oil is suspected to be in the Diesel Exhaust Fluid (DEF) use tests strips A0005850202 and see if they
change color when exposed to DEF. If diesel fuel/oil is found in the DEF remove the DEF filter and check the DEF
filter for diesel fuel/oil if the filter is contaminated then the complete DEF system will need to be replaced.
12
9.7 Diesel Exhaust Fluid in Coolant

1. Ensure Diesel Exhaust Fluid (DEF) has not been improperly added to the coolant surge tank.
2. Connect DiagnosticLink®.
3. If SPN 3364/FMI any (Improper DEF Quality) is present, repair SPN 3364 first.
Note : The EPA10 six-gallon tank header is not removable; tank must be replaced if header is leaking.
4. Remove the DEF tank header from the tank.
4.a For the GHG17 13- and 23-gallon DEF tanks, Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust
Fluid Tank" and Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
4.b For the GHG17 six-gallon DEF tank, Refer to section "Removal of the Six-Gallon Diesel Exhaust Fluid Tank" and
Refer to section "Removal of the Six-Gallon Diesel Exhaust Fluid Tank Header" .
5. Connect the tank header electrical connections and coolant hoses while set on a suitable mount next to the
vehicle.
6. Fill cooling system. Refer to section "Cooling System Fill Procedure"
8. Perform the DEF Coolant Valve Control test:
8.a Choose DEF Coolant Valve Control from the ActionsAftertreatment menu to display the DEF Coolant
Valve Control dialog box:
8.b Enter the required Duration in the box provided.

Note : The maximum time duration for this routine is 300 seconds (five minutes).
8.c Press the Start button to enable the coolant valve. The DEF coolant valve will be set to open for the
time duration indicated:
13
8.d If required, to discontinue the test: Press Stop. The DEF coolant valve will be set to closed:
14
9. Did the DEF tank header leak?

9.a Yes; replace the DEF tank header.
9.b No; contact the Detroit™ Customer Support Center at 800-445-1980.
10. Replace the coolant.
10.a Refer to section "Cooling System Drain Procedure"
10.b Refer to section "Cooling System Fill Procedure"
11. If coolant has contaminated the DEF system, flush the DEF system. Refer to section "Flushing of the Diesel Exhaust
Fluid System"
15
9.8 Diesel Exhaust Fluid in Fuel

Check as follows:
Note : Once fuel filters are removed from the fuel module, do not reinstall the fuel filter caps or fuel filters on to the
fuel filter module until all diagnostics are complete.
1. Take a fuel sample from the fuel filter module by opening the water bowl drain valve and drain the water
bowl in to a clear container. Does fuel drain from the water bowl drain valve?
2. Shake the fuel sample for five seconds, and then observe the smell of the fuel sample. Does the fuel
sample have an ammonia smell?
3. Place the fuel sample on a clean work bench for 15 minutes. Inspect the fuel sample for Diesel Exhaust
Fluid (DEF). The graphic shows separation of fuel (1) and DEF (2) in the fuel sample. Is any DEF present?

3.b No: Go to step 4.
4. Remove the fuel filters from the fuel filter module and the frame-mounted housing (if equipped). Inspect the
inside of the fuel filter module for DEF and rust deposits. The graphic shows DEF (1) and rust (2) in the fuel
filter module. Are any DEF or rust deposits present?
16

4.b No; place a shop towel over the openings of the fuel filter module and frame-mounted housing (if
equipped). Allow the fuel filters and filter module to sit for one hour. Go to step 5.
5. After letting the fuel filters and fuel filter module sit for one hour, inspect the fuel filters and fuel filter module
for dark brown, light brown or white in color crystallization. The graphic shows an example of crystallization
(1) on the fuel filter module and fuel filters. Is any crystallization present?
17
5.a Yes; replace the following:

• all fuel in fuel tanks
• frame-mounted filter housing and filter (if equipped)
• fuel filter module
• low pressure fuel lines
• fuel flange
• high pressure fuel pump
• high pressure fuel rail feed lines
• fuel rail
• high pressure fuel injector lines
• fuel injectors
• cylinder head fittings
• amplifier
• Pressure Limiting Valve (PLV)
• needle return lines
Clean the following:
• fuel tanks
• OEM fuel lines
Note : Crystallization, rust staining and/or corrosion found in the water drain bowl is considered abnormal and is
evidence of contamination in the fuel system.
6. Remove the water drain bowl and inspect for dark brown, light brown, white in color crystallization,
corrosion or rust staining. The graphic shows an example of crystallization (1), corrosion (2) and rust
staining (3) inside the water drain bowl. Is any crystallization, corrosion or rust staining present?
18

• fuel flange
• fuel rail
• fuel injectors
• amplifier
• fuel tanks
• OEM fuel lines
6.b No; diesel exhaust fluid in fuel diagnostic test is complete. Return to the diagnostic test that led to
diesel exhaust fluid in fuel.
19
9.9 Metal in the Fuel System – Two-Filter Fuel System

Description:
The fuel filter function is to remove impurities from the fuel before the fuel reaches the high pressure fuel pump.
These contaminates often originate from fuel storage tanks and the fuel island transfer pump.
With a cartridge-type filter, it is possible to visually see debris on the filter media and in the fuel filter housing.
Debris of any kind found in the fuel filter module or fuel filter media during a service/maintenance event should be
considered normal.
The amount and type of debris can depend on the quality of the fuel, where and how the fuel is stored, and the
transfer system being used.

J-48707 Fuel Filter Module Inlet Outlet Hose
J-48708-1 Fuel Flow Tool
W470589039100 Fuel System Tool Update Kit Without Motor

Control Module (MCM) Cooler
Check as follows:
Note : The following troubleshooting procedure should only be used if there is a fuel system fault code and/ or
excessive noise from the high pressure fuel pump.
Note : The purpose of the fuel filter(s) is to prevent particulate contaminants from entering the fuel system. It is
normal to find some debris on or in the fuel filters.
WARNING
PERSONAL INJURY
20
WARNING
PERSONAL INJURY
1. Remove the chassis return line from the fuel filter module.
2. Clean Fuel Filter Module Inlet/Outlet Hoses (J-48707) and Fuel Flow Tool (J-48708-1) with clean diesel
fuel.
3. Install the Fuel Filter Module Inlet/Outlet Hose tool (J-48707) and the Fuel System Tool Update Kit without
Motor Control Module (MCM) Cooler (W470589039100) on to the chassis return line fitting on the fuel filter
module.
4. Install the opposite end of the Fuel Filter Module Inlet/Outlet Hose (J-48707) onto the Fuel Flow Tool (J-
48708-1).
5. Start and run the engine at idle until the fuel flow tool (J-48708-1) is full of fuel (about 9 liters or 2 ¼
gallons).
6. Use a magnet to check for magnetic metallic debris in the Fuel Flow Tool. Is there magnetic metallic debris
present?
6.a Yes; replace the following components:
• High pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System".
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module - Two-Filter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines -
Two-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter System".
• Frame-mounted filter (if equipped).
21
Clean the following components:

• Clean fuel tanks and filter of contaminated fuel. Refer to section "Fuel Filtration and Fuel Tank Cleaning
(After a High Pressure Fuel Pump Failure)".
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System".
• Doser supply line.
• Frame-mounted filter housing (if equipped).
• OEM Supply and return lines. Refer to OEM procedures.
Note : After completing all repairs, the fuel system must be primed as directed. Refer to section "Priming the Fuel System -
KM63 GEN2 - Two-Filter System" .
6.b No; this procedure has verified that there is no metal in the filtered side fuel system, return to the
diagnostic that lead you to this section. Remove the tools and reinstall the chassis fuel return line onto
the module. Refer to OEM procedures for debris in fuel tanks.
22
Contaminated Fluids
9.1 Fuel in Coolant/Coolant in Fuel

Service Tool Used in the Procedure
W470589012500 DD13 Cylinder Head Leak Tool
W470589002500 DD15/16 Cylinder Head Leak Tool
Note : DEF contamination in the fuel system can be mistaken for coolant in the fuel. When DEF is found to be a
contaminant of the fuel system, its appearance will be a brown or rusty color most notable in the fuel filter module.
steps.
2. Verify that fuel/coolant contamination is present.
3. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for
external coolant leaks. Are any leaks present?
3.a Yes; repair as necessary. Then, Go to step 9.
Note : The fuel injector O-rings and the fuel injector clamp hold-down bolts must be replaced each time they are
removed from the cylinder head.
4. Release the pressure from the cooling system.
5. Remove all six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
NOTICE
Failure to reinstall the fuel injector hold-down clamps may damage the cylinder head
coolant gallery plugs (1).
6. Reinstall the fuel injector hold-down clamps with old fuel injector bolts. Torque bolts to 20 N·m (15 lb·ft) +
90-degree torque turn.
23
7. Pressurize the cooling system per OEM specifications. Inspect for coolant leaks around the fuel injector
cups. Are any leaks present?
7.a Yes; clean the injector cups and replace all six injector cup O-rings. Refer to section "Removal of the Fuel
Injector - Two-Filter System" . Then Go to step 9.

8. Remove the cylinder head. Pressure test the cylinder head. For DD13 engines, use tool W470589012500.
For DD15 and DD16 engines, use tool W470589002500. Are there any leaks present?
For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly" .
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
8.a Yes; replace or repair as necessary. Then Go to step 9.
For the DD13: Refer to section "Installation of the DD13 Cylinder Head Assembly" .
For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly" .
24
8.b No; review the results of the above troubleshooting steps. Then Go to step 9.
9. If fuel has been identified as a contaminant in the coolant, replace the components listed below. All fuel
system repairs should now be complete. If the WIF Light is on refer to Power Service Literature for the fault
that is present.

Fuel Injector Cup Seals 1 This is a kit consisting of six seals.
Filter Module
Cylinder Block
Oil/Coolant Module
Use applicable coolant filter. Note that
some engines may not have a coolant
Coolant Filter (if equipped) 1 filter if previously removed by the
customer.
Use applicable coolant as listed in the
Coolant NA "Coolant Selections" manual (DDC-SVC-
BRO-0002)
.. Refer to section "Installation of the Water
Water Pump 1 Pump" .
25
9.2 Fuel in Diesel Exhaust Fluid

If diesel fuel is suspected in the DEF system, there are three different methods to verify the issue.
1. A visual inspection of a DEF sample can be used to identify contamination. Diesel fuel will separate and
float on top of the DEF. Caution must be used when taking the sample; if the truck has been stationary for
some time and the sample is pulled from the bottom of the DEF tank it may not indicate contamination
because the fuel floats on the surface.
2. Smell can also be used to detect contamination. The DEF should have a slight ammonia smell. If a sweet
smell is noticed, check for coolant contamination. Diesel fuel in the DEF tank should be easily detected by
smell.
3. DEF test strip P/N: A0005850202 can be used to check for diesel fuel or oil contamination of the DEF fluid.
The DEF test strip will change to a darker color if the DEF is contaminated.
The table below identifies parts that must be replaced if the DEF system has been contaminated. Refer to
the Workshop Manual for proper repair procedures.
Parts to be Replaced for Diesel Fuel in the DEF System

Notice: If diesel fuel has been added to the DEF tank and the system has not been turned on, the contamination is isolated
to the DEF tank. If so, the following components need replacing.

26
9.3 Fuel in Oil

J-48710 Air Pressure Test, Fuel System
DiagnosticLink® 7.10 or later
Check as follows:
WARNING
PERSONAL INJURY
1. Perform Low Pressure Leak Test. Refer to section "FIS Low Pressure Leak Test" . Was a leak detected?
Note : The high pressure pump weep hole (1) is located near the six o'clock position where the high pressure fuel
pump meets the flywheel housing.
WARNING
PRESSURIZED FUEL
test.
2. Pressurize the fuel system with shop air using tool J-48710 to 517 kPa (75 psi). Check for air leaks at the
weep hole (1) on the high pressure fuel pump. Is there an air leak present?
27

3. Remove the rocker cover; pressurize the fuel system with shop air using tool J-48710 to 517 kPa (75 psi).
Inspect for leaks at the fuel injector bodies as show below. Was a leak detected?
28
Note : The fuel injector O-rings, the high pressure fuel injector line seal and the fuel injector clamp hold-down bolt
must be replaced each time a fuel injector is removed from the cylinder head.
Refer to section "Removal of the Fuel Injector Cup - Two-Filter System"
Go to step 10.
29
WARNING
HOT OIL
5. Perform Fuel Dye Method; Refer to section "Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System" .
6. Inspect for dye at the weep hole on the high pressure fuel pump. Is dye present?

7. Remove the rocker cover. Inspect for dye at the fuel injector bodies. Was dye detected?
Refer to section "Removal of the Fuel Injector Cup"
Go to step 10.
9. Remove the oil pan and inspect for dye on the gear train. Is there dye present on the gear train?
System" .

10. Is SPN 100/FMI 1 Low Oil Pressure present?
10.a Yes; inspect the rod and main bearings for damage. Refer to section "Inspection of the Main and Connecting Rod
Bearings in Chassis" . Go to step 11.

11. Was a leak found and repaired that would have caused fuel to leak into the oil?
11.a Yes; change engine oil and release unit.
11.b No; advise the customer to change the oil and start to perform oil samples every 10,000 miles.
30
9.4 Coolant in Oil

Note : Appearance of oil will be brown and have a milky-like state. Oil may be above recommended level as well.
2. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Does the
system hold pressure?
2.a Yes, the system holds pressure; Go to step 3.
2.b No; the system leaks down; Go to step 4.
3. Is fault code SPN 100/FMI 1 Low Engine Oil Pressure present?
3.a Yes; Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" . Make necessary repairs.
3.b No; verify that the contaminant in the oil is coolant. Question the driver about coolant consumption.
4. Remove the oil pan. Refer to section "Removal of the Oil Pan" . Pressurize the cooling system, per Original
Equipment Manufacturer (OEM) specifications. Is coolant leaking between the piston and liner?
4.a Yes; Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
5. Is coolant leaking between the liner and block?
6. Is coolant leaking from the gear train or an oil return passage?
7. Remove the cylinder head and inspect for a failed cylinder kit; Refer to section "Inspection of the Cylinder Liner" .
Was a failed cylinder kit found?
oil.
8. Remove the cylinder liner where the leak was found; Refer to section "Inspection of the Cylinder Liner" . Was
damage found?
oil.
8.b No; inspect the cylinder head gasket for torn or debonded grommets and make necessary repairs.
Replace the lower end bearing kit, flush the cooling system and change the oil.
9. Pressure test the oil cooler. Refer to section "Inspection and Pressure Testing of the Oil Cooler" . Were leaks found?
9.a Yes, replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine
oil.
9.b No, remove the cylinder head, inspect the cylinder head gasket for torn or debonded grommets and
make necessary repairs. Replace the lower end bearing kit, flush the cooling system and change the
oil.
31
9.5 Oil in Coolant

1. Verify that the contaminant in the coolant is oil. Combustion gas can darken the coolant appearance as well
and misdiagnose the issue.
2. Pressurize the transmission cooler, per Original Equipment Manufacturer (OEM) specifications. Inspect for
WARNING
PERSONAL INJURY
3. Remove the oil coolant module. Refer to section "Removal of the Oil Coolant Module" .
4. Remove the oil cooler, paying close attention to the seal rings. Refer to section "Removal of the Oil Cooler " .
WARNING
test.
5. Pressure test the oil cooler. Refer to section "Inspection and Pressure Testing of the Oil Cooler" . Are any leaks present?

6. Inspect the cylinder head gasket for leaks.
For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly" .
For DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" . Are leaks present?
6.b No; verify that the contaminant in the coolant is oil. Combustion gas can darken the coolant
appearance as well. Question the driver about oil consumption. Contact the Detroit ™ Customer
Support Center (CSC).
7. If oil has been identified as a contaminant in the coolant, flush the cooling system prior to replacing any
parts. Refer to section "Extended Life Coolant Additive Maintenance Procedures" , and see "Drain, Flush, and Refill
Procedure". See Table 1 for a list of parts to be replaced.
32
Table 1 - Parts List

Filter Module
Oil/Coolant Module
Cylinder Block
Fuel Injector Cup Seal 6
Coolant Filter 1
Discard the coolant filter. Customers
may choose to eliminate the use of the
coolant filters,
Note some engines do not have a
coolant filter.
Coolant N/A Use applicable coolant as listed in the
"Coolant Selections" manual (DDC-SVC-
BRO-0002).
33
9.6 Checking Diesel Exhaust Fluid Quality

To determine if the Diesel Exhaust Fluid (DEF) quality is correct you will need to use the refractometer
W060589009101 in tool kit W060589001900 (DEF Test kit). Retrieve a sample of DEF from the DEF tank taking
the sample at the highest level. Put 2-3 drops on the refractometer and check the concentration level. Good
quality DEF should read between 31.8 – 33.2 if the reading is within specs then the next sample should be taken
at the metering unit. Disconnect the inlet to the metering unit and place the line in the graduated cylinder and
perform the SCR Pressure Test (60 seconds) and retest fluid again.
9.1.1 Checking for Contaminated Diesel Exhaust Fluid

To determine if the Diesel Exhaust Fluid (DEF) has been contaminated multiple things will need to be checked
from color, smell and the use of test strips.
9.1.2 Color
Diesel fuel and oil will float on the top of DEF after letting it set.
• Light blue exposed to copper or Brass
• Rusty color exposed to steel or Galvanized steel
9.1.3 SMELL
DEF can have a slight ammonia smell.
9.1.4 Checking for Diesel Fuel/Oil In Diesel Exhaust Fluid

If diesel fuel/oil is suspected to be in the Diesel Exhaust Fluid (DEF) use tests strips A0005850202 and see if they
change color when exposed to DEF. If diesel fuel/oil is found in the DEF remove the DEF filter and check the DEF
filter for diesel fuel/oil if the filter is contaminated then the complete DEF system will need to be replaced.
34
9.7 Diesel Exhaust Fluid in Coolant

1. Ensure Diesel Exhaust Fluid (DEF) has not been improperly added to the coolant surge tank.
3. If SPN 3364/FMI any (Improper DEF Quality) is present, repair SPN 3364 first.
Note : The EPA10 six-gallon tank header is not removable; tank must be replaced if header is leaking.
4. Remove the DEF tank header from the tank.
4.a For the GHG17 13- and 23-gallon DEF tanks, Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust
Fluid Tank" and Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
4.b For the GHG17 six-gallon DEF tank, Refer to section "Removal of the Six-Gallon Diesel Exhaust Fluid Tank" and
5. Connect the tank header electrical connections and coolant hoses while set on a suitable mount next to the
vehicle.
6. Fill cooling system. Refer to section "Cooling System Fill Procedure"
8. Perform the DEF Coolant Valve Control test:
8.a Choose DEF Coolant Valve Control from the ActionsAftertreatment menu to display the DEF Coolant
Valve Control dialog box:
8.b Enter the required Duration in the box provided.

Note : The maximum time duration for this routine is 300 seconds (five minutes).
8.c Press the Start button to enable the coolant valve. The DEF coolant valve will be set to open for the
time duration indicated:
35
8.d If required, to discontinue the test: Press Stop. The DEF coolant valve will be set to closed:
36
9. Did the DEF tank header leak?

9.a Yes; replace the DEF tank header.
9.b No; contact the Detroit™ Customer Support Center at 800-445-1980.
10. Replace the coolant.
10.a Refer to section "Cooling System Drain Procedure"
10.b Refer to section "Cooling System Fill Procedure"
11. If coolant has contaminated the DEF system, flush the DEF system. Refer to section "Flushing of the Diesel Exhaust
Fluid System"
37
9.8 Diesel Exhaust Fluid in Fuel

Check as follows:
Note : Once fuel filters are removed from the fuel module, do not reinstall the fuel filter caps or fuel filters on to the
fuel filter module until all diagnostics are complete.
1. Take a fuel sample from the fuel filter module by opening the water bowl drain valve and drain the water
bowl in to a clear container. Does fuel drain from the water bowl drain valve?
2. Shake the fuel sample for five seconds, and then observe the smell of the fuel sample. Does the fuel
sample have an ammonia smell?
3. Place the fuel sample on a clean work bench for 15 minutes. Inspect the fuel sample for Diesel Exhaust
Fluid (DEF). The graphic shows separation of fuel (1) and DEF (2) in the fuel sample. Is any DEF present?

4. Remove the fuel filters from the fuel filter module and the frame-mounted housing (if equipped). Inspect the
inside of the fuel filter module for DEF and rust deposits. The graphic shows DEF (1) and rust (2) in the fuel
filter module. Are any DEF or rust deposits present?
38

4.b No; place a shop towel over the openings of the fuel filter module and frame-mounted housing (if
equipped). Allow the fuel filters and filter module to sit for one hour. Go to step 5.
5. After letting the fuel filters and fuel filter module sit for one hour, inspect the fuel filters and fuel filter module
for dark brown, light brown or white in color crystallization. The graphic shows an example of crystallization
(1) on the fuel filter module and fuel filters. Is any crystallization present?
39

• fuel flange
• fuel rail
• fuel injectors
• amplifier
• fuel tanks
• OEM fuel lines
Note : Crystallization, rust staining and/or corrosion found in the water drain bowl is considered abnormal and is
evidence of contamination in the fuel system.
6. Remove the water drain bowl and inspect for dark brown, light brown, white in color crystallization,
corrosion or rust staining. The graphic shows an example of crystallization (1), corrosion (2) and rust
staining (3) inside the water drain bowl. Is any crystallization, corrosion or rust staining present?
40

• fuel flange
• fuel rail
• fuel injectors
• amplifier
• fuel tanks
• OEM fuel lines
6.b No; diesel exhaust fluid in fuel diagnostic test is complete. Return to the diagnostic test that led to
diesel exhaust fluid in fuel.
41
9.9 Metal in the Fuel System – Two-Filter Fuel System

Description:
The fuel filter function is to remove impurities from the fuel before the fuel reaches the high pressure fuel pump.
These contaminates often originate from fuel storage tanks and the fuel island transfer pump.
With a cartridge-type filter, it is possible to visually see debris on the filter media and in the fuel filter housing.
Debris of any kind found in the fuel filter module or fuel filter media during a service/maintenance event should be
considered normal.
The amount and type of debris can depend on the quality of the fuel, where and how the fuel is stored, and the
transfer system being used.

J-48707 Fuel Filter Module Inlet Outlet Hose
J-48708-1 Fuel Flow Tool
W470589039100 Fuel System Tool Update Kit Without Motor

Control Module (MCM) Cooler
Check as follows:
Note : The following troubleshooting procedure should only be used if there is a fuel system fault code and/ or
excessive noise from the high pressure fuel pump.
Note : The purpose of the fuel filter(s) is to prevent particulate contaminants from entering the fuel system. It is
normal to find some debris on or in the fuel filters.
WARNING
PERSONAL INJURY
42
WARNING
PERSONAL INJURY
1. Remove the chassis return line from the fuel filter module.
2. Clean Fuel Filter Module Inlet/Outlet Hoses (J-48707) and Fuel Flow Tool (J-48708-1) with clean diesel
fuel.
3. Install the Fuel Filter Module Inlet/Outlet Hose tool (J-48707) and the Fuel System Tool Update Kit without
Motor Control Module (MCM) Cooler (W470589039100) on to the chassis return line fitting on the fuel filter
module.
4. Install the opposite end of the Fuel Filter Module Inlet/Outlet Hose (J-48707) onto the Fuel Flow Tool (J-
48708-1).
5. Start and run the engine at idle until the fuel flow tool (J-48708-1) is full of fuel (about 9 liters or 2 ¼
gallons).
6. Use a magnet to check for magnetic metallic debris in the Fuel Flow Tool. Is there magnetic metallic debris
present?
6.a Yes; replace the following components:
• High pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System".
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module - Two-Filter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines -
Two-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter System".
• Frame-mounted filter (if equipped).
43
Clean the following components:

• Clean fuel tanks and filter of contaminated fuel. Refer to section "Fuel Filtration and Fuel Tank Cleaning
(After a High Pressure Fuel Pump Failure)".
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System".
• Doser supply line.
• Frame-mounted filter housing (if equipped).
• OEM Supply and return lines. Refer to OEM procedures.
Note : After completing all repairs, the fuel system must be primed as directed. Refer to section "Priming the Fuel System -
KM63 GEN2 - Two-Filter System" .
6.b No; this procedure has verified that there is no metal in the filtered side fuel system, return to the
diagnostic that lead you to this section. Remove the tools and reinstall the chassis fuel return line onto
the module. Refer to OEM procedures for debris in fuel tanks.
44
10.1 How to Retrieve DDEC Reports

Retrieve as follows:
1. Start the PC before turning the ignition ON.
2. Verify that the hardware cables are properly connected.
3. Turn the ignition ON (Key ON, Engine OFF).
4. Double-click the DDEC Reports desktop shortcut (or navigate to Start/All Programs/Detroit Diesel/DDEC
Reports) to launch DDEC Reports.
5. Wait for the Communication Manager to detect and connect to the CPC/VCU. (If connection fails, click
Tools and Set Connection Interface to verify that proper translator is selected)
1
6. Select a vehicle ID from the IDs on the vehicle field or type in a file name and click OK.
2
7. Click Start Extraction to begin the data extraction.
The extraction begins with a progress indicator (0-100% when complete).
3
When the extraction process is complete, the Communications Manager window will minimize and the Trip
Activity Report will automatically be displayed on the screen for review.
4
8. If you wish to view previously extracted reports, click Extraction Log from Communication Manager and
select the desired report by double-clicking (e.g. Vehicle ID BILLCPC10).
5
How to Retrieve DDEC Reports
6
Electrical Connector Repair/Replacement
11.1 Electrical Connector Inspection

Inspect as follows:
1. Inspect the connectors for damage. This includes damage to the plastic shell, thumb release tab (2) and
the sliding lock tab (1). If damage is found the mating connector/component should also be inspected for
damage.
2. Verify the terminal pins are properly locked into the connector body by holding the plastic shell in one hand
while gently pulling/pushing the wire. If the wire slides in/out of the connector, the terminal is not locking
correctly and further inspection is needed to determine the cause.
3. Visually inspect the pins for corrosion. When present, corrosion is visible in the form of green coating
deposits on the pins.
1
4. Verify the terminal pins are not worn/spread by using the wire probe kit tool# DKI470E16022. Slide the
correct wire probes in and out of the female pins and over the male pins. There should be some slight drag
present. The drag should be sufficient to hold the weight of the probe kit while vertically hanging from the
connector terminal.
2
11.2 Electrical Connector Repair

Repair as follows:
If corrosion is present the connector and the component should both be replaced. Corrosion is usually caused by
water intrusion. Steps should also be taken to determine the cause of corrosion. Refer to the chart below for the
list of replacement connectors.
Connectors that are damaged or have pins that are damaged should be replaced. The mating connector should
also be inspected for damage. If damage is found in both mating connectors, both connectors should be replaced.
Refer to the chart below for the list of replacement connectors. The kit contains preassembled pigtails that have
six or fewer pins. If the connector does not exist in the kit, the individual pins should be replaced.
Connectors that have six pins or less should be replaced using a pigtail. The pigtails in the kit are pre-assembled
and requires Phillips Sta-Dry crimp, solder and seal butt connectors to be installed.
Connectors with more than six pins will be repaired using separate pins and connectors that will need to be
assembled as necessary.
HD DD MCM Sensor Wire / Shrink Tube Probe Part # Replacement Pigtail Sensor
Color Part # Location
/ Section
Referenc
e
Crankshaft Position Sensor Red/Red DKI470E16022-37 A0001506136
Intake Manifold Red/Red DKI470E16022-37 A0001506136

Temperature Sensor DD15
and DD16
Intake Manifold Red/Red DKI470E16022-37 A0001506436

Temperature Sensor DD13
Turbocharger Speed Red/Red DKI470E16022-37 N/A

Sensor
Water Pump Speed Sensor Red/Red DKI470E16022-37 A0001506336
3
/ Section
Referenc
e
Electronic Dosing Valve (4) Red/Red DKI470E16022-37 A0001506136
Fuel Cutoff Valve (2) Red/Red DKI470E16022-37 A0001506036
Intake Throttle Valve DD16 Red/Red DKI470E16022-37 A0001506636

Only
Crankcase Breather Speed Red/Red DKI470E16022-37 A0001506336

Sensor
/ Section
Referenc
e
Fuel Compensation Red/Red DKI470E16022-37 A0001506236
Pressure Sensor (3)
Fuel Doser Line Pressure Red/Red DKI470E16022-37 A0001506236

Sensor (5)
Camshaft Position Sensor Red/Red DKI470E16022-37 A0001506336
Valve Cover Injector Red/Red DKI470E16022-37 Replace injector harness

Harness for repairs
120-pin MCM Connector Violet/Black DKI470E16022-40 Replace pins as necessary
4
/ Section
Referenc
e
Engine Oil Pressure Red/Black DKI470E16022-41 A0001506236
Sensor
Supply Fuel Temperature Red/Black DKI470E16022-41 A0001505536

Sensor (2)
Engine Oil Temperature Red/Black DKI470E16022-41 A0001505536

Sensor
Coolant Outlet Red/Black DKI470E16022-41 A0001505536

Temperature Sensor
Coolant Inlet Temperature Red/Black DKI470E16022-41 A0001505536

Sensor
/ Section
Referenc
e
Pre 2016 EGR Delta P Red/Black DKI470E16022-41 A0001500320
Sensor without yellow
locking tab.
Post 2016 EGR Delta P Violet/Black DKI470E16022-40 Repair pins as necessary.

Sensor with yellow locking
tab.
Intake Red/Black DKI470E16022-41 A0001505836

Pressure/Temperature
Sensor (3)
Fuel Rail Pressure Sensor Red/Black DKI470E16022-41 A0001505036

(1)
EGR Actuator DD13 and Red/Black DKI470E16022-41 A0001506136

DD15
5
/ Section
Referenc
e
EGR Actuator DD16 Red/Black DKI470E16022-41 A0001506436
Quantity Control Valve (3) Red/Black DKI470E16022-41 A0001500164
21-pin MCM Connector Light Brown/Black DKI470E16022-42 Replace pins as necessary.
Low Pressure Fuel Sensor Red/Black DKI470E16022-41 A0001505036

(5) for Two-Filter System
Water in the Fuel Sensor Red/Black DKI470E16022-41 A0001502725

(1) for Two-Filter System
Turbocharger Inlet Air Red/Red DKI470E16022-37 A0001505236

Temperature Sensor (2)
Water Pump Power Red/Red DKI470E16022-37 A0001506136
6
HD DD ACM Sensor Wire / Shrink Tube Probe Part # Replacement Pigtail Sensor
/ Section
Referenc
e
Diesel Oxidation Catalyst Red/Black DKI470E16022-41 N/A. Replace the ATD
Inlet Pressure Sensor (1) harness for repairs.

Inlet Temperature Sensor harness for repairs.
(2)

Outlet Temperature Sensor harness for repairs.
(1)
Diesel Particulate Filter Red/Black DKI470E16022-41 N/A. Replace the ATD

Outlet Temperature Sensor harness for repairs.
(1)
Selective Catalyst Red/Black DKI470E16022-41 N/A. Replace the ATD

Reduction Outlet harness for repairs.
Temperature Sensor
Selective Catalytic Red/Black DKI470E16022-41 N/A. Replace the ATD

Reduction Inlet NOx harness for repairs.
Sensor (3)
Selective Catalytic Red/Black DKI470E16022-41 N/A. Replace the ATD

Reduction Outlet NOx harness for repairs.
Sensor (1)
Soot Sensor (3) N/A. Replace the ATD

harness for repairs.
7
12.1 Oil at Purge Valve, Dryer Cartridge or Reservoir

Check as follows:
Note : Compressors normally pass a small amount of oil and oil vapor into the discharge line.An air compressor
operating within the normal operating range has a duty cycle at or below 25%.
The following can lead to oil and/or excessive moisture in the chassis air system:
• Restrictive air filter
• High duty cycle
• Chassis or trailer air system leaks
• Incorrect sized air compressor and/or air dryer
• Air compressor discharge line too short
• Air dryer maintenance
• Leaks in the air compressor air intake causing non filtered air to enter the compressor
1. Check for air system leaks. Refer to section "Air Brake System and Accessory Leakage Test" . Were air system leaks
found?
1.a Yes; repair air system leak as necessary.
2. Check for a blocked, folded, or punctured discharge line. Is there any damage to the discharge line?
2.a Yes; repair is necessary.
Note : For high duty cycle applications a 5/8 inch inner diameter, 12 foot length line is recommended.
3. Is the air compressor discharge line at least nine feet long between the air compressor and air dryer?
3.b No; refer to Freightliner Service Bulletin 42-69 or the OEM manual to increase the size of the discharge
line.
4. Measure the Air Inlet Restriction with a manual gauge under 100% load (do not use the gauge on the air
filter assembly). Is the Air Inlet Restriction greater than 18 H 2 O"?
4.a Yes; repair cause of high inlet restriction.
5. Check for restriction in the compressor air intake tube from the turbo compressor inlet pipe to the
compressor inlet. Were any intake restrictions found?
5.a Yes; repair as necessary.
6. Test the air compressor governor system. Refer to section "Governor System Leakage and Function Test" . Is the
governor functioning correctly?
6.b No; repair as necessary.
7. Check the condition of the air dryer desiccant cartridge. Has the cartridge exceeded its service life?
7.a Yes; replace air dryer cartridge.
8. Does the air dryer have the correct desiccant cartridge installed?
8.a Yes; replace the air compressor.
8.b No; install the correct cartridge.
1
12.2 Will Not Build Air Pressure or Slow to Build Air

Pressure
Check as follows:
found?
2. Is the air compressor the correct size for the current application? Refer to Table A of the Bendix Advanced
Troubleshooting Guide for usage guidelines.
2.b No; install a larger capacity compressor. (Note this may require a change in the air dryer assembly).
4.a Yes; replace cartridge.
5. Measure the Air Inlet Restriction with a manual gauge under 100% load. Do not use the gauge on the air
filter assembly. Is the Air Inlet Restriction greater than 18 H 2 O"?
5.a Yes; repair the cause of high inlet restriction.
6. Check for restriction in the air intake from the turbo compressor inlet pipe to the compressor inlet. Were any
intake restrictions found?
6.a Yes; repair as necessary
7. Check for the presence of metallic debris in the compressor intake port. Was metallic debris present?
7.a Yes; replace air compressor, clean compressor intake pipe and turbo compressor inlet pipe.
8. Is the compressor unloader mechanism functioning properly? Refer to section "Air Compressor Unloader Leakage
Test" .

8.b No; replace the unloader valve. Refer to section "Removal of the Air Compressor Unloader Valve" .
2
Symptom Diagnostics - Air Compressor
12.1 Oil at Purge Valve, Dryer Cartridge or Reservoir

Check as follows:
Note : Compressors normally pass a small amount of oil and oil vapor into the discharge line.An air compressor
operating within the normal operating range has a duty cycle at or below 25%.
The following can lead to oil and/or excessive moisture in the chassis air system:
• Restrictive air filter
• High duty cycle
• Chassis or trailer air system leaks
• Incorrect sized air compressor and/or air dryer
• Air compressor discharge line too short
• Air dryer maintenance
• Leaks in the air compressor air intake causing non filtered air to enter the compressor
found?
1.a Yes; repair air system leak as necessary.
Note : For high duty cycle applications a 5/8 inch inner diameter, 12 foot length line is recommended.
3. Is the air compressor discharge line at least nine feet long between the air compressor and air dryer?
3.b No; refer to Freightliner Service Bulletin 42-69 or the OEM manual to increase the size of the discharge
line.
4. Measure the Air Inlet Restriction with a manual gauge under 100% load (do not use the gauge on the air
filter assembly). Is the Air Inlet Restriction greater than 18 H 2 O"?
4.a Yes; repair cause of high inlet restriction.
5. Check for restriction in the compressor air intake tube from the turbo compressor inlet pipe to the
compressor inlet. Were any intake restrictions found?
6. Test the air compressor governor system. Refer to section "Governor System Leakage and Function Test" . Is the
governor functioning correctly?
7.a Yes; replace air dryer cartridge.
8. Does the air dryer have the correct desiccant cartridge installed?
3
8.b No; install the correct cartridge.
4
12.2 Will Not Build Air Pressure or Slow to Build Air

Pressure
Check as follows:
found?
2. Is the air compressor the correct size for the current application? Refer to Table A of the Bendix Advanced
Troubleshooting Guide for usage guidelines.
2.b No; install a larger capacity compressor. (Note this may require a change in the air dryer assembly).
4.a Yes; replace cartridge.
5. Measure the Air Inlet Restriction with a manual gauge under 100% load. Do not use the gauge on the air
filter assembly. Is the Air Inlet Restriction greater than 18 H 2 O"?
5.a Yes; repair the cause of high inlet restriction.
6. Check for restriction in the air intake from the turbo compressor inlet pipe to the compressor inlet. Were any
intake restrictions found?
6.a Yes; repair as necessary
7. Check for the presence of metallic debris in the compressor intake port. Was metallic debris present?
7.a Yes; replace air compressor, clean compressor intake pipe and turbo compressor inlet pipe.
8. Is the compressor unloader mechanism functioning properly? Refer to section "Air Compressor Unloader Leakage
Test" .

8.b No; replace the unloader valve. Refer to section "Removal of the Air Compressor Unloader Valve" .
5
13.1 ATD Checklist - GHG17

Note : The purpose of this checklist is to determine if there is another component that can contribute to the
Aftertreatment System (ATS) failure. A fuel system or an air management system failure can contribute to ATS
failures. Diagnose any fuel system or air management system fault codes prior to completing this checklist. Once
a repair has been completed, or if there are no failures found, return to the original troubleshooting procedure and
proceed with the necessary repair.
Check as follows:
1. Connect DiagnosticLink .
3. Compare the barometric reading in the Motor Control Module (MCM) to your local atmospheric barometric
pressure. Are the readings within 6.89 kPa (1 psi) of each other?
3.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" Go to step 4.
4. Compare the intake manifold pressure sensor reading to the barometric pressure sensor reading. Are the
readings within 10.34 kPa (1.5 psi) of each other?
4.b No; replace the intake manifold pressure sensor. Refer to section "Removal of the Intake Pressure/Temperature
Sensor" . Go to step 5.
5. Inspect the exhaust manifold, Exhaust Gas Recirculation (EGR) valve and turbocharger on the engine for
soot or other signs of exhaust leaks. Are there any exhaust leaks present?
5.a Yes; repair the exhaust leaks. Go to step 6.
6. Inspect the aftertreatment system for soot or other signs of leaks. Are there any signs of exhaust leaks
present?
7. Remove and inspect the air filter. Is the air filter excessively dirty or restricted?
7.a Yes; replace the air filter. Go to step 8.
7.b No; reinstall the air filter and Go to step 8.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start and run the engine at 900 rpm.

9. Inspect the hose and clamps on the intake system for leaks. Are there any leaks present?
9.a Yes; repair the leaks as necessary after the Charge Air Cooler (CAC) pressure-test in the step below.
Go to step 10.
1

10. Turn the engine OFF.
11. Pressure-test the Charge Air Cooler (CAC). Refer to Original Equipment Manufacturer (OEM) literature for
pressure testing procedures. Does the CAC pass the pressure test?
11.b No; replace the CAC. Refer to OEM literature for removal and installation procedures. Go to step 12.
12. Remove the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" .
13. Inspect the EGR delta P sensor ports in the venturi pipe. Are the ports restricted?
13.a Yes; clean the EGR delta P ports in the venturi pipe. Refer to section "Cleaning of the Exhaust Gas Recirculation
Venturi Pipe Delta P Sensor Ports" . Go to step 14.

14. Refer to Warranty Information Letter 16-036R and review the duty cycle in the DDEC reports for the last
three months (click on view and change to the last three months) and fill out the DDEC Reports Checklist.
Refer to section "How to Retrieve DDEC Reports" .
DDEC Report Checklist

1. Trip distance/Trip duration
2. Idle percentage
3. The percentage of operation between 0-9 mph (Vehicle Speed Histogram)
4. The percentage of operation between 0-19% load (Engine Load Histogram)
5. The percentage of operation between 0-999 rpm
6. The percentage of operation over 1,800 rpm (Engine Speed Histogram)
Screen print examples of DDEC report histograms attached below:
Fig 0.1, From DDEC report: Select "View", then "Speed/RPM"
2
Fig 0.2, From DDEC Report: Select "View" then "Engine Load/RPM"
15. Does the vehicle exhibit signs of a poor duty cycle?

15.a Yes; refer to Warranty Information Letter 16-036R .
15.b No; return to the original troubleshooting procedure and proceed with the necessary repair.
3
13.1 ATD Checklist - GHG17

Note : The purpose of this checklist is to determine if there is another component that can contribute to the
Aftertreatment System (ATS) failure. A fuel system or an air management system failure can contribute to ATS
failures. Diagnose any fuel system or air management system fault codes prior to completing this checklist. Once
a repair has been completed, or if there are no failures found, return to the original troubleshooting procedure and
proceed with the necessary repair.
Check as follows:
3. Compare the barometric reading in the Motor Control Module (MCM) to your local atmospheric barometric
pressure. Are the readings within 6.89 kPa (1 psi) of each other?
3.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" Go to step 4.
4. Compare the intake manifold pressure sensor reading to the barometric pressure sensor reading. Are the
readings within 10.34 kPa (1.5 psi) of each other?
5. Inspect the exhaust manifold, Exhaust Gas Recirculation (EGR) valve and turbocharger on the engine for
soot or other signs of exhaust leaks. Are there any exhaust leaks present?
6. Inspect the aftertreatment system for soot or other signs of leaks. Are there any signs of exhaust leaks
present?
7. Remove and inspect the air filter. Is the air filter excessively dirty or restricted?
7.a Yes; replace the air filter. Go to step 8.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start and run the engine at 900 rpm.

9. Inspect the hose and clamps on the intake system for leaks. Are there any leaks present?
9.a Yes; repair the leaks as necessary after the Charge Air Cooler (CAC) pressure-test in the step below.
Go to step 10.
4

11. Pressure-test the Charge Air Cooler (CAC). Refer to Original Equipment Manufacturer (OEM) literature for
pressure testing procedures. Does the CAC pass the pressure test?
11.b No; replace the CAC. Refer to OEM literature for removal and installation procedures. Go to step 12.
13. Inspect the EGR delta P sensor ports in the venturi pipe. Are the ports restricted?
13.a Yes; clean the EGR delta P ports in the venturi pipe. Refer to section "Cleaning of the Exhaust Gas Recirculation
Venturi Pipe Delta P Sensor Ports" . Go to step 14.

14. Refer to Warranty Information Letter 16-036R and review the duty cycle in the DDEC reports for the last
three months (click on view and change to the last three months) and fill out the DDEC Reports Checklist.
Refer to section "How to Retrieve DDEC Reports" .
DDEC Report Checklist

1. Trip distance/Trip duration
2. Idle percentage
3. The percentage of operation between 0-9 mph (Vehicle Speed Histogram)
4. The percentage of operation between 0-19% load (Engine Load Histogram)
5. The percentage of operation between 0-999 rpm
6. The percentage of operation over 1,800 rpm (Engine Speed Histogram)
Screen print examples of DDEC report histograms attached below:
Fig 0.3, From DDEC report: Select "View", then "Speed/RPM"
5
Fig 0.4, From DDEC Report: Select "View" then "Engine Load/RPM"
15. Does the vehicle exhibit signs of a poor duty cycle?

15.a Yes; refer to Warranty Information Letter 16-036R .
15.b No; return to the original troubleshooting procedure and proceed with the necessary repair.
6
Symptom Diagnostics - ATD Checklist
7
14.1 Belt Coming Off, Shredding or Misalignment
Check as follows:
Note : The belt will naturally track slightly forward on the pulley.
NOTICE
Detroit does not approve the use of belt dressing or other like products as this may result
in premature belt wear.
1
WARNING
PERSONAL INJURY
To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently
snapping back, do not cut the belt to remove it.
Note : Different engine types and different water pump configurations will use different belt part numbers.
2. Check the maintenance records to be sure the belts are not overdue for a maintenance interval. Refer to
section "EPA07/EPA10/GHG14/GHG17 Preventive Maintenance Tables - 93K222(CK-4) and 93K223(FA-4)" . Do the belts
require replacement?
2.a Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts" . Verify repair.
2
Correct Pulley Installation Incorrect Pulley Installation
Correct installation. The stud protrudes past the nut. Incorrect insulation. Pulley has been installed backwards, note
the stud does not protrude past the nut.
3. Visually inspect the alternator pulley for correct installation. The pulley stud should stick out of nut that
secures the pulley in place. Is the pulley installed backwards?
3.a Yes; correct the alternator pulley orientation and replace both belts. Verify repair.
Note : Misalignment will not be caused by a faulty belt tensioner.
3
4. Visually inspect the belts and pulleys for signs of misalignment or damage. The wear pattern should never
reach the edge of the idler pulley surface (A). Rotate each pulley by hand checking each pulley for
misalignment or damage. Do the belts or pulleys show signs of misalignment or damage?
4.a Yes; replace both belts and the damaged pulley . Verify repair.
5. Remove the belts. Refer to section "Removal of the Poly-V-Belts" .
6. Check the belt for fluid contamination. Check for leaks from engine or chassis components. Are there any
fluids leaking onto the belt?
6.a Yes; repair the leaks and replace both belts. Verify repair.
7. Rotate the idler and accessory pulleys by hand while checking for grinding, sticking, and excessive lateral
or radial play. Is damage present?
4
7.a Yes; replace damaged pulley and both belts . Verify repair.
8. Visually inspect the belt tensioner for damage. Make sure the belt tensioner is applying constant adequate
tension on the belt, and make sure that it does not stick or bind. Is damage present?
8.a Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Belt Tensioner" . Verify repair.
9. Is the engine equipped with a strut type belt tensioner?
9.b No; replace both belts. Refer to section "Removal of the Poly-V-Belts" . Verify repair.
Note : Oil leaks from the belt tensioner strut can normally be seen near the bottom of the strut.
10. Inspect the belt tensioner strut. Check for a broken strut mount or oil leaking at the strut (1). Is the strut
mount broken or oil leaking at the strut?
5
6
7
Check as follows:
8
NOTICE
WARNING
PERSONAL INJURY
2.a Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify repair.
9
Correct installation. The stud protrudes past the nut. Incorrect installation. Pulley has been installed backwards,
note the stud does not protrude past the nut.
3. Visually inspect the alternator pulley for correct installation. The pulley stud should protrude from the nut
securing the pulley in place. Is the pulley installed backwards?
10
5. Remove the belts. Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" .
11
tension on the belt, and check for sticking or binding. Is damage present?
8.a Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Hydraulic Belt Tensioner" . Verify
repair.
9. Is the engine equipped with a strut type belt tensioner (external springs)?
9.b No; replace both belts. Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify repair.
12
13
repair.
14
Check as follows:
15
NOTICE
WARNING
PERSONAL INJURY
2.a Yes; replace both belts.
For the Hydraulic Belt Tensioner, Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify
repair.
For the Friction Belt Tensioner, Refer to section "Removal of the Poly-V-Belts (Friction Belt Tensioner)" . Verify repair.
16
Correct installation. The stud protrudes past the nut. Incorrect installation. Pulley has been installed backwards;
note the stud does not protrude past the nut.
3. Visually inspect the alternator pulley for correct installation. The pulley stud should protrude from the nut
securing the pulley in place. Is the pulley installed backwards?
17
5. Remove the belts.
For the Hydraulic Belt Tensioner, Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify repair.
18

tension on the belt, and check for sticking or binding. Is damage present?
8.a Yes; replace the belt tensioner and both belts.
For the Hydraulic Belt Tensioner, Refer to section "Removal of the Hydraulic Belt Tensioner" . Verify repair.
For the Friction Belt Tensioner, Refer to section " Removal of the Friction Belt Tensioner" . Verify repair.
9. Is the engine equipped with a strut type belt tensioner (external springs)?
9.b No; replace both belts. Refer to section "Removal of the Poly-V-Belts (Friction Belt Tensioner)" . Verify repair.
19
20
repair.
21
Symptom Diagnostics - Belt Coming Off
22
15.1 Combustion Gas in Coolant

Note : Overfilling the coolant reservoir will cause the surge tank to push coolant out, this is sometimes
misdiagnosed as Combustion Gas in Coolant. If an engine is pushing coolant out of the surge tank, the coolant
loss diagnostics should be completed first Refer to section "Symptom Diagnostics - Coolant Loss". During normal
engine operation the coolant level will expand and contract between the two level lines depending on temperature.
The min/low and max/full marks on the coolant surge tank represent the acceptable operating range of the coolant
level. No coolant needs to be added if the coolant level is at the number two line.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Verify that the contaminant in the coolant is combustion gas. Oil can darken the coolant appearance and
lead to misdiagnosis. The use of combustion gas detection products is not approved by Detroit Diesel; due
to the nature of the emission control systems a false positive result will be likely.
2. Pressure test the Exhaust Gas Recirculation (EGR) cooler. For DD15/16, Refer to section "Testing of the DD15 and
DD16 Exhaust Gas Recirculation Cooler - In Chassis" . Did the EGR cooler pass testing and inspection?

2.b No; replace the EGR cooler.
For DD13, Refer to section "Installation of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly" .
For DD15/16, Refer to section "Installation of the DD15 and DD16 Exhaust Gas Recirculation Cooler" .
3. Bypass the coolant supply and return to the air compressor.
Note : Some bubbles may appear in the cooling system due to normal system pressurization.
4. Does the coolant system still appear to be pressurized by air or combustion gas?
1

4.b No; replace the air compressor.
5. Perform a Relative Cylinder Compression Test, Refer to section "Relative Cylinder Compression Test" . Was a
suspect cylinder identified?
5.b No; Combustion gas was not identified as a contaminant in the cooling system. Overfilling the coolant
reservoir and oil in the coolant are commonly misdiagnosed as combustion gas in coolant.
6. Remove the cylinder head. Refer to section "Inspection of the Cylinder Head" and
6.a For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly" .
6.b For DD15/16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
7. Inspect the cylinder head gasket. Is the cylinder head gasket damaged?
7.a Yes; replace the cylinder head gasket.
8. Inspect the cylinder head for cracks and damaged valves. Refer to section "Inspection of the Cylinder Head" . Is the
cylinder head or valves damaged?
8.a Yes; replace the cylinder head.
For DD13, Refer to section "Installation of the DD13 Cylinder Head Assembly" .
For DD15/16, Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly" .
8.b No; Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
2
Symptom Diagnostics - Combustion Gas in Coolant
15.1 Combustion Gas in Coolant

Note : Overfilling the coolant reservoir will cause the surge tank to push coolant out, this is sometimes
misdiagnosed as Combustion Gas in Coolant. If an engine is pushing coolant out of the surge tank, the coolant
loss diagnostics should be completed first Refer to section "Symptom Diagnostics - Coolant Loss" . During normal engine
operation the coolant level will expand and contract between the two level lines depending on temperature. The
min/low and max/full marks on the coolant surge tank represent the acceptable operating range of the coolant
level. No coolant needs to be added if the coolant level is at the number two line.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Verify that the contaminant in the coolant is combustion gas. Oil can darken the coolant appearance and
lead to misdiagnosis. The use of combustion gas detection products is not approved by Detroit Diesel; due
to the nature of the emission control systems a false positive result will be likely.
2. Pressure test the Exhaust Gas Recirculation (EGR) cooler. For DD15/16, Refer to section "Testing of the DD15 and
DD16 Exhaust Gas Recirculation Cooler - In Chassis" . Did the EGR cooler pass testing and inspection?

3
3. Bypass the coolant supply and return to the air compressor.

Note : Some bubbles may appear in the cooling system due to normal system pressurization.
4. Does the coolant system still appear to be pressurized by air or combustion gas?
4.b No; replace the air compressor.
5. Perform a Relative Cylinder Compression Test, Refer to section "Relative Cylinder Compression Test" . Was a
suspect cylinder identified?
5.b No; Combustion gas was not identified as a contaminant in the cooling system. Overfilling the coolant
reservoir and oil in the coolant are commonly misdiagnosed as combustion gas in coolant.
6. Remove the cylinder head. Refer to section "Inspection of the Cylinder Head" and
6.a For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly" .
6.b For DD15/16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
7. Inspect the cylinder head gasket. Is the cylinder head gasket damaged?
8. Inspect the cylinder head for cracks and damaged valves. Refer to section "Inspection of the Cylinder Head" . Is the
cylinder head or valves damaged?
8.a Yes; replace the cylinder head.
For DD13, Refer to section "Installation of the DD13 Cylinder Head Assembly" .
For DD15/16, Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly" .
8.b No; Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
4
16.1 Symptom Diagnostics - Coolant Loss

Note : Prior to diagnosing a coolant loss complaint, make sure that the coolant is not being unnecessarily
overfilled. The min/low and max/full marks on the coolant surge tank represent the acceptable operating range of
the coolant level. During normal operation, the coolant level will expand and contract between the two lines,
depending on temperature. No coolant needs to be added if the coolant level is at the number two line. Overfilling
the coolant reservoir will cause the surge tank to push coolant out.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Are any Original Equipment Manufacturer (OEM) components leaking coolant externally?
1.a Yes; inspect the vehicle for the source of the coolant loss and consult OEM procedures for repair
instructions.
2. Inspect the vehicle for any aftermarket components plumbed into the cooling system. Are there any
aftermarket components plumbed into the cooling system on the vehicle?
3. Inspect the aftermarket components; refer to OEM guidelines. Are aftermarket components the source of
coolant loss?
1
4. Pressure test the surge tank cap(s). Do the cap(s) hold the correct rated pressure?
5. Check engine coolant fan operation. Does the fan function correctly?
6. Pressure test the cooling system and inspect for coolant leaks. Is the engine leaking coolant externally?
7. Is the external leak at the cylinder head to cylinder block joint?
7.a Yes; remove the cylinder head.
For DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly"
For DD15/16, Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly"
Go to step 8.
7.b No; inspect the engine for the source for the coolant leak and make the repair.
8. Inspect the cylinder head gasket coolant grommet(s) for damage. Are the grommet(s) damaged?
9. Inspect the cylinder liner for scuffs. Are the liners scuffed?
9.a Yes; replace the scuffed liner(s), Refer to section "Removal of the Cylinder Liner" .
9.b No; test the cylinder liner upper O-ring, Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
10. Is there coolant contamination in the Diesel Exhaust Fluid (DEF)?
10.a Yes; replace the DEF tank header assembly. Select the proper tank:
Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
11. Is there coolant contamination in the oil?
11.a Yes; Refer to section "Coolant in Oil" .
12. Is there coolant contamination in the fuel?
12.a Yes; Refer to section "Fuel in Coolant/Coolant in Fuel" .
13. Pressure test the Exhaust Gas Recirculation (EGR) cooler. Does the EGR cooler pass testing and
inspection?
Refer to section "Testing of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly - In Chassis"
Refer to section "Testing of the DD15 and DD16 Exhaust Gas Recirculation Cooler - In Chassis"
13.a Yes; release the vehicle and monitor coolant consumption. During normal operation, the coolant level
will expand and contract. Overfilling the coolant reservoir will cause the surge tank to push coolant out.
2
Symptom Diagnostics - Coolant Loss
16.1 Symptom Diagnostics - Coolant Loss

Note : Prior to diagnosing a coolant loss complaint, make sure that the coolant is not being unnecessarily
overfilled. The min/low and max/full marks on the coolant surge tank represent the acceptable operating range of
the coolant level. During normal operation, the coolant level will expand and contract between the two lines,
depending on temperature. No coolant needs to be added if the coolant level is at the number two line. Overfilling
the coolant reservoir will cause the surge tank to push coolant out.
1. MAX/FULL Mark
2. MIN/LOW Mark
3. Operating Range
Check as follows:
1. Are any Original Equipment Manufacturer (OEM) components leaking coolant externally?
1.a Yes; inspect the vehicle for the source of the coolant loss and consult OEM procedures for repair
instructions.
3. Inspect the aftermarket components; refer to OEM guidelines. Are aftermarket components the source of
coolant loss?
3

4. Pressure test the surge tank cap(s). Do the cap(s) hold the correct rated pressure?
6. Pressure test the cooling system and inspect for coolant leaks. Is the engine leaking coolant externally?
7. Is the external leak at the cylinder head to cylinder block joint?
7.a Yes; remove the cylinder head.
For DD15/16, Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly"
Go to step 8.
7.b No; inspect the engine for the source for the coolant leak and make the repair.
8. Inspect the cylinder head gasket coolant grommet(s) for damage. Are the grommet(s) damaged?
9. Inspect the cylinder liner for scuffs. Are the liners scuffed?
9.a Yes; replace the scuffed liner(s), Refer to section "Removal of the Cylinder Liner" .
9.b No; test the cylinder liner upper O-ring, Refer to section "Testing of the Cylinder Liner Upper O-Ring" .
10. Is there coolant contamination in the Diesel Exhaust Fluid (DEF)?
10.a Yes; replace the DEF tank header assembly. Select the proper tank:
Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
11. Is there coolant contamination in the oil?
11.a Yes; Refer to section "Coolant in Oil" .
12. Is there coolant contamination in the fuel?
12.a Yes; Refer to section "Fuel in Coolant/Coolant in Fuel" .
13. Pressure test the Exhaust Gas Recirculation (EGR) cooler. Does the EGR cooler pass testing and
inspection?
Refer to section "Testing of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly - In Chassis"
Refer to section "Testing of the DD15 and DD16 Exhaust Gas Recirculation Cooler - In Chassis"
13.a Yes; release the vehicle and monitor coolant consumption. During normal operation, the coolant level
will expand and contract. Overfilling the coolant reservoir will cause the surge tank to push coolant out.
4
17.1 Poor Engine Brake Performance

Use this procedure to determine the cause of poor engine brake performance when no codes are present. Verify
the customer complaint before beginning any troubleshooting.
Check as follows:
Note : Engine brakes do not enable until engine oil temperature reaches 50°C (122°F). The front engine brake
solenoid controls cylinders 1, 2, and 3. The rear engine brake solenoid controls cylinders 4, 5, and 6. The engine
brakes are most effective at higher engine speeds; performance increases as engine speed increases.
Typical engine brake solenoid related brake performance symptoms are:
• Front solenoid - Loss of low engine braking.
• Rear solenoid - Medium engine braking feels like low and high will be slightly better than low due to EGR
flow.
Note : Not everyone can accurately "feel" the difference between low, medium and high engine braking as it
varies with engine speed. Additionally, there are other causes for poor engine brake performance. Complete all
troubleshooting before replacing the engine brake solenoids.
1. Using DiagnosticLink , check all modules, including Transmission Control Module (TCM), Antilock Brake
System (ABS and chassis) for active or inactive codes. Are faults present?
1.a Yes; perform the troubleshooting for all fault codes first.
2. Is the vehicle equipped with a manual transmission?
3. Using DiagnosticLink, view the clutch switch status. Push the clutch pedal to the floor, then release the
clutch pedal to the original position. Does the clutch pedal status change?
3.b No; diagnose and repair the clutch switch.
4. Using DiagnosticLink, view the service brake switch status. Push the service brake to the floor, then release
the service brake to the original position. Does the service brake status change?
4.b No; diagnose and repair the service brake switch.
5. With the engine OFF for a minimum of five minutes, check the oil level. Is the oil level within the minimum
and maximum marks on the dipstick?
6. Is the oil level above the maximum mark on the dipstick with no oil previously added?
7. Visually inspect and/or test for contamination in the oil. Is the oil contaminated with coolant or fuel?
7.a Yes; Refer to section "Coolant in Oil" or Refer to section "Oil in Coolant" . Repair as necessary and verify repairs.
8. Fill oil to the proper level and Go to step 9.
9. Does the engine still have poor engine brake performance?
9.b No; release vehicle.
10. Check the oil pressure using DiagnosticLink. Refer to section "Engine Mechanical Specifications" . Is the oil pressure
within specification?
1

10.b No; perform the low oil pressure troubleshooting for fault code SPN 100/FMI 1 low oil pressure. Refer to
section "SPN 100/FMI 1 - GHG17" .
11. Measure air inlet restriction and/or inspect the air filter. Is the air filter restricted or plugged?
11.a Yes; replace and verify repairs.
12. Pressurize the intake tract, including the Charge Air Cooler (CAC) and associated piping. Inspect for leaks.
Was a leak found?
12.a Yes; repair and/or replace as necessary and verify repairs.
13. Inspect the exhaust manifolds and turbocharger mounting flange for exhaust leaks. Are leaks present?
14. Inspect the EGR pipes (hot pipe, venturi and delivery pipe) for leaks. Are leaks present?
Note : Oil residue at the turbocharger compressor wheel is normal. Excessive oil can be caused by excessive idle
time, high air inlet restriction, or high crankcase pressure. Do NOT replace the turbocharger.
15. Remove the turbo inlet pipe/elbow and inspect the turbo compressor wheel for damage. Is damage
present?
15.a Yes; replace the turbocharger and verify repairs.
16. Perform a Relative Compression Test using DiagnosticLink. Refer to section "Relative Cylinder Compression Test" .
Was a faulty cylinder found?
16.a Yes; perform a Mechanical Cylinder Compression Test. Refer to section "Mechanical Cylinder Compression Test"
and then repair as necessary. Verify repairs.
17. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" . Go to step 18.
NOTICE
The cam journal area is lubricated by oil that has to travel through the rocker shaft. If the
shaft is installed incorrectly, the oil passages do not line up. This will result in insufficient
lubrication and damage to the cam journal and rocker arm bushings.
18. Inspect the exhaust rocker shaft to ensure it is installed with the groove towards the rear of the engine. Is
the exhaust rocker shaft installed correctly?
18.b No; check the camshafts and valve train for damage, and repair as necessary.
2
19. Remove the engine brake solenoids from the cam frame housing. Refer to section "Removal of the Engine Brake
Solenoid" . Go to step 20.
3
20. Inspect the engine brake solenoids for damage, including the screen and O-rings. Is any damage found?
20.a Yes; replace the parts on the engine brake solenoid and verify repairs.
Note : The front engine brake solenoid controls cylinders 1, 2, and 3. The rear engine brake solenoid controls
cylinders 4, 5, and 6.
21. With the front engine brake solenoid removed from the cam frame housing, use a rubber tip blow gun
regulated at 345 kPa (50 psi). Apply 345 kPa (50 psi) into the solenoid outlet port/engine activation port (1)
of the cam frame housing. Do all the actuator pistons in the engine brake rocker arms extend upwards for
the appropriate cylinders?
21.b No; replace the engine brake rocker with the stuck actuator pistons. Refer to section "Removal of the Exhaust
Rocker Shaft Assembly" .
4
22. Remove the air pressure; do the actuator pistons (1) retract?
22.b No; replace the engine brake rocker with the stuck actuator pistons (2). Refer to section "Removal of the
Exhaust Rocker Shaft Assembly" .
5
23. With the rear engine brake solenoid removed from the cam frame housing, use a rubber-tip blow gun
regulated at 345 kPa (50 psi). Apply 345 kPa (50 psi) into the solenoid outlet port/engine activation port of
the cam frame housing. Do the actuator pistons in the engine brake rocker arms extend outwards for the
appropriate cylinders?
23.b No; replace the engine brake rocker(s) with the stuck actuator pistons. Refer to section "Removal of the
24. Remove the air pressure; do the actuator pistons retract?

25. Check the camshaft timing. Refer to section "Camshaft Timing Verification" . Do camshaft timing marks line up per
procedures?
25.b No; repair as necessary and verify repair.
26. Check valve lash and engine brake adjustments. Refer to section "Setting the Valve and Engine Brake Lash" . Was
valve lash correct?
26.b No; adjust valve lash, assemble the engine and verify repairs.
27. Replace both engine brake solenoids. Refer to section "Installation of the Engine Brake Solenoid" then Go to step 28.
28.a Yes; replace all six exhaust rockers arms that have actuator pistons. Refer to section "Removal of the Exhaust
Rocker Shaft Assembly" and verify repairs.
28.b No; troubleshooting is complete.
6
17.2 Inoperative Engine Brake

Note : There are various conditions that will inhibit the operation of the engine brakes such as oil temperature,
engine rpm, wheel slip and fault codes in other modules. Engine brakes do not enable until engine oil temperature
reaches 50°C (122°F). The engine brakes are most effective at higher engine speeds. Refer to section "Engine
Brake System" in the operator's manual for more information.
3. Check for any engine oil temperature sensor fault codes. Are any engine oil temperature sensor fault codes
present?
3.a Yes; diagnose the engine oil temperature sensor fault codes first.
4. Check for fault codes in the other drivetrain-related modules. Are there any fault codes present in the other
vehicle drivetrain modules?
4.a Yes; diagnose the other fault codes first.
5. Does the engine have any performance concerns?
5.a Yes; diagnose the engine power performance concerns.
6. Check the CPC parameters to determine if the engine brakes are properly configured. Refer to the GHG17
DDEC Electronic Controls Manual (DDC-SVC-MAN-0127) to verify the parameters. Are the engine brakes
correctly configured?
Engine Brake Switch Programming Options

Parameter Group Parameter Options Default Access
13 Engine Brake Switch 0 = Hardwired 0 = Hardwired DiagnosticLink
Config 1 = Info from J1939 Professional, VEPS
(muxed)
2 = Info from LIN
255 = Not Available
13 2 14 DI Selection 0 = Disable 1 = Engine Brake Low DiagnosticLink
1 = Engine Brake Low Professional, VEPS
2 = Evobus Retarder
Lever Stage 1
3 = CC Hysteresis Low
4 = RemAP IVS1
13 2 15 DI Selection 0 = Disable 1 = Engine Brake High DiagnosticLink
1 = Engine Brake High Professional, VEPS
2 = Evobus Retarder
Lever Stage 2
3 = CC Hysteresis High
4 = RemAP IVS1

6.b No; correct the engine brake parameter configuration.
7. Is the vehicle equipped with a clutch pedal?
8. Use DiagnosticLink to monitor the clutch pedal status. Does the clutch pedal status change when the clutch
pedal is depressed and then released?
7

8.b No; diagnose and repair the clutch pedal switch.
9. Monitor the accelerator pedal position. Is the clutch pedal position zero%?
9.b No; repair the accelerator pedal concern.
10. Use DiagnosticLink to check the engine brake parameter status. Does the engine brake status parameter
change from red (off/disable/false) to green when the engine brake on/off switch is turned on?
10.b No; repair the engine brake on/off switch concern.
11. Monitor the "Engine Brake Low" status. Does the engine brake low status change from red (open) to green
(closed, short to ground) when the engine brake low switch is turned on?

11.b No; diagnose and repair the "engine brake low" switch concern.
12. Monitor the "engine brake medium" status when the engine brake medium on/off switch is turned to the on
position. Does the engine brake low status change from red (open) to green (closed, short to ground) when
the engine brake low switch is turned on?
8

12.b No; diagnose and repair the engine brake medium on/off switch concern.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
13. Start and run the engine until the oil temperature is greater than 50°C (122°F) degrees.
9
15. Remove the rocker cover.

16. Install the cam shaft gear timing cover.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
17. Start and let the engine run at idle.

18. Use DiagnosticLink to activate the front engine brakes. Do the pistons on the front engine brakes move?
18.b No; replace the front engine brake solenoid.
19. Use DiagnosticLink to activate the rear engine brakes. Do the pistons on the rear engine brakes move?
19.b No; replace the rear engine brake solenoid.
21. Adjust the engine brake lash. Remove the camshaft gear cover and reinstall the rocker cover. Release the
vehicle.
10
Symptom Diagnostics - Engine Brake
17.1 Poor Engine Brake Performance

Use this procedure to determine the cause of poor engine brake performance when no codes are present. Verify
the customer complaint before beginning any troubleshooting.
Check as follows:
Note : Engine brakes do not enable until engine oil temperature reaches 50°C (122°F). The front engine brake
solenoid controls cylinders 1, 2, and 3. The rear engine brake solenoid controls cylinders 4, 5, and 6. The engine
brakes are most effective at higher engine speeds; performance increases as engine speed increases.
Typical engine brake solenoid related brake performance symptoms are:
• Front solenoid - Loss of low engine braking.
• Rear solenoid - Medium engine braking feels like low and high will be slightly better than low due to EGR
flow.
Note : Not everyone can accurately "feel" the difference between low, medium and high engine braking as it
varies with engine speed. Additionally, there are other causes for poor engine brake performance. Complete all
troubleshooting before replacing the engine brake solenoids.
1. Using DiagnosticLink , check all modules, including Transmission Control Module (TCM), Antilock Brake
System (ABS and chassis) for active or inactive codes. Are faults present?
1.a Yes; perform the troubleshooting for all fault codes first.
2. Is the vehicle equipped with a manual transmission?
3. Using DiagnosticLink, view the clutch switch status. Push the clutch pedal to the floor, then release the
clutch pedal to the original position. Does the clutch pedal status change?
3.b No; diagnose and repair the clutch switch.
4. Using DiagnosticLink, view the service brake switch status. Push the service brake to the floor, then release
the service brake to the original position. Does the service brake status change?
4.b No; diagnose and repair the service brake switch.
5. With the engine OFF for a minimum of five minutes, check the oil level. Is the oil level within the minimum
and maximum marks on the dipstick?
6. Is the oil level above the maximum mark on the dipstick with no oil previously added?
7. Visually inspect and/or test for contamination in the oil. Is the oil contaminated with coolant or fuel?
7.a Yes; Refer to section "Coolant in Oil" or Refer to section "Oil in Coolant" . Repair as necessary and verify repairs.
8. Fill oil to the proper level and Go to step 9.
11

10. Check the oil pressure using DiagnosticLink. Refer to section "Engine Mechanical Specifications" . Is the oil pressure
10.b No; perform the low oil pressure troubleshooting for fault code SPN 100/FMI 1 low oil pressure. Refer to
11. Measure air inlet restriction and/or inspect the air filter. Is the air filter restricted or plugged?
11.a Yes; replace and verify repairs.
12. Pressurize the intake tract, including the Charge Air Cooler (CAC) and associated piping. Inspect for leaks.
Was a leak found?
13. Inspect the exhaust manifolds and turbocharger mounting flange for exhaust leaks. Are leaks present?
14. Inspect the EGR pipes (hot pipe, venturi and delivery pipe) for leaks. Are leaks present?
Note : Oil residue at the turbocharger compressor wheel is normal. Excessive oil can be caused by excessive idle
time, high air inlet restriction, or high crankcase pressure. Do NOT replace the turbocharger.
15. Remove the turbo inlet pipe/elbow and inspect the turbo compressor wheel for damage. Is damage
present?
15.a Yes; replace the turbocharger and verify repairs.
16. Perform a Relative Compression Test using DiagnosticLink. Refer to section "Relative Cylinder Compression Test" .
Was a faulty cylinder found?
16.a Yes; perform a Mechanical Cylinder Compression Test. Refer to section "Mechanical Cylinder Compression Test"
and then repair as necessary. Verify repairs.
NOTICE
The cam journal area is lubricated by oil that has to travel through the rocker shaft. If the
shaft is installed incorrectly, the oil passages do not line up. This will result in insufficient
lubrication and damage to the cam journal and rocker arm bushings.
18. Inspect the exhaust rocker shaft to ensure it is installed with the groove towards the rear of the engine. Is
the exhaust rocker shaft installed correctly?
18.b No; check the camshafts and valve train for damage, and repair as necessary.
12
19. Remove the engine brake solenoids from the cam frame housing. Refer to section "Removal of the Engine Brake
Solenoid" . Go to step 20.
13
20. Inspect the engine brake solenoids for damage, including the screen and O-rings. Is any damage found?
20.a Yes; replace the parts on the engine brake solenoid and verify repairs.
Note : The front engine brake solenoid controls cylinders 1, 2, and 3. The rear engine brake solenoid controls
cylinders 4, 5, and 6.
21. With the front engine brake solenoid removed from the cam frame housing, use a rubber tip blow gun
regulated at 345 kPa (50 psi). Apply 345 kPa (50 psi) into the solenoid outlet port/engine activation port (1)
of the cam frame housing. Do all the actuator pistons in the engine brake rocker arms extend upwards for
the appropriate cylinders?
21.b No; replace the engine brake rocker with the stuck actuator pistons. Refer to section "Removal of the Exhaust
Rocker Shaft Assembly" .
14
22. Remove the air pressure; do the actuator pistons (1) retract?
22.b No; replace the engine brake rocker with the stuck actuator pistons (2). Refer to section "Removal of the
15
23. With the rear engine brake solenoid removed from the cam frame housing, use a rubber-tip blow gun
regulated at 345 kPa (50 psi). Apply 345 kPa (50 psi) into the solenoid outlet port/engine activation port of
the cam frame housing. Do the actuator pistons in the engine brake rocker arms extend outwards for the
appropriate cylinders?
24. Remove the air pressure; do the actuator pistons retract?

25. Check the camshaft timing. Refer to section "Camshaft Timing Verification" . Do camshaft timing marks line up per
procedures?
25.b No; repair as necessary and verify repair.
26. Check valve lash and engine brake adjustments. Refer to section "Setting the Valve and Engine Brake Lash" . Was
valve lash correct?
26.b No; adjust valve lash, assemble the engine and verify repairs.
27. Replace both engine brake solenoids. Refer to section "Installation of the Engine Brake Solenoid" then Go to step 28.
28.a Yes; replace all six exhaust rockers arms that have actuator pistons. Refer to section "Removal of the Exhaust
Rocker Shaft Assembly" and verify repairs.
28.b No; troubleshooting is complete.
16
17.2 Inoperative Engine Brake

Note : There are various conditions that will inhibit the operation of the engine brakes such as oil temperature,
engine rpm, wheel slip and fault codes in other modules. Engine brakes do not enable until engine oil temperature
reaches 50°C (122°F). The engine brakes are most effective at higher engine speeds. Refer to section "Engine
Brake System" in the operator's manual for more information.
3. Check for any engine oil temperature sensor fault codes. Are any engine oil temperature sensor fault codes
present?
3.a Yes; diagnose the engine oil temperature sensor fault codes first.
4. Check for fault codes in the other drivetrain-related modules. Are there any fault codes present in the other
vehicle drivetrain modules?
5. Does the engine have any performance concerns?
5.a Yes; diagnose the engine power performance concerns.
6. Check the CPC parameters to determine if the engine brakes are properly configured. Refer to the GHG17
DDEC Electronic Controls Manual (DDC-SVC-MAN-0127) to verify the parameters. Are the engine brakes
correctly configured?
Engine Brake Switch Programming Options

Parameter Group Parameter Options Default Access
13 Engine Brake Switch 0 = Hardwired 0 = Hardwired DiagnosticLink
Config 1 = Info from J1939 Professional, VEPS
(muxed)
2 = Info from LIN
255 = Not Available
13 2 14 DI Selection 0 = Disable 1 = Engine Brake Low DiagnosticLink
1 = Engine Brake Low Professional, VEPS
2 = Evobus Retarder
Lever Stage 1
3 = CC Hysteresis Low
4 = RemAP IVS1
13 2 15 DI Selection 0 = Disable 1 = Engine Brake High DiagnosticLink
1 = Engine Brake High Professional, VEPS
2 = Evobus Retarder
Lever Stage 2
3 = CC Hysteresis High
4 = RemAP IVS1

6.b No; correct the engine brake parameter configuration.
7. Is the vehicle equipped with a clutch pedal?
8. Use DiagnosticLink to monitor the clutch pedal status. Does the clutch pedal status change when the clutch
pedal is depressed and then released?
17

8.b No; diagnose and repair the clutch pedal switch.
9. Monitor the accelerator pedal position. Is the clutch pedal position zero%?
9.b No; repair the accelerator pedal concern.
10. Use DiagnosticLink to check the engine brake parameter status. Does the engine brake status parameter
change from red (off/disable/false) to green when the engine brake on/off switch is turned on?
10.b No; repair the engine brake on/off switch concern.
11. Monitor the "Engine Brake Low" status. Does the engine brake low status change from red (open) to green
(closed, short to ground) when the engine brake low switch is turned on?

11.b No; diagnose and repair the "engine brake low" switch concern.
12. Monitor the "engine brake medium" status when the engine brake medium on/off switch is turned to the on
position. Does the engine brake low status change from red (open) to green (closed, short to ground) when
the engine brake low switch is turned on?
18

12.b No; diagnose and repair the engine brake medium on/off switch concern.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
13. Start and run the engine until the oil temperature is greater than 50°C (122°F) degrees.
19
15. Remove the rocker cover.

16. Install the cam shaft gear timing cover.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
17. Start and let the engine run at idle.

18. Use DiagnosticLink to activate the front engine brakes. Do the pistons on the front engine brakes move?
18.b No; replace the front engine brake solenoid.
19. Use DiagnosticLink to activate the rear engine brakes. Do the pistons on the rear engine brakes move?
19.b No; replace the rear engine brake solenoid.
21. Adjust the engine brake lash. Remove the camshaft gear cover and reinstall the rocker cover. Release the
vehicle.
20
18.1 Engine Oil Leaks

Note : Detroit™ and the Department of Transportation (DOT) define an external fluid leak as a condition where
fluids are pooling or leaking onto the ground.
Fig 0.1, Example of an Oil Leak - Very Wet with Evidence That Fluid Leaks onto the Ground
1
Fig 0.2, Example of a Seep - Residue Accumulation on the Surface But Remains on that Surface and Does Not Drip onto the Ground
Note : Block porosity is an immediate issue and does not happen over time. If there was a block porosity concern
present, the porosity issue would be evident when the engine is new.
Check as follows:
steps.
2. Was an oil change recently performed on this vehicle?
2.a Yes; check to make sure that the oil filter and drain plug were properly installed and clean any oil
presence spilled from the previous service interval.
3. Is oil pooling or leaking onto the ground?
3.b No; no leaks are present, release the vehicle. Refer to 12WO-2.
4. Check vehicle repair history. Are there any recent repairs that could have resulted in oil spills on the engine
that would appear as an oil leak?
4.a Yes; examine the oil spill area of the engine to make sure it is not being perceived as an oil leak.
Note : Isolating the exact location can be difficult due to fan blast and road grime that can cause the leaking oil to
migrate. Oil leaks tend to move in a downward and rearward direction. Look for the highest point of any oil trace.
5. Inspect the entire vehicle for signs of leaks; note any leaks that could be confused for an engine oil leak.
Was the source of the leak identified as being caused by the engine?
5.b No; identify the non-engine component causing the leak and refer to the component OEM literature for
additional information on troubleshooting/repair of the oil leak.
2
6. Visually inspect the rocker cover gasket, starting at the left front of the engine and continuing down the left
side toward the rear of the engine. Is there an external oil leak coming from the rocker cover gasket?
6.a Yes; replace the rocker cover gasket. Refer to section "Removal of the Rocker Cover" .
7. Visually inspect the Camshaft Position (CMP) sensor for sign of external oil leaks. Is there an external oil
leak coming from the CMP sensor?
7.a Yes; replace the O-ring on the CMP sensor. Refer to section "Removal of the Camshaft Position Sensor" .
8. Visually inspect the camshaft housing seal, starting at the front left and continuing down the left side to the
rear. Pay special attention to the rear corner, as leaks are hard to see in this area. Are there any external
oil leaks coming from the cam frame housing seal?
8.a Yes; replace the cam housing seal. Refer to section "Removal of the Camshaft Housing Assembly" .
9. Visually inspect the cylinder head gasket (1), starting at the left front of the engine and continuing down the
left side to the rear of the engine. Keep in mind that the oil supply ports are at the front and the rear of the
block. Are there any external oil leaks coming from the cylinder head gasket?
9.a Yes; remove the cylinder head and inspect the head gasket oil supply and return seals for damage.
Repair as necessary.
3
1. Cylinder Head Gasket

2. Rocker Cover Gasket
3. Camshaft Housing Cup Plugs (behind crossover pipe)
4. Camshaft Housing Seal
5. Oil Gallery Cup Plugs
6. Front Cover Seal (behind damper)
7. Crankshaft Seal (behind damper)
8. Oil Pan Gasket
Fig 0.3, Front of Engine (steps 10 - 13)
10. Is oil leaking from the front of the engine?

11. Visually inspect the camshaft housing cup plugs (behind the crossover pipe) (3). Are there any external
leaks present?
12. Visually inspect the oil gallery cup plugs (5) in the cylinder block. Are there any external leaks present?
12.a Yes, repair as necessary.
13. Looking behind the damper, inspect for a leaking front cover seal (6) or a leaking crankshaft seal (7). Is
either seal leaking?
4
1. Cylinder Block Cover Plate (if equipped)

5. Turbo Oil Supply and Return
6. Oil Pan Gasket
7. Right Oil Drain Plug
8. Crankcase Breather and Tube
Fig 0.4, Right Side (steps 14 - 20)
14. Is oil leaking from the right side of the engine?

15. Inspect the right side oil drain plug (6). Is there an oil leak present at the oil drain plug?
16. Inspect the crankcase breather (4). Check for leaks at the inlet and outlet tubes, fittings, mounting surface
to the cylinder block, and the housing-to-cap seal. Are there any external oil leaks present?
16.a Yes; Refer to section "High Crankcase Pressure" .
17. Is oil leaking at the boost pipe?
17.a Yes; inspect for loose clamps, seeping, worn or damaged boost pipe and for a dirty air filter. Then Go to
step 18.
5
18. Inspect the turbocharger assembly and related parts.

Refer to section "Inspection of the DD13 and DD15 Turbocharger"
Refer to section "Inspection of the DD16 Turbocharger"
Check for leaks at the inlet and outlet pipes, oil supply and drain lines, speed sensor, speed sensor O-ring,
sealing surface between the turbocharger assembly and the engine block. Are there any external oil leaks
present?
1. Oil Pan Gasket

2. Oil Thermostat Cover Plate Seal
3. Oil Coolant Module (see 13TS-10)
4. Injector Harness Grommets
7. High Pressure Transfer Line Seals
8. Cam Position Sensor O-ring
10. High Pressure Pump Mounting Seal
11. Oil Gallery Cup Plug between High Pressure Pump and Air Compressor
12. Power Steering Pump Mounting Gasket
13. Air Compressor Mounting Seal
14. Left Oil Pan Plug
Fig 0.5, Left Side (steps 21 - 33)
6
19. Is oil leaking from the left side of the engine?

20. Inspect the left side oil pan plug (11). Is there an oil leak present at the oil pan plug?
21. Visually inspect the oil pressure and oil temperature sensors for signs of external oil leaks. Leaks can be
present at the sensors or O-rings. Is there an external oil leak coming from either sensor?
22. Visually inspect the injector harness grommets (1). Are there any external leaks present?
22.a Yes; replace the injector harness grommets.
23. Visually inspect the high pressure fuel injector line seals for each cylinder. Are any of the high pressure fuel
injector line seals leaking?
23.a Yes; replace the high pressure fuel line injector line seal(s) that are leaking.
Note : When inspecting the oil coolant module, consider that oil might be spilled around the filler neck and oil filter
cap area during service intervals. These spills can sometimes lead to misdiagnosis.
24. Inspect the oil coolant module. Check for leaks at the oil fill neck, oil filter cap, oil thermostat cover, plugs,
and around the sealing surface between the oil coolant module and the engine block. Are there any
external oil leaks present?
7

25. Inspect the oil dipstick tube. Are there any external oil leaks present?
26. Inspect the cylinder block oil gallery cup plug, located two inches under the high pressure fuel pump (8). Is
there an external oil leak at the cup plug?
26.a Yes; replace the cup plug. Refer to section "Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump" .
27. Check for leaks at the High Pressure Fuel Pump (HPFP) (7). Are there any external oil leaks at the HPFP
weep hole or where the HPFP mates to the engine block?
28. Remove the HPFP and inspect its camshaft seal. Is damage present?
28.a Yes; install a new HPFP and mounting O-ring.
28.b No; install a new mounting O-ring and reinstall the HPFP.
29. Inspect the air compressor assembly; check for oil leaks at the compressor's cup plug. Are there any
30. Inspect the air compressor flange where it mates to the engine block. Is there an external oil leak present?
30.a Yes; remove the air compressor, clean the area, replace the O-ring, and reinstall the air compressor.
31. Inspect the seal between the rear of the air compressor and the power steering pump. Is there an external
oil leak present?
31.a Yes; remove the power steering pump, replace the seal, and reinstall the power steering pump.
8
1. Oil Pan Gasket

2. Access Plate for #3 Idler
4. Camshaft Housing Cup Plugs
8. Rear Crank Seal (behind flywheel)
9. Flywheel Housing Gasket
Fig 0.6, Back of Engine (steps 34 to 38)
32. Visually inspect the camshaft housing cup plugs (1). Is there an external oil leak present?
33. Visually inspect the camshaft housing seal (3). Is there an external oil leak present?
34. Visually inspect the access plate for #5 idler (4). Is there an external oil leak present?
9
36. Visually inspect the flywheel housing for leaks (6). Is there a leak on the lower 6 inches of the flywheel
housing?
36.b No; the oil leak is generated by either the flywheel housing gasket or the rear crankshaft seal. Inspect
and repair as necessary.
Note : For oil pan gasket warranty submissions, you may choose to use the image below to mark the location of
the leak on the oil pan gasket. When replacing an oil pan gasket, Refer to section "Installation of the Oil Pan".
37. Inspect the oil pan starting at the front of the engine working towards the rear of the engine. Is there an
external oil leak present?

37.b No; Refer to section "Engine Oil Leaks - Oil Developer Method" .
10
18.2 Engine Oil Leaks - Oil Developer Method

This test is only to be performed after determining the area of the engine containing the leak. Prior to completing
this test complete the Symptom Oil Leaks diagnostics, refer to "Symptom Diagnostics - Oil Leaks" to determine
the area of the engine where the leak is most evident. The purpose of this procedure is to help narrow down an oil
leak when an engine is heavily coated with grime or oil, making it difficult to identify the source of the oil leak.
fluids are pooling up or leaking onto the ground.
Fig 0.7, Example of an Oil Leak: Very Wet with Evidence that Fluid Leaks onto the Ground
11
Fig 0.8, Example of a Seep: Residue Accumulation on the Surface but Remains on that Surface and does not Drip onto the Ground
Check as follows:
Note : When diagnosing an engine oil leak, the source and location of the leak MUST be positively identified prior
to repair.
steps.
2. Inspect the engine for any oil leaks. If oil leaks are present, record the location of the oil leak.
WARNING
FIRE HAZARD
3. Steam clean the engine. Refer to section "Enhanced Steam Clean" .
WARNING
ENGINE EXHAUST
4. Start a Parked Regen and allow it to run for 30 minutes. This will allow the engine to reach operating
temperature and to run through various rpm ranges.
12
5. Turn ignition ON (key ON, engine OFF).

Note : On hard-to-reach areas you may need to attach tube extender to the end of aerosol can.
6. Spray a thin even layer of Magnaflux Spotcheck SKD-S2 Aerosol Developer (commonly known as
Spotcheck Developer) on the suspected area. Additional coating may be necessary if the area is heavily
covered with road grime or debris.
7. Allow the Spotcheck Developer to dry for two minutes.
8. The Spotcheck Developer will turn white over dry areas. It will leave a white haze over any area where
fresh oil is not present. Fresh oil leaks will show as a damp or wet trace of oil.
Spotcheck Developer Sprayed on a Leaking Cylinder Block Cover Plate, Allowed Two Minutes to Dry. The
Developer Will Only Turn White on the Areas that Do Not Have Fresh Oil.
13
Spotcheck Developer Sprayed on a Leaking Crankcase Breather, Allowed Two Minutes to Dry. The Developer
Will Only Turn White on the Areas That Do Not Have Fresh Oil.
14
Spotcheck Developer Sprayed on a Leaking Cam Housing Cup Plug, Allowed Two Minutes to Dry. The
15
Spotcheck Developer Sprayed on a Leaking Oil Gallery Cup Plug, Allowed Two Minutes to Dry. The Developer
16
Spotcheck Developer Sprayed on a Leaking Oil Coolant Module, Allowed Two Minutes to Dry. The Developer
17
Spotcheck Developer Will Leave a White Haze Over Areas Where Fresh Oil is Not Present, Allowed Two
Minutes to Dry. The Black Areas Indicate Fresh Oil.
9. Identify the source of the oil leak by observing the visible fresh oil on top of the Spotcheck Developer and
tracing it down to the source of the oil leak.
18
Symptom Diagnostics - Engine Oil Leaks
18.1 Engine Oil Leaks

fluids are pooling or leaking onto the ground.
Fig 18.9, Example of an Oil Leak - Very Wet with Evidence That Fluid Leaks onto the Ground
19
Fig 18.10, Example of a Seep - Residue Accumulation on the Surface But Remains on that Surface and Does Not Drip onto the
Ground
Note : Block porosity is an immediate issue and does not happen over time. If there was a block porosity concern
present, the porosity issue would be evident when the engine is new.
Check as follows:
steps.
2. Was an oil change recently performed on this vehicle?
2.a Yes; check to make sure that the oil filter and drain plug were properly installed and clean any oil
presence spilled from the previous service interval.
3. Is oil pooling or leaking onto the ground?
3.b No; no leaks are present, release the vehicle.
4. Check vehicle repair history. Are there any recent repairs that could have resulted in oil spills on the engine
that would appear as an oil leak?
4.a Yes; examine the oil spill area of the engine to make sure it is not being perceived as an oil leak.
Note : Isolating the exact location can be difficult due to fan blast and road grime that can cause the leaking oil to
migrate. Oil leaks tend to move in a downward and rearward direction. Look for the highest point of any oil trace.
5. Inspect the entire vehicle for signs of leaks; note any leaks that could be confused for an engine oil leak.
Was the source of the leak identified as being caused by the engine?
5.b No; identify the non-engine component causing the leak and refer to the component OEM literature for
additional information on troubleshooting/repair of the oil leak.
20
6. Visually inspect the rocker cover gasket, starting at the left front of the engine and continuing down the left
side toward the rear of the engine. Is there an external oil leak coming from the rocker cover gasket?
6.a Yes; replace the rocker cover gasket. Refer to section "Removal of the Rocker Cover" .
7. Visually inspect the Camshaft Position (CMP) sensor for sign of external oil leaks. Is there an external oil
leak coming from the CMP sensor?
7.a Yes; replace the O-ring on the CMP sensor. Refer to section "Removal of the Camshaft Position Sensor" .
8. Visually inspect the camshaft housing seal, starting at the front left and continuing down the left side to the
rear. Pay special attention to the rear corner, as leaks are hard to see in this area. Are there any external
oil leaks coming from the cam frame housing seal?
9. Visually inspect the cylinder head gasket (1), starting at the left front of the engine and continuing down the
left side to the rear of the engine. Keep in mind that the oil supply ports are at the front and the rear of the
block. Are there any external oil leaks coming from the cylinder head gasket?
9.a Yes; remove the cylinder head and inspect the head gasket oil supply and return seals for damage.
Repair as necessary.
21

3. Camshaft Housing Cup Plugs (behind crossover pipe)
5. Oil Gallery Cup Plugs
6. Front Cover Seal (behind damper)
7. Crankshaft Seal (behind damper)
8. Oil Pan Gasket
Fig 18.11, Front of Engine (steps 10 - 13)
10. Is oil leaking from the front of the engine?

11. Visually inspect the camshaft housing cup plugs (behind the crossover pipe) (3). Are there any external
leaks present?
12. Visually inspect the oil gallery cup plugs (5) in the cylinder block. Are there any external leaks present?
13. Looking behind the damper, inspect for a leaking front cover seal (6) or a leaking crankshaft seal (7). Is
either seal leaking?
22
1. Cylinder Block Cover Plate (if equipped)

5. Turbo Oil Supply and Return
6. Oil Pan Gasket
7. Right Oil Drain Plug
8. Crankcase Breather and Tube
Fig 18.12, Right Side (steps 14 - 20)
14. Is oil leaking from the right side of the engine?

15. Inspect the right side oil drain plug (6). Is there an oil leak present at the oil drain plug?
16. Inspect the crankcase breather (4). Check for leaks at the inlet and outlet tubes, fittings, mounting surface
to the cylinder block, and the housing-to-cap seal. Are there any external oil leaks present?
16.a Yes; Refer to section "High Crankcase Pressure" .
17. Is oil leaking at the boost pipe?
17.a Yes; inspect for loose clamps, seeping, worn or damaged boost pipe and for a dirty air filter. Then Go to
step 18.
23
18. Inspect the turbocharger assembly and related parts.

Check for leaks at the inlet and outlet pipes, oil supply and drain lines, speed sensor, speed sensor O-ring,
sealing surface between the turbocharger assembly and the engine block. Are there any external oil leaks
present?
1. Oil Pan Gasket

2. Oil Thermostat Cover Plate Seal
3. Oil Coolant Module (see 13TS-10)
4. Injector Harness Grommets
7. High Pressure Transfer Line Seals
8. Cam Position Sensor O-ring
10. High Pressure Pump Mounting Seal
11. Oil Gallery Cup Plug between High Pressure Pump and Air Compressor
12. Power Steering Pump Mounting Gasket
13. Air Compressor Mounting Seal
14. Left Oil Pan Plug
Fig 18.13, Left Side (steps 21 - 33)
24
19. Is oil leaking from the left side of the engine?

20. Inspect the left side oil pan plug (11). Is there an oil leak present at the oil pan plug?
21. Visually inspect the oil pressure and oil temperature sensors for signs of external oil leaks. Leaks can be
present at the sensors or O-rings. Is there an external oil leak coming from either sensor?
22. Visually inspect the injector harness grommets (1). Are there any external leaks present?
22.a Yes; replace the injector harness grommets.
23. Visually inspect the high pressure fuel injector line seals for each cylinder. Are any of the high pressure fuel
injector line seals leaking?
23.a Yes; replace the high pressure fuel line injector line seal(s) that are leaking.
Note : When inspecting the oil coolant module, consider that oil might be spilled around the filler neck and oil filter
cap area during service intervals. These spills can sometimes lead to misdiagnosis.
24. Inspect the oil coolant module. Check for leaks at the oil fill neck, oil filter cap, oil thermostat cover, plugs,
and around the sealing surface between the oil coolant module and the engine block. Are there any
25

25. Inspect the oil dipstick tube. Are there any external oil leaks present?
26. Inspect the cylinder block oil gallery cup plug, located two inches under the high pressure fuel pump (8). Is
there an external oil leak at the cup plug?
26.a Yes; replace the cup plug. Refer to section "Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump" .
27. Check for leaks at the High Pressure Fuel Pump (HPFP) (7). Are there any external oil leaks at the HPFP
weep hole or where the HPFP mates to the engine block?
28. Remove the HPFP and inspect its camshaft seal. Is damage present?
28.a Yes; install a new HPFP and mounting O-ring.
28.b No; install a new mounting O-ring and reinstall the HPFP.
29. Inspect the air compressor assembly; check for oil leaks at the compressor's cup plug. Are there any
30. Inspect the air compressor flange where it mates to the engine block. Is there an external oil leak present?
30.a Yes; remove the air compressor, clean the area, replace the O-ring, and reinstall the air compressor.
31. Inspect the seal between the rear of the air compressor and the power steering pump. Is there an external
oil leak present?
31.a Yes; remove the power steering pump, replace the seal, and reinstall the power steering pump.
26
1. Oil Pan Gasket

4. Camshaft Housing Cup Plugs
8. Rear Crank Seal (behind flywheel)
9. Flywheel Housing Gasket
Fig 18.14, Back of Engine (steps 34 to 38)
32. Visually inspect the camshaft housing cup plugs (1). Is there an external oil leak present?
33. Visually inspect the camshaft housing seal (3). Is there an external oil leak present?
27
36. Visually inspect the flywheel housing for leaks (6). Is there a leak on the lower 6 inches of the flywheel
housing?
36.b No; the oil leak is generated by either the flywheel housing gasket or the rear crankshaft seal. Inspect
and repair as necessary.
Note : For oil pan gasket warranty submissions, you may choose to use the image below to mark the location of
the leak on the oil pan gasket. When replacing an oil pan gasket, Refer to section "Installation of the Oil Pan" .
37. Inspect the oil pan starting at the front of the engine working towards the rear of the engine. Is there an
external oil leak present?

37.b No; Refer to section "Engine Oil Leaks - Oil Developer Method" .
28
18.2 Engine Oil Leaks - Oil Developer Method

This test is only to be performed after determining the area of the engine containing the leak. Prior to completing
this test complete the Symptom Oil Leaks diagnostics, refer to "Symptom Diagnostics - Oil Leaks" to determine
the area of the engine where the leak is most evident. The purpose of this procedure is to help narrow down an oil
leak when an engine is heavily coated with grime or oil, making it difficult to identify the source of the oil leak.
fluids are pooling up or leaking onto the ground.
Fig 18.15, Example of an Oil Leak: Very Wet with Evidence that Fluid Leaks onto the Ground
29
Fig 18.16, Example of a Seep: Residue Accumulation on the Surface but Remains on that Surface and does not Drip onto the
Ground
Check as follows:
Note : When diagnosing an engine oil leak, the source and location of the leak MUST be positively identified prior
to repair.
steps.
2. Inspect the engine for any oil leaks. If oil leaks are present, record the location of the oil leak.
WARNING
FIRE HAZARD
3. Steam clean the engine. Refer to section "Enhanced Steam Clean" .
WARNING
ENGINE EXHAUST
4. Start a Parked Regen and allow it to run for 30 minutes. This will allow the engine to reach operating
temperature and to run through various rpm ranges.
30

Note : On hard-to-reach areas you may need to attach tube extender to the end of aerosol can.
6. Spray a thin even layer of Magnaflux Spotcheck SKD-S2 Aerosol Developer (commonly known as
Spotcheck Developer) on the suspected area. Additional coating may be necessary if the area is heavily
covered with road grime or debris.
7. Allow the Spotcheck Developer to dry for two minutes.
8. The Spotcheck Developer will turn white over dry areas. It will leave a white haze over any area where
fresh oil is not present. Fresh oil leaks will show as a damp or wet trace of oil.
Spotcheck Developer Sprayed on a Leaking Cylinder Block Cover Plate, Allowed Two Minutes to Dry. The
31
Spotcheck Developer Sprayed on a Leaking Crankcase Breather, Allowed Two Minutes to Dry. The Developer
32
Spotcheck Developer Sprayed on a Leaking Cam Housing Cup Plug, Allowed Two Minutes to Dry. The
33
Spotcheck Developer Sprayed on a Leaking Oil Gallery Cup Plug, Allowed Two Minutes to Dry. The Developer
34
Spotcheck Developer Sprayed on a Leaking Oil Coolant Module, Allowed Two Minutes to Dry. The Developer
35
Spotcheck Developer Will Leave a White Haze Over Areas Where Fresh Oil is Not Present, Allowed Two
Minutes to Dry. The Black Areas Indicate Fresh Oil.
9. Identify the source of the oil leak by observing the visible fresh oil on top of the Spotcheck Developer and
tracing it down to the source of the oil leak.
36
19.1 Diesel Fuel Contamination

When raw fuel is present in the Aftertreatment Device (ATD), the source of the fuel must be diagnosed and
repaired before cleaning the aftertreatment. .
After repairing the source of the raw fuel, follow the steps below to try to recover the aftertreatment from the fuel
contamination.
Check as follows:
1. Remove the Diesel Particulate Filter (DPF) from the aftertreatment.
NOTICE
Cracks may be symmetrical along the structure or in a webbed pattern indicating
extensive cell damage in the interior of the substrate.
2. Inspect the DPF(s) for any signs of face cracking. Are there any vertical cracks (1, 2) in the DPF substrate?
2.a Yes; replace the DPF(s).
3. Inspect the face of the DPF(s) for any signs of burn-through or melting of the substrate cells (see graphic
below). This would indicate the DPF overheated due to the raw fuel present in the ATD. Are any of the cells
damaged due to the melted substrate?
1

4. If the DPF has no physical damage, turn the DPF(s) upside down to allow for any raw fuel still present
within the DPF filter substrate to drain. The DPF should sit for a minimum of 10 hours.
5. Inspect the Diesel Oxidation Catalyst (DOC) for any sign of cracking. Are there any cracks in the DOC?
2
5.a Yes; for a 1-BOX™ emissions package, replace the DOC/Selective Catalytic Reduction (SCR) module.
For a Two-Box option, replace the DOC.
5.b No; for a 1-Box™ emissions package, Go to step 6. For a Two-Box option, Go to step 7.
6. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for pooling fuel. Is there
fuel present in the DOC/SCR?
6.a Yes; remove the DOC/SCR module and rotate it in different directions, allowing the fuel to drain. Use
shop towels to adsorb the fuel. Let the module drain for a minimum of 10 hours.
7. Clean the exhaust system piping from the turbocharger outlet to the aftertreatment inlet, removing any
remaining fuel.
8. Reassemble and install the Aftertreatment System (ATS).
3
WARNING
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WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
NOTICE
Running the engine at idle for one hour MUST be done before performing a parked
regeneration. Failure to do so may result in damaging the Aftertreatment System.
9. Run the engine at idle for one hour. Continuously monitor the ATD temperature. If the temperatures exceed
621°C (1150°F), depress the accelerator pedal position to 100%. This will maximize airflow through the
aftertreatment and reduce internal temperatures.
10. Check for leaks and active fault codes. Are any leaks or active fault codes present?
10.a Yes; repair as necessary. Go to step 11.
11. Is there any smoke coming from the tailpipe after the one-hour idle burn?
11.a Yes; run the engine at high idle for a maximum of three hours or until the exhaust system stops
smoking. Go to step 12.
WARNING
HOT EXHAUST
During parked regeneration the exhaust gases will be extremely HOT and could cause a
fire if directed at combustible materials. The vehicle must be parked outside.
NOTICE
Increasing the accelerator pedal position to 100% will cancel the parked regeneration and
maximize airflow across the ATS for cooling purposes.
12. Perform a parked regeneration. Monitor DOC outlet temperature values, DPF outlet temperature values
and SCR outlet temperature values. If any of these temperature values rise above 650°C (1200°F),
increase the accelerator pedal position to 100% for one minute. Are any fault codes present?
4
12.a Yes; if fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are present, replace the DOC/SCR module and
the DPF(s). Verify repair.
12.b No; if fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are NOT present, Go to step 13.
13. Did the parked regeneration have to be cancelled?
WARNING
HOT EXHAUST
14. After a 30-minute engine cold soak from the first parked regeneration, perform a second parked
regeneration. Monitor DOC outlet temperature values, DPF outlet temperature values and SCR outlet
temperature values. Did any of these temperature values rise above 650°C (1200°F)?
14.a Yes; replace the DOC/SCR module and the DPF(s). Verify repair.
WARNING
HOT EXHAUST
15. During the last parked regeneration, was NOx conversion efficiency at 85% or better?
15.a Yes; release the vehicle.
15.b No; replace the aftertreatment.
5
19.2 Coolant Contamination

When coolant is present in the aftertreatment, the source of the coolant must be diagnosed and repaired before
cleaning the aftertreatment. .
After repairing the source of the coolant, follow the steps below to try to recover the aftertreatment from the
coolant contamination.
Check as follows:
NOTICE
below). Are any of the cells damaged due to the melted substrate?
6

4. Since the DPF has no physical damage, turn the DPF(s) upside down to allow for any coolant still present
within the DPF filter substrate to drain.
7
5.b No; for a 1-BOX™emissions package, Go to step 6. For a Two-Box option, Go to step 7.
6. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for any pools of
coolant. Is there coolant present within the DOC/SCR module?
6.a Yes; use shop towels to adsorb and remove as much of the coolant as possible.
7. Clean the exhaust system piping from the turbocharger outlet to the aftertreatment inlet.
8. Reassemble the Aftertreatment System (ATS).
8
WARNING
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NOTICE
9. Run the engine at idle for one hour.

11.a Yes; run the engine at high idle for a maximum of three hours, or until the exhaust system stops
WARNING
HOT EXHAUST
Note : Increasing the accelerator pedal position to 100% will cancel the parked regeneration and maximize airflow
across the ATS for cooling purposes.
12. Perform a parked regeneration and monitor NOx conversion efficiency. Is the NOx conversion efficiency
above 85%?
9
19.3 Oil Contamination

When oil is present in the aftertreatment, the source of the oil must be diagnosed and repaired before cleaning the
aftertreatment. .
After repairing the source of the oil, follow the steps below to try to recover the aftertreatment from the oil
contamination.
Check as follows:
NOTICE
2.a Yes; the DPF(s) will need replacing. Go to step 3.
3. Inspect the face of the DPF(s) for any signs of burn-through or melting of the substrate cells; see graphic
below. This would indicate the DPF overheated due to the oil present in the ATD. Are any of the cells
10
4. Since the DPF has no physical damage, turn the DPF(s) upside down to allow for any oil still present within
the DPF filter substrate to drain. The DPF should sit for a minimum of 10 hours.
5. Inspect the DOC for any sign of cracking. Are there any cracks in the DOC?
5.a Yes; for a 1-BOX, replace the DOC/Selective Catalytic Reduction (SCR) module. For a Two-Box,
replace the DOC. Clean the exhaust piping from the turbo outlet to the aftertreatment inlet before
installing the aftertreatment. Verify repair.
5.b No; for a 1-BOX, go to step 6. For a Two-Box, Go to step 7.
11
6. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for pooling oil. Is there
oil present in the DOC/SCR module?
6.a Yes; use shop towels to adsorb and clean out the oil.
WARNING
PERSONAL INJURY
12
NOTICE
WARNING
HOT EXHAUST
12. Perform a parked regeneration. Monitor DOC, DPF, and SCR outlet temperature sensors. If any of these
temperature values rise above 650°C (1200°F), increase the accelerator pedal position to 100% for one
minute. Are any active fault codes present?
12.a If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are present, replace the DOC/SCR module and the
DPF(s). Verify repair.
12.b If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are NOT present and the parked regeneration was
cancelled, Go to step 14.
WARNING
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regeneration. Monitor DOC, DPF, and SCR outlet temperature values. Did any of these temperature values
rise above 650°C (1200°F)?
13
WARNING
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15. During the last parked regeneration, was NOx conversion efficiency 85% or better?
14
Symptom Diagnostics - Fluid in the Aftertreatment
19.1 Diesel Fuel Contamination

When raw fuel is present in the Aftertreatment Device (ATD), the source of the fuel must be diagnosed and
repaired before cleaning the aftertreatment.
After repairing the source of the raw fuel, follow the steps below to try to recover the aftertreatment from the fuel
contamination.
Check as follows:
NOTICE
1.a Yes; replace the DPF(s). Go to step 4.
below). This would indicate the DPF overheated due to the raw fuel present in the ATD. Are any of the cells
15
2.a Yes; replace the DPF(s). Go to step 4.

3. If the DPF has no physical damage, turn the DPF(s) upside down to allow for any raw fuel still present
within the DPF filter substrate to drain. The DPF should sit for a minimum of 10 hours. Go to step 4.
16
For a Two-Box option, replace the DOC. Go to step 5.
4.b No; for a 1-Box™ emissions package, Go to step 8. For a Two-Box option, Go to step 9.
remaining fuel. Reassemble and install the Aftertreatment System (ATS). Go to step 6.
WARNING
HOT EXHAUST
6. Perform a parked regeneration with new aftertreatment parts. Did the parked regeneration complete without
any issues?
17

6.b No; troubleshoot active fault code.
7. If previously disabled, re-enable Progressive Shift. Repairs are complete; Test-E Fuel System
troubleshooting is completed.
8. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for pooling fuel. Is there
fuel present in the DOC/SCR?
8.a Yes; remove the DOC/SCR module and rotate it in different directions, allowing the fuel to drain. Use
shop towels to adsorb the fuel. Let the module drain for a minimum of 10 hours. Go to step 9.
remaining fuel.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Note : Progressive Shift will need to be re-enabled at the end of the diagnostic.
11. If enabled, disable Progressive Shift, PGR 023/040, prior to running engine.
NOTICE
18
WARNING
HOT EXHAUST
NOTICE
Increasing the accelerator pedal position to 100% will cancel the parked regeneration and
maximize airflow across the ATS for cooling purposes.
15. Perform a parked regeneration. Monitor DOC outlet temperature values, DPF outlet temperature values
and SCR outlet temperature values. If any of these temperature values rise above 650°C (1200°F),
increase the accelerator pedal position to 100% for one minute. Are any fault codes present?
15.a Yes; if fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are present, replace the DOC/SCR module and
the DPF(s). Go to step 19.
15.b No; if fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are NOT present, Go to step 16.
WARNING
HOT EXHAUST
WARNING
HOT EXHAUST
18. During the last parked regeneration, was NOx conversion efficiency at 85% or better?
18.b No; replace the aftertreatment. Go to step 19.
19
WARNING
HOT EXHAUST
19. Perform a parked regeneration with new aftertreatment parts. Did the parked regeneration complete without
any issues?
20. If previously disabled, re-enable Progressive Shift. Repairs are complete; Test-E - Three-Filter Fuel System
has ended.
20
19.2 Coolant Contamination

When coolant is present in the aftertreatment, the source of the coolant must be diagnosed and repaired before
cleaning the aftertreatment. .
After repairing the source of the coolant, follow the steps below to try to recover the aftertreatment from the
coolant contamination.
Check as follows:
NOTICE
below). Are any of the cells damaged due to the melted substrate?
21

4. Since the DPF has no physical damage, turn the DPF(s) upside down to allow for any coolant still present
within the DPF filter substrate to drain.
22
5.b No; for a 1-BOX™emissions package, Go to step 6. For a Two-Box option, Go to step 7.
6. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for any pools of
coolant. Is there coolant present within the DOC/SCR module?
6.a Yes; use shop towels to adsorb and remove as much of the coolant as possible.
8. Reassemble the Aftertreatment System (ATS).
23
WARNING
PERSONAL INJURY
NOTICE
9. Run the engine at idle for one hour.

11.a Yes; run the engine at high idle for a maximum of three hours, or until the exhaust system stops
WARNING
HOT EXHAUST
12. Perform a parked regeneration and monitor NOx conversion efficiency. Is the NOx conversion efficiency
above 85%?
24
19.3 Oil Contamination

When oil is present in the aftertreatment, the source of the oil must be diagnosed and repaired before cleaning the
aftertreatment. .
After repairing the source of the oil, follow the steps below to try to recover the aftertreatment from the oil
contamination.
Check as follows:
NOTICE
3. Inspect the face of the DPF(s) for any signs of burn-through or melting of the substrate cells; see graphic
below. This would indicate the DPF overheated due to the oil present in the ATD. Are any of the cells
25
4. Since the DPF has no physical damage, turn the DPF(s) upside down to allow for any oil still present within
the DPF filter substrate to drain. The DPF should sit for a minimum of 10 hours.
5. Inspect the DOC for any sign of cracking. Are there any cracks in the DOC?
5.a Yes; for a 1-BOX, replace the DOC/Selective Catalytic Reduction (SCR) module. For a Two-Box,
replace the DOC. Clean the exhaust piping from the turbo outlet to the aftertreatment inlet before
installing the aftertreatment. Verify repair.
5.b No; for a 1-BOX, go to step 6. For a Two-Box, Go to step 7.
26
6. For a 1-BOX, inspect the DOC/SCR module, especially in the SCR mixing chamber for pooling oil. Is there
oil present in the DOC/SCR module?
6.a Yes; use shop towels to adsorb and clean out the oil.
WARNING
PERSONAL INJURY
27
NOTICE
WARNING
HOT EXHAUST
12. Perform a parked regeneration. Monitor DOC, DPF, and SCR outlet temperature sensors. If any of these
temperature values rise above 650°C (1200°F), increase the accelerator pedal position to 100% for one
minute. Are any active fault codes present?
12.a If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are present, replace the DOC/SCR module and the
DPF(s). Verify repair.
12.b If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are NOT present and the parked regeneration was
cancelled, Go to step 14.
WARNING
HOT EXHAUST
regeneration. Monitor DOC, DPF, and SCR outlet temperature values. Did any of these temperature values
rise above 650°C (1200°F)?
28
WARNING
HOT EXHAUST
15. During the last parked regeneration, was NOx conversion efficiency 85% or better?
29
20.1 High Crankcase Pressure

Check as follows:
Note : This procedure should be completed for High Crankcase Pressure. If the crankcase breather is leaking oil,
Refer to section "Engine Oil Leaks".
1. Verify that the crankcase pressure is high. Refer to section "Crankcase Pressure Test" .
2. Inspect the crankcase breather. Check for leaks at the inlet and outlet tubes, fittings, mounting surface to
the cylinder block, and the housing-to-cap seal. Are there any external oil leaks present?
2.a Yes; repair or replace the crankcase breather, if needed. Refer to section "Removal of the Crankcase Breather
Assembly" and Go to step 8.

3. Is the vehicle slow at building air pressure?
3.a Yes; Refer to section "Will Not Build Air Pressure or Slow to Build Air Pressure" .
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
4. Perform a parked regen and observe DOC inlet pressure. Was the DOC inlet pressure above 6 kPa (0.8
psi)?
4.a Yes; diagnose the cause for high DOC inlet pressure and verify the repair.
5. Inspect the crankcase breather for an obstruction in the breather inlet passage and tube? Is an obstruction
present?
5.a Yes; clear the obstruction or replace the crankcase breather, if needed. Refer to section "Removal of the
Crankcase Breather Assembly" , then Go to step 6.

6. Verify the repair by running a crankcase pressure test; Refer to section "Crankcase Pressure Test" . Is the
crankcase pressure high?
7. Was the crankcase breather replaced at any point during this procedure?
7.b No; replace the crankcase breather. Refer to section "Removal of the Crankcase Breather Assembly" , then, Go to
step 8.
8. Perform a Relative Cylinder Compression Test; Refer to section "Relative Cylinder Compression Test" . Did the
Relative Cylinder Compression Test identify a possible suspect cylinder?
1
8.b No; repair is complete.

9. Perform a Mechanical Cylinder Compression Test; Refer to section "Mechanical Cylinder Compression Test" . Did the
Mechanical Cylinder Compression Test pass?
9.a Yes; replace the turbocharger and verify repair.
For DD13 and DD15; Refer to section "Removal of the DD13 and DD15 Turbocharger"
For DD16; Refer to section "Removal of the DD16 Turbocharger"
9.b No; Refer to section "Symptom Diagnostics - Low Engine Compression" .
2
Symptom Diagnostics - High Crankcase Pressure
20.1 High Crankcase Pressure

Check as follows:
Note : This procedure should be completed for High Crankcase Pressure. If the crankcase breather is leaking oil,
Refer to section "Engine Oil Leaks" .
1. Verify that the crankcase pressure is high. Refer to section "Crankcase Pressure Test" .
2. Inspect the crankcase breather. Check for leaks at the inlet and outlet tubes, fittings, mounting surface to
the cylinder block, and the housing-to-cap seal. Are there any external oil leaks present?
2.a Yes; repair or replace the crankcase breather, if needed. Refer to section "Removal of the Crankcase Breather
Assembly" and Go to step 8.

3. Is the vehicle slow at building air pressure?
3.a Yes; Refer to section "Will Not Build Air Pressure or Slow to Build Air Pressure" .
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
4. Perform a parked regen and observe DOC inlet pressure. Was the DOC inlet pressure above 6 kPa (0.8
psi)?
4.a Yes; diagnose the cause for high DOC inlet pressure and verify the repair.
5. Inspect the crankcase breather for an obstruction in the breather inlet passage and tube? Is an obstruction
present?
5.a Yes; clear the obstruction or replace the crankcase breather, if needed. Refer to section "Removal of the
Crankcase Breather Assembly" , then Go to step 6.

6. Verify the repair by running a crankcase pressure test; Refer to section "Crankcase Pressure Test" . Is the
crankcase pressure high?
7. Was the crankcase breather replaced at any point during this procedure?
7.b No; replace the crankcase breather. Refer to section "Removal of the Crankcase Breather Assembly" , then, Go to
step 8.
8. Perform a Relative Cylinder Compression Test; Refer to section "Relative Cylinder Compression Test" . Did the
Relative Cylinder Compression Test identify a possible suspect cylinder?
3

9. Perform a Mechanical Cylinder Compression Test; Refer to section "Mechanical Cylinder Compression Test" . Did the
Mechanical Cylinder Compression Test pass?
9.a Yes; replace the turbocharger and verify repair.
For DD13 and DD15; Refer to section "Removal of the DD13 and DD15 Turbocharger"
For DD16; Refer to section "Removal of the DD16 Turbocharger"
9.b No; Refer to section "Symptom Diagnostics - Low Engine Compression" .
4
21.1 Unable to Start a Regeneration

This diagnostic is typically Unable to Start a Regeneration.
Check as follows:
1. Connect using DiagnosticLink™ and then turn the ignition ON (key ON, engine OFF).
2. Using DiagnosticLink, check for fault codes. Are fault codes present?
2.a Yes; troubleshoot all codes first.
WARNING
HOT EXHAUST
Note : If the unit is in zone zero, the system will not initiate a parked regeneration without using DiagnosticLink.
3. Using DiagnosticLink, go to Service Routines/DPF System/Perform Parked Regeneration/Start. Does the
regeneration start successfully?
3.a Yes; let the regeneration complete. If any fault(s) becomes active during regeneration, follow
troubleshooting for that fault(s).
4. Using DiagnosticLink, monitor the Regen Inhibit Switch Status. Is the Regen Inhibit Switch Status
On/Active/True?
4.a Yes; turn off the regen inhibit switch and perform a regen.
5. Using DiagnosticLink, monitor vehicle speed. Is vehicle speed 0 mph?
5.b No; refer to OEM service information for diagnostic information. Repair as necessary.
6. Using DiagnosticLink, monitor coolant temperature. Is coolant temperature at least 60ºC (140ºF)?
6.b No; verify thermostat is operating properly and coolant temperature sensor(s) is in operation. Repair as
necessary.
7. Using DiagnosticLink, monitor ASL004: Active Governor Type. Does governor type show Idle Speed
Governor?
7.b No; disengage PTO.
8. Using DiagnosticLink, monitor the clutch switch. Depress and release clutch. Does the clutch switch change
state from ON to OFF to ON?
8.b No; check switch operation and configuration. Repair as necessary.
9. Using DiagnosticLink, monitor the parking brake switch. Disengage and engage parking brakes. Does the
parking brake switch change state from ON to OFF to ON?
10. Using DiagnosticLink, monitor the neutral safety switch (if equipped). Shift automatic transmission into gear,
and back to neutral. Does the neutral safety switch change state (N to R, N to D)?
1
10.b No; check neutral switch operation and configuration. Repair as necessary.
11. Using DiagnosticLink, monitor the regeneration switch. Press and hold switch. Does it change state from
OFF to ON?
11.a Yes; retain a log file of an attempted regeneration and contact the Customer Support Center at (800)
445-1980.
2
21.2 Unable to Complete a Parked Regeneration

Unable to Complete a Parked Regeneration
Check as follows:
1. Connect using DiagnosticLink .
3. Using DiagnosticLink, go to the Identification tab and verify MCM software level. Is the software up to date
with the latest available on the server?
3.b No; update MCM to latest software level and perform a parked regeneration to verify repairs.
4. Are any of the following fault codes present?
• SPN 3246/FMI 0 DPF Outlet Temp very high
• SPN 3250/FMI 0 DOC Outlet Temp very high
• SPN 3480/FMI ALL Hydrocarbon (HC) Doser Fuel Supply Pressure
• SPN 3556/ FMI ALL Regen Temperature out of range
• SPN 51/FMI 2 Intake Throttle Position deviation error
• SPN 3711/FMI 14 High Idle Regen (aborted) - Low Exhaust Temp
• SPN 3713/FMI 14 High Idle Regen (aborted) - Low Regen Temp
• SPN 4077/FMI ALL Hydrocarbon (HC) Doser Fuel Line Pressure
4.a Yes; perform the troubleshooting for the fault code.
5. Using DiagnosticLink (Key ON, Engine OFF), is the barometric pressure reading above 68 kPa(10 psi) and
below 110 kPa(16 psi)?
5.b No; try a test MCM.
6. Compare Inlet Manifold Pressure (IMP) and Barometric Pressure reading. Are both sensors reading within
4.14 kPa (0.6 psi)?
6.b No; replace the Inlet Manifold Pressure sensor.
7. Inspect for plugged ports in the EGR Venturi Pipe. Are the EGR Venturi Pipe ports plugged?
7.a Yes; clean ports using procedure in 14 TS-2 .
8. Inspect complete exhaust system for leaks. Are there exhaust leaks before the ATD?
8.a Yes; repair as needed.
9. Inspect entire air intake system including the Charge Air Cooler (CAC) for loose clamps, leaks and/or
restrictions.
9.a If air intake system leaks or restrictions are found, repair as necessary.
9.b If no air intake system leaks are found, Go to step 10.
3
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
10. Run engine at 1200 rpm for 10 minutes.

11. Monitor DOC Inlet and Outlet temperatures. Are the temperatures within 25°C (45°F) of each other?
12. Disconnect DOC Outlet Temperature Sensor and inspect connector for damaged, bent, spread, or
corroded pins. If Temperature Sensor connector is OK, check connections upstream of the MCM (ATD
harness 10-pin connector pin 5, VIH 31-pin connector pin 17, and MCM 120-pin connector pin 29).
4
12.a If damage is found, repair connector as necessary.

12.b If no damage is found, replace the DOC Outlet Temperature Sensor.
WARNING
HOT EXHAUST
engine speed reach 1100 rpm?
5
13.b No; Refer to section "Unable to Start a Regeneration " .

14. Using DiagnosticLink, monitor DOC inlet temperature. Does the DOC inlet temperature reach 280 °C (536
°F)?
14.b No; Check valve lash and engine brake rocker lash. If either is out of adjustment, readjust the lash and
retest.
15. Using the chart tab in DiagnosticLink, monitor DOC outlet temp and DOC Model Delay. Is there a difference
greater than +/- 55.5°C (100°F) in the last 2/3 of the regen?

15.b No; retain the log file and contact the Customer Support Center at (800) 445-1980.
16. During the above high idle regen, monitor Doser fuel line pressure when Fuel Cutoff Valve is 100%. Is the
Doser fuel line pressure above 275 kPa (40 psi)?
6

16.b No; replace the HC doser block assembly. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " and
then Go to step 18.
Note : Soot can accumulate in the S-pipe under the fuel doser injector valve housing.
17. Inspect fuel line from the doser block assembly to the doser injector valve for kinks. Are there any kinks?
17.a Yes; replace the lines. Go to step 20.
17.b No; replace the doser injector valve and clean port in S-pipe. Go to step 20.
7
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

Note : It may take up to three purge attempts to completely remove air from the system. Do not exceed three
attempts.
19. Using DiagnosticLink, perform a purge hydrocarbon doser service routine.
20. Initialize a high idle regen. Using the chart tab in DiagnosticLink, monitor DOC outlet temp and DOC Model
Delay. Is there a difference of +/- 55.5 ºC (100 ºF) in the last 2/3 of the regen?
8
20.a Yes; Remove ATD and inspect for a pushed out Diesel Oxidation Catalyst (DOC). If DOC damage is
found, Refer to section "SPN 3250/FMI 0 - GHG17" .
20.b No; verify operation is satisfactory and no warning lamps illuminate. If warning lamps illuminate,
troubleshoot the codes. If assistance is required, contact the Customer Support Center at 800-445-
1980. Release the truck.
9
21.3 High Idle Regeneration Initiates -- Runs Indefinitely

This diagnostic is typically high idle regeneration initiates but runs indefinitely.
Note : Truck must be at operating temperature before continuing with this testing.
1. Connect Detroit Diagnostic Link (DDDL) or Detroit Diesel Reprogramming Station (DDRS) and check for
codes. Are codes present?
1.a Yes; repair all codes first.
2. Using DiagnosticLink® (key ON, engine OFF), monitor the intake pressure sensor and compare to baro
pressure sensor. Are the pressures within 0.5 psi of each other?
2.b No; replace the defective sensors.
3. Using DiagnosticLink®, monitor the coolant temperature sensor. Is coolant temperature at least 60 ºC (140
ºF)?
3.b No; verify thermostat is operating properly and coolant temperature sensor(s) is in operation.
4. Check fuel pressure, is it within specifications?
4.b No; locate and repair the cause of low fuel pressure.
5. Verify operation of doser block. Is it operating properly?
6. Verify operation of doser injector. Is it operating properly?
7. Check the doser system for fuel leaks. Is the system leaking?
7.a Yes; repair leaks.
8. Using DiagnosticLink®, monitor DOC outlet temperature. Is DOC outlet temperature at least 260 ºC (500
ºF)?
8.b No; verify DOC outlet temperature sensor operation. Repair as necessary.
9. Using DiagnosticLink®, verify Intake Throttle Valve (ITV) operation. Is the ITV operating properly?
10. Verify DOC operation. Is the DOC operating properly?
10.a Yes; Call Detroit™ Customer Support Center.
10.b No; replace DOC.
10
Symptom Diagnostics - Regeneration
21.1 Unable to Start a Regeneration

This diagnostic is typically Unable to Start a Regeneration.
Check as follows:
1. Connect using DiagnosticLink™ and then turn the ignition ON (key ON, engine OFF).
2. Using DiagnosticLink, check for fault codes. Are fault codes present?
2.a Yes; troubleshoot all codes first.
WARNING
HOT EXHAUST
regeneration start successfully?
3.a Yes; let the regeneration complete. If any fault(s) becomes active during regeneration, follow
troubleshooting for that fault(s).
4. Using DiagnosticLink, monitor the Regen Inhibit Switch Status. Is the Regen Inhibit Switch Status
On/Active/True?
4.a Yes; turn off the regen inhibit switch and perform a regen.
5. Using DiagnosticLink, monitor vehicle speed. Is vehicle speed 0 mph?
5.b No; refer to OEM service information for diagnostic information. Repair as necessary.
6. Using DiagnosticLink, monitor coolant temperature. Is coolant temperature at least 60ºC (140ºF)?
6.b No; verify thermostat is operating properly and coolant temperature sensor(s) is in operation. Repair as
necessary.
7. Using DiagnosticLink, monitor ASL004: Active Governor Type. Does governor type show Idle Speed
Governor?
7.b No; disengage PTO.
8. Using DiagnosticLink, monitor the clutch switch. Depress and release clutch. Does the clutch switch change
state from ON to OFF to ON?
9. Using DiagnosticLink, monitor the parking brake switch. Disengage and engage parking brakes. Does the
parking brake switch change state from ON to OFF to ON?
11
10. Using DiagnosticLink, monitor the neutral safety switch (if equipped). Shift automatic transmission into gear,
and back to neutral. Does the neutral safety switch change state (N to R, N to D)?
10.b No; check neutral switch operation and configuration. Repair as necessary.
11. Using DiagnosticLink, monitor the regeneration switch. Press and hold switch. Does it change state from
OFF to ON?
11.a Yes; retain a log file of an attempted regeneration and contact the Customer Support Center at (800)
445-1980.
12
21.2 Unable to Complete a Parked Regeneration

Unable to Complete a Parked Regeneration
Check as follows:
1. Connect using DiagnosticLink .
3. Using DiagnosticLink, go to the Identification tab and verify MCM software level. Is the software up to date
with the latest available on the server?
3.b No; update MCM to latest software level and perform a parked regeneration to verify repairs.
• SPN 3246/FMI 0 DPF Outlet Temp very high
• SPN 3250/FMI 0 DOC Outlet Temp very high
• SPN 3480/FMI ALL Hydrocarbon (HC) Doser Fuel Supply Pressure
• SPN 3556/ FMI ALL Regen Temperature out of range
• SPN 51/FMI 2 Intake Throttle Position deviation error
• SPN 3711/FMI 14 High Idle Regen (aborted) - Low Exhaust Temp
• SPN 3713/FMI 14 High Idle Regen (aborted) - Low Regen Temp
• SPN 4077/FMI ALL Hydrocarbon (HC) Doser Fuel Line Pressure
5. Using DiagnosticLink (Key ON, Engine OFF), is the barometric pressure reading above 68 kPa(10 psi) and
below 110 kPa(16 psi)?
5.b No; try a test MCM.
6. Compare Inlet Manifold Pressure (IMP) and Barometric Pressure reading. Are both sensors reading within
4.14 kPa (0.6 psi)?
6.b No; replace the Inlet Manifold Pressure sensor.
7. Inspect for plugged ports in the EGR Venturi Pipe. Are the EGR Venturi Pipe ports plugged?
7.a Yes; clean ports using procedure in 14 TS-2 .
8. Inspect complete exhaust system for leaks. Are there exhaust leaks before the ATD?
restrictions.
9.a If air intake system leaks or restrictions are found, repair as necessary.
13
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ENGINE EXHAUST
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10. Run engine at 1200 rpm for 10 minutes.

11. Monitor DOC Inlet and Outlet temperatures. Are the temperatures within 25°C (45°F) of each other?
12. Disconnect DOC Outlet Temperature Sensor and inspect connector for damaged, bent, spread, or
corroded pins. If Temperature Sensor connector is OK, check connections upstream of the MCM (ATD
harness 10-pin connector pin 5, VIH 31-pin connector pin 17, and MCM 120-pin connector pin 29).
14
12.a If damage is found, repair connector as necessary.

12.b If no damage is found, replace the DOC Outlet Temperature Sensor.
WARNING
HOT EXHAUST
engine speed reach 1100 rpm?
15
13.b No; Refer to section "Unable to Start a Regeneration " .

14. Using DiagnosticLink, monitor DOC inlet temperature. Does the DOC inlet temperature reach 280 °C (536
°F)?
14.b No; Check valve lash and engine brake rocker lash. If either is out of adjustment, readjust the lash and
retest.
15. Using the chart tab in DiagnosticLink, monitor DOC outlet temp and DOC Model Delay. Is there a difference
greater than +/- 55.5°C (100°F) in the last 2/3 of the regen?

15.b No; retain the log file and contact the Customer Support Center at (800) 445-1980.
16. During the above high idle regen, monitor Doser fuel line pressure when Fuel Cutoff Valve is 100%. Is the
Doser fuel line pressure above 275 kPa (40 psi)?
16

16.b No; replace the HC doser block assembly. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " and
then Go to step 18.
Note : Soot can accumulate in the S-pipe under the fuel doser injector valve housing.
17. Inspect fuel line from the doser block assembly to the doser injector valve for kinks. Are there any kinks?
17.a Yes; replace the lines. Go to step 20.
17.b No; replace the doser injector valve and clean port in S-pipe. Go to step 20.
17
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ENGINE EXHAUST
WARNING
PERSONAL INJURY

Note : It may take up to three purge attempts to completely remove air from the system. Do not exceed three
attempts.
19. Using DiagnosticLink, perform a purge hydrocarbon doser service routine.
20. Initialize a high idle regen. Using the chart tab in DiagnosticLink, monitor DOC outlet temp and DOC Model
Delay. Is there a difference of +/- 55.5 ºC (100 ºF) in the last 2/3 of the regen?
18
20.a Yes; Remove ATD and inspect for a pushed out Diesel Oxidation Catalyst (DOC). If DOC damage is
found, Refer to section "SPN 3250/FMI 0 - GHG17" .
20.b No; verify operation is satisfactory and no warning lamps illuminate. If warning lamps illuminate,
troubleshoot the codes. If assistance is required, contact the Customer Support Center at 800-445-
1980. Release the truck.
19
21.3 High Idle Regeneration Initiates -- Runs Indefinitely

This diagnostic is typically high idle regeneration initiates but runs indefinitely.
Note : Truck must be at operating temperature before continuing with this testing.
1. Connect Detroit Diagnostic Link (DDDL) or Detroit Diesel Reprogramming Station (DDRS) and check for
codes. Are codes present?
1.a Yes; repair all codes first.
2. Using DiagnosticLink® (key ON, engine OFF), monitor the intake pressure sensor and compare to baro
pressure sensor. Are the pressures within 0.5 psi of each other?
2.b No; replace the defective sensors.
3. Using DiagnosticLink®, monitor the coolant temperature sensor. Is coolant temperature at least 60 ºC (140
ºF)?
3.b No; verify thermostat is operating properly and coolant temperature sensor(s) is in operation.
4. Check fuel pressure, is it within specifications?
4.b No; locate and repair the cause of low fuel pressure.
5. Verify operation of doser block. Is it operating properly?
6. Verify operation of doser injector. Is it operating properly?
7. Check the doser system for fuel leaks. Is the system leaking?
7.a Yes; repair leaks.
8. Using DiagnosticLink®, monitor DOC outlet temperature. Is DOC outlet temperature at least 260 ºC (500
ºF)?
8.b No; verify DOC outlet temperature sensor operation. Repair as necessary.
9. Using DiagnosticLink®, verify Intake Throttle Valve (ITV) operation. Is the ITV operating properly?
10. Verify DOC operation. Is the DOC operating properly?
10.a Yes; Call Detroit™ Customer Support Center.
10.b No; replace DOC.
20
22.1 Symptom Diagnostics - Oil Present at the

Turbocharger Compressor Housing
Note: Some oil residue at the turbocharger compressor housing is acceptable (See figure 1 below). This residue
may look like a soot coating on the compressor housing and will be dry to touch. This residue occurs over a long
period of time usually in combination with high idle time.
Excessive oil (See figure 2 below) in the turbocharger compressor housing will be wet to touch and can be
present from a number of different failure modes;
• High Air Intake restriction
• Boost leaks
• High crankcase pressure
• Obstructed turbo oil drain
• Failed turbo
If the failure mode is one other than a failed turbo, once repaired the turbocharger will no longer pass oil.
If it is uncertain whether the compressor housing is acceptable or excessive, complete the following diagnostics.
Do NOT replace the turbocharger without completing the following diagnostics.
1. Acceptable oil in the turbocharger compressor housing 2. Excessive oil in the turbocharger compressor housing
Check as follows:
1. Apply the parking brake, chock the wheels, and perform any other applicable safety steps.
2. Inspect the Turbocharger.
For DD13 and DD15 : Refer to section "Inspection of the DD13 and DD15 Turbocharger" . Is the turbocharger visually
damaged?
For DD16 : Refer to section "Inspection of the DD16 Turbocharger" . Is the turbocharger visually damaged?
2.a Yes; clean out air systems and replace the turbocharger.
1

3. Connect Diagnostic Link®.
4. Inspect for any active fault codes. Are any fault codes active?
4.a Yes; perform troubleshooting for active fault code(s).
5. Inspect the hood cowl for any debris that may cause a high air intake restriction (ice buildup, leaves, dirt,
etc). Was an obstruction found?
5.a Yes; clean out all debris/obstructions found in hood cowl. Clean out air systems and Go to step 11.
6. Visually inspect the air filter. Is the air filter wet/plugged/obstructed?
6.a Yes; replace the air filter. Clean out air systems and Go to step 11.
7. Check for air system leaks from the turbo compressor to the intake manifold. Were air system leaks found?
7.a Yes; Repair leak(s) as necessary. Clean out air systems and Go to step 11.
8. Perform a crankcase pressure test. Refer to section "Crankcase Pressure Test" . Is crankcase pressure in range?
8.b No; Repair cause of excessive crankcase pressure, clean out all air systems, and Go to step 11.
Note : The turbo drain pipe gasket can cause an obstruction if installed incorrectly.
9. Remove and inspect the turbo oil drain pipe (1) and cylinder block for damage/restrictions. Was
damage/restrictions found?
9.a Yes; replace turbo oil drain pipe (See figure above (1)). Clean out all air systems and Go to step 11.
2

Note : The Turbocharger is a non-serviceable part. Do not remove the compressor housing for cleaning.
10. Clean the inside of the turbocharger compressor elbow (1) .
11. Warm up the engine until oil temperature reaches 60°C (140°F).
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PERSONAL INJURY
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3
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12. Run the engine at 900 rpm for 20 minutes. Is oil present in the previously cleaned turbocharger compressor
elbow ?
1. Clean - no oil passing 2. Oil passing after cleaning
12.a Yes; replace turbocharger. Clean out all air systems .

12.b No; release unit.
4
22.1 Symptom Diagnostics - Oil Present at the

Turbocharger Compressor Housing
Note : It is normal to have some oil present in the turbocharger. This will not affect engine performance.
Possible causes:
• Intake air restriction
• Boost leaks
• High crankcase pressure
• Obstruction in the turbocharger oil drain line
• Failed turbocharger assembly
Note : To clean the air system, use a clean rag to wipe the turbocharger elbow pipe between the turbocharger to
the charge air cooler and the inlet in the charge air cooler.
Check as follows:
NOTICE
The turbocharger is a non-serviceable part and should not be disassembled.
1. Turn the ignition OFF.

2. Inspect the turbocharger for damage. Is the turbocharger damaged?
2.a Yes; determine what caused the damage and repair that issue. Then replace the turbocharger.
5. Check for fault codes. Are there any turbocharger/air flow related fault codes present?
5.a Yes; diagnose the other fault codes first. Once repairs are complete, clean the oil out of the air system
and release the vehicle.
6. Inspect the hood cowl for any obstructions such as leaves, dirt, snow, ice, water etc. Are there any
obstructions present?
5
6
6.a Yes; clear the obstructions, clean the oil out of the air system and release the vehicle.
7. Visually inspect the air filter. Is the air filter excessively dirty or restricted?
7.a Yes; replace the air filter, clean the oil out of the air system and release the vehicle.
8. Check for leaks in the charge air system. Are there any leaks in the charge air system?
8.a Yes; repair the leaks, clean the oil out of the air system and release the vehicle.
9. Perform a crankcase pressure test. Refer to section "Crankcase Pressure Test" . Does the crankcase have
excessive pressure?
9.a Yes; diagnose the cause of the high crankcase pressure; Refer to section "High Crankcase Pressure" . Once
the repair is complete, clean the oil out of the air system and release the vehicle.
10. Remove and inspect the turbocharger oil drain pipe (1).
7
11. Is the turbocharger oil drain pipe kinked or restricted?

11.a Yes; replace turbocharger oil drain pipe, clean the oil out of the air system and release the vehicle.
12. Is there a complaint of oil consumption?
12.a Yes; clean out the air system and perform the lube oil consumption test. Refer to Lube Oil Consumption
Report . If the vehicle is confirmed to have an oil consumption concern, Refer to section "Check for Excessive Oil
Consumption" .
12.b No; clean the air system and release the vehicle.
8
Symptom Diagnostics - Oil Present at the Turbocharger

Compressor Housing
9
23.1 Hard Start/No Start - Two-Filter Fuel System (This

Test Must Be Done First)
Check as follows:
1. Inspect the Exhaust Gas Recirculation (EGR) hot pipe for fuel, coolant, or oil. Is fuel present in the EGR hot
pipe?
For the DD13, Refer to section "Cleaning of the DD13 Exhaust Gas Recirculation System"
1.a Yes; fuel is present. Refer to section "Test-E - Two-Filter Fuel System" .
2. Is coolant present in the EGR hot pipe?
2.a Yes; coolant is present. Pressurize the cooling system according to Original Equipment Manufacturer
(OEM) specifications.
3. Is oil present in the EGR hot pipe?
3.a Yes; oil is present. Inspect turbocharger inlet and outlet for oil. Repair as necessary.
3.b No; reinstall the EGR hot pipe with new sealing gaskets and exhaust clamps. Refer to section "Installation of
the Exhaust Gas Recirculation Hot Pipe" . Go to step 4.
4. Will the engine rotate with the starter?

4.b No; Refer to section "Test-B - Two-Filter Fuel System" .
5. Check fuel tank levels; do both tanks have at least a ¼ tank of fuel?
5.b No; add fuel and retest. If starting concern is still present, Go to step 6.
6. Check for fuel contamination, including DEF, water, gasoline, kerosene, coolant, etc. Is contamination
found?
6.a Yes; refer to the Contaminated Fluids section.
7. Using DiagnosticLink , check for other related fault codes. Are any fault codes present?
7.a Yes; correct the additional fault codes first.
8. Were the fuel filters just replaced?
8.a Yes; inspect the stand pipe, pre-filter check ball and fuel filter O-rings for damage. If damage is found,
for the stand pipe and pre-filter check ball, install a new fuel filter module. For the fuel filter O-rings,
install new fuel filters.
Note : If at any point during cranking there is an audible knock or hydraulic sounds, do not attempt to restart the
engine. Remove the EGR hot pipe to inspect for fuel. If fuel is found, Refer to section "Test-E - Two-Filter Fuel
System".
9. Perform a Fuel System Integrity Check routine. For more details on the Fuel System Integrity Check
routine, Refer to section "Fuel System Integrity Check Routine Operation Overview - Two-Filter Fuel System" . Does the engine
start?
9.a Yes; allow the Fuel System Integrity Check routine to complete and Refer to section "Test-D - Two-Filter Fuel
System" .
1
9.b No; repeat the start attempt with Fuel System Integrity Check routine one more time on the same log
file. If the engine still does not start, Refer to section "Test A - Two-Filter Fuel System" .
2
23.2 Test A - Two-Filter Fuel System
NOTICE
“Hard Start/No Start – Two Filter Fuel System” test MUST be completed before
performing this test. Refer to section "Hard Start/No Start - Two-Filter Fuel System (This
Test Must Be Done First)".

J-48704 HP Fuel Rail Test Caps
Pressure Limiting Valve (PLV) return line.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
Check as follows:
1. Review Fuel System Integrity Check (FSIC) routine log file using DiagnosticLink 8.0 or higher. Is the
engine speed over 150 rpm while cranking?
1.b No; perform the following checks. If any are the cause of cranking speed under 150 rpm, fix the issue
and attempt to start the engine using FSIC. If cranking speed is now above 150 rpm and engine does
not start, Go to step 2.
• Verify battery voltage; refer to Original Equipment Manufacturer (OEM) specifications.
• Perform a cranking compression test.
• Remove the accessory drive belt and check cranking speed.
• Remove the air compressor and check cranking speed.
2. Is fuel compensation pressure over 241 kPa (35 psi) while cranking?
3

3. Does “Engine State” equal “Start” while cranking?
3.b No; correct status of the AUX shutdown switch or starter type.
4. Does Kw/Nw show or stay “ON / Enabled / True” while cranking the engine?
4.b No; repair the camshaft or crankshaft sensor failure; refer to appropriate troubleshooting.
5. Is the actual fuel rail pressure over 150 bar (2176 psi)?
6. Is the actual fuel mass over 0 mg/St?
7. Did the vehicle exhibit a no-start condition prior to coming in for service?
7.a Yes; replace the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
7.b No; replace the fuel injectors, fuel rail, and high pressure fuel lines. Refer to section "Removal of the Fuel
8. Perform the PLV flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System" . Was PLV flow
greater than 25 mL (0.84 oz.) while cranking?
9. Has the PLV previously been replaced?
9.a Yes; replace the rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
9.b No; replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
10. Is the correct PLV installed on the engine? Refer to section "Inspection of the Pressure Limiting Valve - Two-Filter System"
.
10.a Yes; contact the Detroit™ Customer Support Center at 800-445-1980.
10.b No; install correct PLV.
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PERSONAL INJURY
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4
WARNING
ENGINE EXHAUST
11. Install Detroit-approved priming tool. Start priming, and attempt to start the engine with Manual FSIC. Does
the engine start?
11.a Yes; after one minute, remove the priming source and allow engine to reach 65°C (149°F). Go to “Test
C." Refer to section "Test-C - Two-Filter Fuel System" .
12. During start attempt, does fuel compensation pressure increase to more than 241 kPa (35 psi)?
13. Remove and inspect the two-stage valve. Refer to section "Removal of the Two-Stage Valve - Two-Filter System " . Was
damage found?
13.a Yes; replace the two-stage valve. Refer to section "Installation of the Two-Stage Valve - Two-Filter System" .
14. Remove and inspect the fuel filters and fuel filter stand pipe. Refer to section "Removal of the Coalescer/Final Filter –
Two Filter System " . Was any damage found to the fuel filters?
14.a Yes; replace the damaged filter. Refer to section "Installation of the Coalescer/Final Filter - Two Filter System" .
14.b No; re-install fuel filters, ensuring that the filter is seated correctly. Refer to section "Installation of the
Coalescer/Final Filter - Two Filter System" . Go to step 15.
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15. Attempt to start the engine. Does the engine start?

15.a Yes; release vehicle to customer.
15.b No; replace the Low Pressure Relief Valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter
System" .
5
16.a Yes; replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
17. Check for aerated fuel. Is the fuel aerated?
17.a Yes; determine cause of aerated fuel and repair as necessary. Refer to section "Aerated Fuel Test – Two-Filter
Fuel System" .

18. Cap the fuel rail at all six fuel injector feed connections using J-48704 tool (HP Fuel Rail Test Caps) and
attempt to start the engine. Does the fuel rail pressure reach the desired rail pressure?
18.b No; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter
System" .
19. Does the fuel rail pressure bleed down under 100 bar (1450 psi) in less than two minutes?
System" .
19.b No; replace the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
6
23.3 Test-B - Two-Filter Fuel System
Check as follows:
WARNING
PERSONAL INJURY
To avoid injury from the sudden release of a high-pressure hose connection, wear a face
shield or goggles.
CAUTION
ELECTRICAL SHOCK
1. Was this vehicle recently reprogrammed or were any modules replaced?
1.a Yes; verify the starter type and transmission type are set correctly. Refer to the appropriate Application
and Installation manual.
2. Using DiagnosticLink® 8.0 or higher, check for stored or active codes. Are codes present?
2.a Yes; troubleshoot code(s) first.
3. Check all battery cables and connections. Are cables and connections OK?
3.b No; reconnect or replace if necessary.
4. Measure and record the voltage at the battery terminals. Refer to Original Equipment Manufacturer (OEM)
guidelines. Was the battery voltage at or above OEM specifications?
4.b No; charge the batteries.
5. Load test the batteries according to OEM specifications. Did the batteries pass the load test?
5.b No; replace the defective battery (or batteries) and verify repair.
6. Check for battery voltage between the positive and negative connections at the starter motor. Is battery
voltage present at the starter motor connections?
6.b No; inspect the wiring between the battery and starter. Repair or replace as necessary.
7. Attempt to manually rotate the engine using W904589046300 Engine Barring Tool. Does the engine rotate
normally?
7.a Yes; remove and bench test the starter. Inspect the flywheel and ring gear. Repair or replace damaged
or faulty components as necessary.
7.b No; remove the accessory belts, then Go to step 8.
8. Attempt to rotate the engine with the W904589046300 Engine Barring Tool. Does the engine rotate
normally with the accessory drive belt removed?
7
8.a Yes; identify and replace the seized accessory components (i.e. alternator, A/C compressor, water
pump, cooling fan, etc.).
9. Inspect the gear-driven components (i.e. turbo compound, high pressure fuel pump, air compressor, etc.)
for signs of binding or failure. Are all of the gear-driven components OK?
9.a Yes; inspect bearings for damage. Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" .
9.b No; replace gear-driven components as necessary and verify repair.
8
23.4 Test-C - Two-Filter Fuel System
NOTICE
Hard Start/No Start - Two-Filter Fuel System test MUST be complete before performing
this test. Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be
Done First)".
Check as follows:
WARNING
PERSONAL INJURY
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PERSONAL INJURY
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PERSONAL INJURY
1. After removing the Detroit-approved priming tool, does the engine quit running?
1.a Yes; remove and inspect the pressure relief valve for damage. If damage is found, replace the
pressure relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" . If no air or damage
is found, Go to step 5.
2. Is the two-stage valve stuck in stage 1?
2.a Yes; remove and inspect the two-stage valve (stuck in stage 1). Refer to section "Removal of the Two-Stage
Valve - Two-Filter System " .

3. Is the low pressure pump and drive coupler damaged?
3.a Yes; remove and inspect the low pressure pump and drive coupler. Refer to section "Removal of the Low
Pressure Fuel Pump - Two-Filter System" .

4. Check for air in the system. Is the fuel aerated?
4.a Yes; Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
4.b No; allow the Fuel System Integrity Check routine to complete. Go to step 5.
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PERSONAL INJURY
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5. Once the rail pressure drops below 10 bar (145 psi), restart the Fuel System Integrity Check routine and
attempt to restart the engine without using a priming source. Does the engine restart?
5.b No; remove and inspect the pressure relief valve for damage. If damage is found, replace the pressure
relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" . If no damage is found, Go to
step 6.
6. Perform a Fuel Injection System (FIS) Low Pressure Leak Test routine. Refer to section "FIS Low Pressure Leak
Test" . Did the fuel system pass the FIS Low Pressure Leak Test routine?

6.b No; inspect fuel system for leaks. Refer to section "FIS Low Pressure Leak Test" .
Fuel System" .
7.b No; Inspect the vehicle side fuel system return line for leaks/loose fittings.
10
23.5 Test-D - Two-Filter Fuel System
NOTICE
“Hard Start/No Start – Two-Filter Fuel System” test MUST be completed before performing
Done First)".

DiagnosticLink 8.0 or higher
W470589099100 Fuel Doser Test Plug
Check as follows:
1. Review Fuel System Integrity Check (FSIC) routine log file using DiagnosticLink 8.0 or higher. Is engine
speed over 150 rpm while cranking?
and attempt to start the engine using the Fuel System Integrity Check (FSIC). If cranking speed is now
above 150 rpm and engine does not start, Go to step 2.
2. Review the FSIC routine log file using DiagnosticLink 8.0 or higher and monitor fuel compensation pressure
and Low Pressure Pump Outlet (LPPO) pressure. Refer to section "Normal Fuel System Pressures - Two-Filter System" .
Is LPPO or Fuel Compensation pressure out of spec?
2.a Yes; replace fuel filters.
Refer to section "Removal of the Fuel Prefilter – Two Filter System" .
Refer to section "Removal of the Coalescer/Final Filter – Two Filter System " .
3. Check for aerated fuel; Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Is the fuel aerated?
3.a Yes; repair the cause of air in the fuel system and retest. Verify the repair.
Test" . Did the FIS Low Pressure Leak Test fail?
4.a Yes; inspect the fuel system for leaks. Refer to section "Potential Fuel Leak Points - Two-Filter Fuel System" .
5. Perform the Chassis Fuel System Isolation Test. Refer to section "Chassis Fuel System Isolation Test." Is
the starting difficulty still present?
5.b No; check chassis fuel system lines per OEM procedures.
11
6. Remove and inspect the needle return pressure control valve. Refer to section "Removal of the Needle Return
Pressure Control Valve – Two-Filter System " . Was damage found?
6.a Yes; replace the needle return pressure control valve. Refer to section "Installation of the Needle Return Pressure
Control Valve - Two-Filter System" .
6.b No; replace the Fuel Filter Module. Refer to section "Removal of the Fuel Filter Module - Two-Filter System" .
12
23.6 Test-E - Two-Filter Fuel System
NOTICE
This test is only to be performed if fuel is found in the Exhaust Gas Recirculation (EGR)
hot pipe or if directed here from the oil pressure diagnostics. Please see table below for
examples of fuel in the EGR hot pipe. Fuel in the EGR hot pipe is known to be caused by a
faulty fuel injector. This failure mode can lead to extensive damage. Test E is a repair path
to identify all progressive damage. No repairs are to be performed until all progressive
damage has been identified prior to step 11.Refer to section "Test-E Worksheet". Print
Test-E Worksheet to help record all repairs that will need to be made in the tables
provided
faulty fuel injector. This failure mode can lead to extensive damage.
Test E is a repair path to identify all progressive damage. No repairs are to be performed
until all progressive damage has been identified prior to step 11. . Print Test-E Worksheet
to help record all repairs that will need to be made in the tables provided
Examples of Fuel in EGR Hot Pipe
WARNING
EXPLOSION
The air intake manifold contains combustible gas. To avoid injury from explosion, do not
connect the air inlet manifold to any devices or lines external to the manifold.
Identifying the Failure

1. Inspect the turbocharger for damage.
13
For DD13 and DD15: Refer to section "Inspection of the DD13 and DD15 Turbocharger" .
For DD16: Refer to section "Inspection of the DD16 Turbocharger" .
Is any damage present?
1.a Yes; in the Test-E worksheet, record an X in the "replace" column for the turbocharger.
For DD13 and DD15 engine, Go to step 6.
For DD16 engines, Go to step 5.
1.b No; for DD13 and DD15 engines, Go to step 6.
2. Inspect the axial power turbine for damage. Refer to section "Inspection of the Axial Power Turbine" . Is any damage
present?
2.a Yes; in the Test-E worksheet, record an X in the "replace" column for the Axial Power Turbine. Go to step
6.

Checking If Engine Ran Backwards
Note : Soot, oil or fuel in the air intake system can indicate that the engine ran backwards.
Note : When SPN 100/FMI 1 Engine Oil Pressure Low, SPN 636/FMI 2 No Match of Camshaft and Crankshaft
Signals, SPN 723/FMI 31 Reverse Engine Rotation Detected or SPN 1636/FMI 4 Intake Manifold Temperature
Circuit Failed Low are present in DiagnosticLink, this can indicate the engine ran backwards.
Note : A fuel injector failure may result in an excessive amount of fuel contamination in the lubricating oil.
Note : Do not remove the intake manifold unless there is solid debris that cannot be cleaned with the intake
manifold in place.
3. Inspect the Charge Air Cooler (CAC), CAC piping, turbocharger inlet elbow and air filter for signs of soot,
oil, or fuel. Is soot, oil or fuel present?
3.a Yes; in the Test-E worksheet, record an X in the "clean" column to clean all soot, oil or fuel from the
CAC, CAC piping, turbocharger inlet elbow, and air filter housing. Record to replace the air filter. Go to
step 7.

4. Remove and inspect the intake manifold temperature sensor, inlet manifold pressure (boost) sensor, and
charge air cooler outlet temperature sensor (if equipped) for signs of damage to the sensor tips. Are any
sensor tips damaged?
4.a Yes; in the Test-E worksheet, record an X in the "replace" column for the damaged sensor(s). Go to step
9.

Inspecting For Possible Bearing Damage
5. Has SPN 100/FMI 1 Engine Oil Pressure Low occurred in the last 30 days or 5000 miles?
6. Inspect rod and main bearings for damage. Refer to section "Inspection of the Main and Connecting Rod Bearings in
Chassis" . Is any damage present?
6.a Yes; in the Test-E worksheet, record an X in the "replace" column for all damaged components. Go to
step 10.
6.b No; in the Test-E worksheet, record an X in the "replace" column for the lower end bearing kit. Go to step
10.
Checking for an Engine Overspeed

Note : If any parts are missing from the engine brake rocker arms, they MUST be found and reinstalled or
replaced if damaged.
7. Check the maximum engine speed in DDEC Reports. You must view the Life-To-Date data instead of Trip
Activity data. Life-To-Date data can be found by selecting the “View” drop down menu, then selecting “Life-
To-Date”, and then selecting “Engine”. In the resulting page view, look at the Peak Engine rpm and the date
it occurred. Is the maximum engine speed greater than 3000 rpm?
14
7.a Yes; view past warranty and repair history to determine if both camshafts were replaced after the
engine overspeed. If they have not been replaced, record an X in the “replace” column for both
camshafts in the Test-E worksheet. Inspect the engine brake rocker arms for loose actuator piston
retainers and loose or missing return springs. Record necessary repairs. Go to step 11.
7.b No; complete all repairs from Test-E Worksheet. Refer to section "Test-E Worksheet" . Go to step 12.
8. Perform a cylinder leak-down test. Refer to section "Cylinder Leak-Down Test" . Did all cylinders pass the leak-down
test?
8.a Yes; complete all repairs from Test-E Worksheet. Refer to section "Test-E Worksheet" . Go to step 12.
8.b No; in the Test-E worksheet, record an X in the "replace" column for necessary repairs. Complete all
repairs from Test-E Worksheet. Refer to section "Test-E Worksheet" . Go to step 12.
Inspection of Aftertreatment
9. Review the fault codes. Is SPN 3250/FMI 0 DOC Outlet Temperature Very High or SPN 3246/FMI 0 DPF
Outlet Temperature Very High present?
9.a Yes; clean the exhaust system. Replace the DOC(s) and DPF(s). If equipped, replace the SCR
catalyst. Go to step 14.
NOTICE
Improper cleaning of the exhaust system may result in damage to the Aftertreatment
System (ATS).
10. Remove the DPF(s) from the ATS. Inspect the DPF(s) and ATS for raw fuel. Is any raw fuel present in the
DPF(s) or ATS?
10.a Yes; clean the exhaust system. For 1-BOX™ emissions package, replace both the DPF and the
DOC/SCR module assembly. Prime the fuel system. Go to step 16.
For all others, let the ATS drain for more than 10 hours. Reassemble and install the ATS. Prime the
fuel system. Go to step 14.
10.b No; clean the exhaust system. Prime the fuel system. Go to step 14.
NOTICE
Running the engine at high idle for one hour MUST be done before performing a parked
WARNING
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15
12. Run the engine at high idle for one hour. Check for leaks and fault codes. Are any leaks or fault codes
present?
13. Is any smoke coming from the tailpipe?
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14. Perform a parked regeneration. Monitor Diesel Oxidation Catalyst (DOC) outlet temperature values, Diesel
Particulate Filter (DPF) outlet temperature values and Selective Catalytic Reduction (SCR) outlet
temperature values. If any of these temperature values rise above 650°C (1200°F), increase the
accelerator pedal position to 100% for one minute. Are any fault codes present or did the parked
regeneration have to be cancelled?
14.a Yes; if fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are present, replace the DOC(s) and DPF(s). If
equipped, replace the SCR catalyst. Go to step 19.
14.b If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are not present and the parked regeneration was
cancelled Go to step 18.
14.c No; Go to step 20.
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16
15.a Yes; replace the DOC(s) and DPF(s). If equipped, replace the SCR catalyst. Go to step 19.
15.b No; repairs are complete; Test-E - Two-Filter Fuel System has ended.
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16. Perform a parked regeneration with new aftertreatment parts. Did the parked regeneration complete with no
issues?
has ended.
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ENGINE EXHAUST
Note : Crystallization or rust on the fuel filters or in the fuel filter module is a result of Diesel Exhaust fluid (DEF)
contamination. Fuel filters will show this contamination if set out in atmosphere about 60 minutes.
18. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, coolant, etc. Was
contamination found?
18.a Yes; record the contaminant in the Contamination Table. Refer to section "Test-E Worksheet" and the
corresponding section for "contaminated fluids." Record any parts that may need replacement. Go to step
2.

Note : Loose or failed fuel injector hold-down bolt(s) are normally caused by hydro-locking of the cylinder.
Evidence of loose fuel injector hold-down bolt(s) can be identified by carbon/soot deposits above the fuel injector
copper washer on the fuel injector body.
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19. Inspect for loose fuel injector hold down bolt(s). Remove the fuel injectors from the engine. Were any fuel
injector hold-down bolt(s) loose?
19.a Yes; in the Test-E worksheet, record an X in the "replace" column for the fuel injector cup(s) on the
cylinders that had a loose fuel injector hold-down bolt. Go to step 3.
20. Inspect the fuel injector tips for damage. Are any fuel injector tips damaged?
20.a Yes; in the Test-E worksheet, record an X in the "replace" column for the EGR cooler. Go to step 4.
20.b No; in the Test-E worksheet, record an X in the "clean" column for the EGR cooler. For DD15, Refer to
section "Cleaning of the DD15 Exhaust Gas Recirculation System" . For DD16, Refer to section "Cleaning of the DD16
Exhaust Gas Recirculation System" . Go to step 6.
17

present?
6.

manifold in place.
step 7.

9.

step 10.
10.

18
test?
NOTICE
System (ATS).
DPF(s) or ATS?
NOTICE
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19
present?
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20
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issues?
has ended.
21
23.7 Test-E Worksheet

Note : Components listed under step * have already been identified from fuel in the hot pipe to be either replaced
or cleaned.
manifold in place.
TEST-E Worksheet
Step Component Action
Clean Replace No Action
* All six Fuel Injectors X
* Change Engine Oil X
* EGR hot pipe X
* EGR cold pipe X
* EGR venturi X
* Intake Elbow X
* Intake Manifold X
1 Contamination See Contamination Table below
3 Fuel Injector Cups
4 EGR Cooler
5 Turbocharger
6 Axial Power Turbine
7 Charge Air Cooler
7 Intake Piping
7 Air Filter housing
7 Air Filter
7 Turbocharger elbow
8 Intake Manifold Temp
Sensor
8 Intake Manifold
Pressure sensor
8 Charge Air Cooler
Outlet Temp Sensor
8 Lower End Bearing Kit
8 Crankshaft
8 Connecting Rod
8 Cylinder Block
9 Camshafts
9 Rocker assembly
10 Cylinder Head
10 Piston
10 Liner
12-17 DPF (s)
12-17 DOC (s)
12-17 SCR Catalyst
22
Contamination Table
Contaminant List of parts to be replaced under "contaminated fluids"
___________________________________ _________________________________________________
or cleaned.
manifold in place.
23
TEST-E Worksheet
* EGR hot pipe X
* EGR cold pipe X
* EGR venturi X
* Intake Elbow X
* Intake Manifold X
4 EGR Cooler
5 Turbocharger
7 Charge Air Cooler
7 Intake Piping
7 Air Filter
Sensor
8 Intake Manifold
Pressure sensor
8 Charge Air Cooler
Outlet Temp Sensor
8 Crankshaft
8 Connecting Rod
8 Cylinder Block
9 Camshafts
9 Rocker assembly
10 Cylinder Head
10 Piston
10 Liner
12-17 DPF (s)
12-17 DOC (s)
12-17 SCR Catalyst
Contamination Table
___________________________________ _________________________________________________
24

Check as follows:
pipe?

found?
engine. Remove the EGR hot pipe to inspect for fuel. If fuel is found, Refer to section "Test-E - Two-Filter Fuel System" .
9. Attempt to start the engine with Manual FSIC enabled. Refer to section "Fuel System Integrity Check Routine Operation
Overview - Two-Filter Fuel System" for more details on FSIC. Does the engine start?
9.a Yes; allow engine to reach operating temperature and Refer to section "Test-D - Two-Filter Fuel System" .
9.b No; repeat start attempt with Manual FSIC one more time on same log file. If engine still does not start,
Refer to section "Test-A - Two-Filter Fuel System" .
25
23.2 Test-A - Two-Filter Fuel System
NOTICE

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Check as follows:
26

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the engine start?
9.a Yes; after one minute, remove the priming source and allow engine to reach 65°C (149°F). Go to “Test
C." Refer to section "Test-C - Two-Filter Fuel System" .
27

damage found?
12. Remove and inspect the fuel filters and fuel filter stand pipe. Refer to section "Removal of the Coalescer/Final Filter " .
Was any damage found to the fuel filters?
12.a Yes; replace the damaged filter. Refer to section "Installation of the Coalescer/Final Filter" .
12.b No; re-install fuel filters, ensuring that the filter is seated correctly. Refer to section "Installation of the
Coalescer/Final Filter" . Go to step 13.
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System" .
Fuel System" .

28

System" .
System" .
29
Check as follows:
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shield or goggles.
CAUTION
ELECTRICAL SHOCK
normally?
30
31
NOTICE
Done First)".
Check as follows:
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1. After removing the Detroit-approved priming tool, does the engine quit running?
1.a Yes; remove and inspect the pressure relief valve for damage. If damage is found, replace the
pressure relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" . If no air or damage
is found, Go to step 5.
2. Is the two-stage valve stuck in stage 1?
2.a Yes; remove and inspect the two-stage valve (stuck in stage 1). Refer to section "Removal of the Two-Stage
Valve - Two-Filter System " .

3. Is the low pressure pump and drive coupler damaged?
3.a Yes; remove and inspect the low pressure pump and drive coupler. Refer to section "Removal of the Low
Pressure Fuel Pump - Two-Filter System" .

4. Check for air in the system. Is the fuel aerated?
4.b No; allow the Fuel System Integrity Check routine to complete. Go to step 5.
32
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5. Once the rail pressure drops below 10 bar (145 psi), restart the Fuel System Integrity Check routine and
attempt to restart the engine without using a priming source. Does the engine restart?
5.b No; remove and inspect the pressure relief valve for damage. If damage is found, replace the pressure
relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" . If no damage is found, Go to
step 6.

Fuel System" .
7.b No; Inspect the vehicle side fuel system return line for leaks/loose fittings.
33
NOTICE
Done First)".

Check as follows:
Refer to section "Removal of the Fuel Prefilter" .
Refer to section "Removal of the Coalescer/Final Filter " .
34
35
NOTICE
provided
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EXPLOSION
36
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2.

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present?
6.

37
manifold in place.
step 7.

9.

step 10.
10.

test?
38
NOTICE
System (ATS).
DPF(s) or ATS?
NOTICE
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present?
39
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issues?
40

has ended.
41

or cleaned.
manifold in place.
Note : Prior to completing the EGR cooler cleaning procedure, the EGR cooler must be removed from the engine.
42
TEST-E Worksheet
* EGR hot pipe X
* EGR cold pipe X
* EGR venturi X
* Intake Elbow X
* Intake Manifold X
4 EGR Cooler
5 Turbocharger
7 Charge Air Cooler
7 Intake Piping
7 Air Filter
Sensor
8 Intake Manifold
Pressure sensor
8 Charge Air Cooler
Outlet Temp Sensor
8 Crankshaft
8 Connecting Rod
8 Cylinder Block
9 Camshafts
9 Rocker assembly
10 Cylinder Head
10 Piston
10 Liner
12-17 DPF (s)
12-17 DOC (s)
12-17 SCR Catalyst
Contamination Table
___________________________________ _________________________________________________
43
Symptom Diagnostics - Hard Start/No Start

Check as follows:
pipe?

found?
engine. Remove the EGR hot pipe to inspect for fuel. If fuel is found, Refer to section "Test-E - Two-Filter Fuel System" .
9. Attempt to start the engine with Manual FSIC enabled. Refer to section "Fuel System Integrity Check Routine Operation
Overview - Two-Filter Fuel System" for more details on FSIC. Does the engine start?
9.a Yes; allow engine to reach operating temperature and Refer to section "Test-D - Two-Filter Fuel System" .
44
9.b No; repeat start attempt with Manual FSIC one more time on same log file. If engine still does not start,
Refer to section "Test-A - Two-Filter Fuel System" .
45
23.2 Test-A - Two-Filter Fuel System
NOTICE

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Check as follows:
46

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the engine start?
9.a Yes; go to “Test C." Refer to section "Test-C - Two-Filter Fuel System" .
47
damage found?
12. Remove and inspect the fuel filters and fuel filter stand pipe. Refer to section "Removal of the Coalescer/Final Filter " .
Was any damage found to the fuel filters?
12.a Yes; replace the damaged filter. Refer to section "Installation of the Coalescer/Final Filter" .
12.b No; reinstall fuel filters, ensuring that the filter is seated correctly. Refer to section "Installation of the
Coalescer/Final Filter" . Go to step 13.
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System" .
Fuel System" .

48
System" .
System" .
49
Check as follows:
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shield or goggles.
CAUTION
ELECTRICAL SHOCK
normally?
50
51
NOTICE
Done First)".
Check as follows:
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1. Allow engine to run for one minute and then remove the Detroit-approved priming tool; does the engine quit
running?
1.b No; allow engine to reach 65°C (149°F), then shut down engine. Go to step 2.
2. Once the rail pressure drops below 10 bar (145 psi), attempt to restart the engine without using a priming
source. Does the engine restart?
3. Remove and inspect the pressure relief valve for damage. Refer to section "Removal of the Pressure Relief Valve -
Two-Filter System" . Is the valve damaged?
3.a Yes; replace the pressure relief valve.
52

4. Install the Detroit-approved priming tool, start priming, restart the engine, turn the primer off, and then
monitor LPPO fuel pressure. Is LPPO below specified range at idle? Refer to section "Normal Fuel System
Pressures" .

5. Remove and inspect the two-stage valve. Refer to section "Removal of the Two-Stage Valve - Two-Filter System " . Is the
two-stage valve stuck in stage 1?
5.a Yes; replace the two-stage valve.

7. Check for aerated fuel. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Is the fuel aerated?
Fuel System" .

8. Perform the Chassis Fuel System Isolation test. Refer to section "Chassis Fuel System Isolation Test" . Did the test
pass?
8.b No; repair as necesssary.
9. With Chassis Fuel System Isolation Test lines still connected, start the engine and monitor LPPO. Is LPPO
below specified range at idle? Refer to section "Normal Fuel System Pressures" .
9.b No; repair the cause of inlet restriction.
10. Remove and inspect the pressure relief valve for damage. Refer to section "Removal of the Pressure Relief Valve -
Two-Filter System" . Is the valve damaged?
10.a Yes; replace the pressure relief valve.

11. Inspect the pre-filter for any debris or plugging. Is the pre-filter plugged?
11.b No; replace the low pressure fuel pump. Refer to section "Removal of the Low Pressure Fuel Pump - Two-Filter
System" .
12. Is the pre-filter debris caused by contaminated fuel?

12.a Yes; refer to the appropriate contaminated fluid troubleshooting.
Refer to section "Metal in the Fuel System – Two-Filter Fuel System" .
Refer to section "Diesel Exhaust Fluid in Fuel" .
12.b No; replace the pre-filter.
53
NOTICE
Done First)".

Check as follows:
54
55
NOTICE
provided
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EXPLOSION
56
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2.

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present?
6.

57
manifold in place.
step 7.

9.

step 10.
10.

test?
58
NOTICE
System (ATS).
DPF(s) or ATS?
13.a Yes; Refer to section "Diesel Fuel Contamination" .
NOTICE
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present?
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59
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equipped, replace the SCR catalyst. Go to step 19. If fault codes SPN 3250/FMI 0 or SPN 3246/FMI 0 are
not present and the parked regeneration was cancelled Go to step 18.
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issues?
has ended.
60

or cleaned.
manifold in place.
Note : Prior to completing the EGR cooler cleaning procedure, the EGR cooler must be removed from the engine.
61
TEST-E Worksheet
* EGR hot pipe X
* EGR cold pipe X
* EGR venturi X
* Intake Elbow X
* Intake Manifold X
4 EGR Cooler
5 Turbocharger
7 Charge Air Cooler
7 Intake Piping
7 Air Filter
Sensor
8 Intake Manifold
Pressure sensor
8 Charge Air Cooler
Outlet Temp Sensor
8 Crankshaft
8 Connecting Rod
8 Cylinder Block
9 Camshafts
9 Rocker assembly
10 Cylinder Head
10 Piston
10 Liner
12-17 DPF (s)
12-17 DOC (s)
12-17 SCR Catalyst
Contamination Table
___________________________________ _________________________________________________
62
24.1 Belt Drive Noise

Excessive belt drive noise can be caused by a damaged or worn belt, damaged pulleys, inadequate belt tension,
or a damaged accessory component.
Inspect as follows:
NOTICE
1
2.a Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts" . Verify repair.
3. Remove the belts. Refer to section "Removal of the Poly-V-Belts" .
4. Check the belts for fluid contamination. Check for leaks from engine or chassis components. Are there any
fluids leaking onto the belts?
4.a Yes; repair the leak and replace both belts. Verify repair.
5. Visually inspect the condition of the belts. Refer to section "Inspection of the Poly-V-Belts" . Are the belts damaged?
5.a Yes; replace both belts and inspect the pulleys for damage. Refer to section "Installation of the Poly-V-Belts" .
Verify repair.
2
3
4
24.2 Different Engine Noise

Different engine noises that are heard when a problem occurs are listed in the following table.
Type of Noise Check the Following:

Whining Noise Gear Train; refer to Section "Check Gear Train"
Air intake including the Charge Air Cooler and all hoses
Whistling Noise Turbocharger clamps
Gaskets in exhaust system
Internal turbocharger damage
Low Pitch Knock Rod bearings

Pistons
Wrist pin
Valve train damage

Fuel system problems
High Pitch Knock/Squeal Belt accessory drive
Belt;
Alternator
A/C compressor
Water pump
5
24.3 Excessive Overhead Engine Noise
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2. Record the engine speed and coolant temperature where the noise is most noticeable.
Note : Small scratches and light scoring are considered normal wear for overhead valve train components
(camshaft housing, camshaft journals, camshaft lobes, rocker arm shafts, rocker arm bushings and rocker arm
rollers).
3. Shut off the engine.
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4. Remove the rocker cover and adjust the valves and engine brakes; Refer to section "Setting the Valve and Engine
Brake Lash" .
5. Reinstall the rocker cover and air cleaner.
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6
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6. Start the engine again and check for the abnormal noise at the operating conditions recorded in step 2. Is
the abnormal ticking or rattling noise still present after adjusting the valves and engine brakes?
6.b No; repairs are complete. Release the vehicle.
8. Remove the rocker cover. Using a paint pen, number the exhaust and intake rocker arms with the cylinder
position.
9. Remove the exhaust and intake rocker arm shaft assemblies; Refer to section "Removal of the Intake Rocker Shaft
Assembly" and Refer to section "Removal of the Exhaust Rocker Shaft Assembly" .
Note : There are three rockers on the exhaust side; the problem only affects the front two rockers. The brake
rocker arm (last in position) does not need to be inspected.
10. Inspect the first two exhaust rocker arms on each cylinder for excessive clearance between the rocker shaft
and rocker arm. Refer to section "Setting the Valve and Engine Brake Lash" .
11. Inspect the intake rocker arms for excessive clearance on the rocker arm shaft. Refer to section "Setting the Valve
and Engine Brake Lash" .
Note : If any rocker arms have excessive clearance, the rocker arm shaft is the primary failed part (PFP) and must
be replaced along with any loose rocker arm(s). It is not necessary to replace all of the rocker arms, only the ones
with excessive clearance.
12. Do any of the rocker arms have excessive clearance?
12.a Yes; replace the rocker arm shaft and any rocker arms with excessive clearance. Any rocker arms with
acceptable clearance can be reinstalled. Refer to section "Installation of the Intake Rocker Shaft Assembly" and
Refer to section "Installation of the Exhaust Rocker Shaft Assembly" .

13. Repeat steps 10 through 12 for all cylinders. Repair as necessary.
7
24.4 Gear Train Noise

A whining noise indicates a problem with the gear train.
1. Drain the engine oil.
2. Remove the oil pan. Refer to section "Removal of the Oil Pan" .
3. Move the fuel doser feed line.
4. Remove the Crankcase Position (CKP) sensor. Refer to section "Removal of the Crankshaft Position Sensor" .
5. Remove the fuel pump gear plate. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System" .
6. Remove the flywheel housing. Refer to section "Removal of the Flywheel Housing" .
7. Inspect the gear train for damage.
8. Inspect the thrust washers and gear bushings for damage.
9. Check the gear lash. Refer to section "Checking and Adjusting Gear Lash with Camshaft Housing Removed" .
8
24.5 Lower End Engine Noise

Check as follows:
2. Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" .
9

Inspect as follows:
NOTICE
10
2.a Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify repair.
3. Remove the belts. Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" .
5.a Yes; replace both belts and inspect the pulleys for damage. Refer to section "Installation of the Poly-V-Belts
(Hydraulic Belt Tensioner)" . Verify repair.

repair.
11
12
repair.
13



Pistons
Wrist pin
Valve train damage

Belt;
Alternator
A/C compressor
Water pump
14
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rollers).
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Brake Lash" .
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15
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position.

16

17

Check as follows:
18
Symptom Diagnostics - Noise

Inspect as follows:
19
NOTICE
2.a Yes; replace both belts.
repair.
3. Remove the belts.
For the Hydraulic Belt Tensioner, Refer to section "Removal of the Poly-V-Belts (Hydraulic Belt Tensioner)" . Verify repair.
5.a Yes; replace both belts and inspect the pulleys for damage.
repair.
7.a Yes; replace the belt tensioner and both belts.
For the Hydraulic Belt Tensioner, Refer to section "Removal of the Hydraulic Belt Tensioner" . Verify repair.
For the Friction Belt Tensioner, Refer to section " Removal of the Friction Belt Tensioner" . Verify repair.
8. Is the engine equipped with a strut-type belt tensioner?
8.b No; replace both belts. Refer to section "Removal of the Poly-V-Belts (Friction Belt Tensioner)" . Verify repair.
20
21
repair.
22



Pistons
Wrist pin
Valve train damage

Belt;
Alternator
A/C compressor
Water pump
23
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rollers).
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Brake Lash" .
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24
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position.

25

26

Check as follows:
27
25.1 Symptom Diagnostics - Low Engine Compression

Check as follows:
Note : This diagnostic should only be performed after a manual compression test has been performed to ensure
low engine compression is verified.
1. Conduct a Mechanical Cylinder Compression Test. Refer to section "Mechanical Cylinder Compression Test" . Is
compression within specification?
1.a Yes; no repair is needed.
2. Are all the actuator pistons on the engine brake rocker arms retracted (1)?
2.b No; replace the engine brake rocker(s) that has a stuck actuator piston (2). Refer to section "Removal of the
3. Check the camshaft timing. Refer to section "Camshaft Timing Verification" . Is the camshaft timing within
specifications?
3.b No; correct engine/camshaft timing and verify repair.
4. Check valve lash and engine brake adjustments. Refer to section "Setting the Valve and Engine Brake Lash" . Is an
adjustment required?
4.a Yes; adjust as necessary and verify repair.
For the DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly"
1
For the DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly"
6. Inspect the cylinder head gasket for damage to the fire seal at the cylinder(s) with low compression. Is
damage present?
6.a Yes; measure the liner protrusion. Refer to section "Installation of the Cylinder Liner" . Repair as necessary and
verify repair.
7. Inspect the following engine components:
Refer to section "Inspection of the Cylinder Head"
Refer to section "Inspection of the Cylinder Liner"
Refer to section "Inspection of the Piston, Piston Rings and Connecting Rod"
Refer to section "Inspection of the Intake and Exhaust Valves"
8. Did any of the above inspections identify the cause of low engine compression?
8.a Yes; repair as necessary and verify repairs.
9. Inspect the main and connecting rod bearings for damage. Refer to section "Inspection of the Main and Connecting
Rod Bearings in Chassis" .
10. Has the cause of low compression been identified?

10.b No; review the results of the above troubleshooting steps.
2
Symptom Diagnostics - Low Engine Compression
25.1 Symptom Diagnostics - Low Engine Compression

Check as follows:
Note : This diagnostic should only be performed after a manual compression test has been performed to ensure
low engine compression is verified.
1. Conduct a Mechanical Cylinder Compression Test. Refer to section "Mechanical Cylinder Compression Test" . Is
compression within specification?
1.a Yes; no repair is needed.
2. Are all the actuator pistons on the engine brake rocker arms retracted (1)?
2.b No; replace the engine brake rocker(s) that has a stuck actuator piston (2). Refer to section "Removal of the
3. Check the camshaft timing. Refer to section "Camshaft Timing Verification" . Is the camshaft timing within
specifications?
3.b No; correct engine/camshaft timing and verify repair.
4. Check valve lash and engine brake adjustments. Refer to section "Setting the Valve and Engine Brake Lash" . Is an
adjustment required?
4.a Yes; adjust as necessary and verify repair.
3

For the DD13, Refer to section "Removal of the DD13 Cylinder Head Assembly"
For the DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly"
6. Inspect the cylinder head gasket for damage to the fire seal at the cylinder(s) with low compression. Is
damage present?
6.a Yes; measure the liner protrusion. Refer to section "Installation of the Cylinder Liner" . Repair as necessary and
verify repair.
7. Inspect the following engine components:
Refer to section "Inspection of the Cylinder Head"
Refer to section "Inspection of the Cylinder Liner"
Refer to section "Inspection of the Piston, Piston Rings and Connecting Rod"
Refer to section "Inspection of the Intake and Exhaust Valves"
8. Did any of the above inspections identify the cause of low engine compression?
9. Inspect the main and connecting rod bearings for damage. Refer to section "Inspection of the Main and Connecting
Rod Bearings in Chassis" .
10. Has the cause of low compression been identified?

10.b No; review the results of the above troubleshooting steps.
4
26.1 Noisy 1-Box™ Aftertreatment

This diagnostic is used to identify the cause of a loud 1-Box Aftertreatment.
Check as follows:
1. Visually inspect the entire exhaust system for signs of leaks or damage. Is any damage found?
2. Inspect that the aftertreatment inlet heat shields are not broken loose and rattling. Is there a loose or
damaged heat shield?
2.a Yes; repair the heat shield. If the inlet heat shield has tabs, refer to 11 TS-6 .
3. Inspect the inboard and outboard Diesel Particulate Filter (DPF) covers and verify nothing is loose or
rattling. Is there a loose DPF cover?
3.a Yes; repair the loose cover.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the aftertreatment inlet pipe and start the engine to verify the noise is coming from the
aftertreatment. Did the noise go away once the aftertreatment inlet was disconnected?
4.a Yes; reconnect the aftertreatment inlet and Go to step 5.
4.b No; inspect other truck components to identify the noise.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
1
WARNING
HOT EXHAUST
6. Start the engine and run a Parked Regen. Monitor Diesel Oxidation Catalyst (DOC) inlet pressure and
engine speed during the regen.
NOTICE
If DOC inlet pressure is 19.9 kPa (2.9 psi) or higher at any time during the parked regen,
immediately stop the regen because turbocharger damage may occur. Go to step 9.
7. Review the parked regen log file. Compare your DOC inlet pressure reading to the screen shots below to
identify a possible cause of the aftertreatment noise.
7.a If the DOC inlet pressure starts out above 10 kPa (1.45 psi) and decreases during a parked regen, this
indicates that the DPFs were plugged and the parked regen has cleared them. Go to step 8.
7.b If the DOC inlet pressure starts above the pressure specified below and stays high, the DOC is
considered plugged. Go to step 9.
Emissions Year Pressure

GHG17 6 KPa (.89 psi)
GHG17 DD15 AT Only 7 KPa (1.01 psi)
2
8. Verify the noise is gone and complete the ATD check list to possibly identify why the unit was plugged. Refer
to section "GHG17 Perform Performance Check - Low Temperature ATD" .
9. Perform the DOC air cleaning service procedure. After completing the service procedure, verify the noise is
gone and release the vehicle. Refer to section "Diesel Oxidation Catalyst Air Cleaning" .
3
26.1 Noisy 1-Box™ Aftertreatment

This diagnostic is used to identify the cause of a loud 1-Box Aftertreatment.
Check as follows:
2. Inspect that the aftertreatment inlet heat shields are not broken loose and rattling. Is there a loose or
damaged heat shield?
2.a Yes; repair the heat shield. If the inlet heat shield has tabs, refer to 11 TS-6 .
3. Inspect the inboard and outboard Diesel Particulate Filter (DPF) covers and verify nothing is loose or
rattling. Is there a loose DPF cover?
3.a Yes; repair the loose cover.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the aftertreatment inlet pipe and start the engine to verify the noise is coming from the
aftertreatment. Did the noise go away once the aftertreatment inlet was disconnected?
4.a Yes; reconnect the aftertreatment inlet and Go to step 5.
4.b No; inspect other truck components to identify the noise.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4
WARNING
HOT EXHAUST
6. Start the engine and run a Parked Regen. Monitor Diesel Oxidation Catalyst (DOC) inlet pressure and
engine speed during the regen.
NOTICE
If DOC inlet pressure is 19.9 kPa (2.9 psi) or higher at any time during the parked regen,
immediately stop the regen because turbocharger damage may occur. Go to step 9.
7. Review the parked regen log file. Compare your DOC inlet pressure reading to the screen shots below to
identify a possible cause of the aftertreatment noise.
7.a If the DOC inlet pressure starts out above 10 kPa (1.45 psi) and decreases during a parked regen, this
indicates that the DPFs were plugged and the parked regen has cleared them. Go to step 8.
7.b If the DOC inlet pressure starts above the pressure specified below and stays high, the DOC is
considered plugged. Go to step 9.
Emissions Year Pressure

GHG17 6 KPa (.89 psi)
GHG17 DD15 AT Only 7 KPa (1.01 psi)
5
8. Verify the noise is gone and complete the ATD check list to possibly identify why the unit was plugged. Refer
to section "GHG17 Perform Performance Check - Low Temperature ATD" .
9. Perform the DOC air cleaning service procedure. After completing the service procedure, verify the noise is
gone and release the vehicle. Refer to section "Diesel Oxidation Catalyst Air Cleaning" .
6
Symptom Diagnostics - Noisy One-Box Aftertreatment
7
27.1 GHG17 EGR Slow Learn Routine

Note : This procedure is only available in DiagnosticLink® 8.03 SP 1 or greater.
1. Connect DiagnosticLink.
2. Click on the "Troubleshooting" tab in the left hand menu, then click "Symptom Diagnostics - EGR Slow
Learn Routine" in the main window and finally click on the "Next" button in the lower right hand corner.
1
3. Select "GHG17 EGR Slow Learn Routine" in the main window and click the "Next" button in the lower right
hand corner to start the procedure.
Follow the directions in the procedure to complete the EGR Slow Learn Routine.
2
Symptom Diagnostics - EGR Slow Learn Routine
27.1 GHG17 EGR Slow Learn Routine

Note : This procedure is only available in DiagnosticLink 8.03 SP 1 or greater.
2. Click on the "Troubleshooting" tab in the left hand menu, then click "Symptom Diagnostics - EGR Slow
Learn Routine" in the main window and finally click on the "Next" button in the lower right hand corner.
3
3. Select "GHG17 EGR Slow Learn Routine" in the main window and click the "Next" button in the lower right
hand corner to start the procedure.
Follow the directions in the procedure to complete the EGR Slow Learn Routine.
4
28.1 Optimized Idle Thermostat does not power up
Check as follows:
1. Disconnect the Optimized Idle Thermostat connector.
2. Inspect the sensor harness for bent, spread, or corroded pins.
2.a If damage is found, repair as necessary.
2.b If no damage is found, Go to step 3.
3. Turn the key to the on position, engine off.
4. Measure the voltage between pin 5 of the Optimized Idle Thermostat harness side connector, and ground.
Is the voltage within 1.5 volts of battery voltage.
4.b No, repair the circuit short between pin 5 of the Optimized Idle Thermostat connector and ignition feed.
1
5. Measure the resistance between pin 6 of Optimized Idle Thermostat harness side connector and ground. Is
the resistance greater than 5 ohms?
5.a Yes, repair the open circuit between pin 6 of Optimized Idle Thermostat connector and vehicle ground.
5.b No, replace the Optimized Idle Thermostat.
2
28.2 Optimized Idle does not Arm
Check as follows:
Note : Optimized Idle will not normally function while connected to DiagnosticLink. To allow Optimized Idle to
function while connected to DiagnosticLink®, go to "Actions", click on "Engine Idle Shutdown" from the drop-down
and select "Allow shutdown" from the pop-up window.
1. Is MCM fault code SPN 1663 /FMI 7 present?
1.a Yes; troubleshoot this code first.
2. With the ignition in the ON position, turn the thermostat on by pressing any button on the display. Does the
Optimized Idle Thermostat power up?
2.b No; disconnect the Optimized Idle Thermostat electrical connector and check pin 6 for vehicle ground
and pin 5 for ignition. Repair as necessary.
3
3. Was the CPC recently programmed?

3.a Yes; check for proper CPC parameter settings. Refer to section "Optimized Idle" of the A&I Manual.
4. Test the functionality of Battery Run Mode; Refer to section "Optimized Idle" of the A&I Manual. Does Optimized
Idle start the engine for Battery Run mode?
5. Using DiagnosticLink , verify the operation of the Optimized Idle Safety Loop and the Vehicle Speed
Sensor (VSS). Under Instrumentation, go to the Chart tab and select the following on the chart:
• DSL: Parking Brake
• DSL: Hood Tilt Switch
• DSL: Neutral Switch
• ASL: Road Speed
Cycle each switch and monitor their functionality. Monitor the Road Speed; it should read zero when the
vehicle is stationary.
4
Was a fault with either the Optimized Idle Safety Loop or VSS found?
6. Is the vehicle equipped with an Auxiliary Power Unit (APU) or ParkSmart?
6.a Yes; vehicles with an APU or ParkSmart may not use Optimized Idle to control the cab temperatures. If
this is the customer’s complaint, refer to the APU or ParkSmart operation instructions.
7. Connect to DiagnosticLink and run through an Optimized Idle cycle. Go to step 8.
function while connected to DiagnosticLink, go to "Actions", click on "Engine Idle Shutdown" from the drop-down
8. Under Instrumentation, go to the Chart tab and select the following on the chart:
• ASL: Road Speed
• ASL002: Engine Speed
• DSL: Clutch Open
• ASL: Vehicle Power Shutdown Status
• ASL: OI Thermostat Status
• ASL: Optimized Idle Lamp Status
• ASL: Optimized Idle Time
• AS094: Actual Torque Load
5
• DSL: Service Brake

• ASL: Optimized Idle Run Reason Status
• ASL: Optimized Idle System Status
Using DiagnosticLink, determine which of the above is causing Optimized Idle to fail; Refer to section "Optimized
Idle" of the A&I Manual for operating conditions. Repair as necessary. If no failure is found, Go to step 9.
9. Under Instrumentation, go to the Chart tab and select the following on the chart :
• ASL: Latest OI Dropout Reason t0
These chart selections will display the last five known reasons for Optimized Idle to fail. The value column
will display the last known reason for an Optimized Idle failure. Repair as necessary. If no failure is found,
Go to step 10.
6
10. Check the Optimized Idle Thermostat settings; Refer to section “Thermostat Operation” of the Optimized
Idle User Manual (DDC-SVC-MAN-0019) . Is the Optimized Idle Thermostat properly configured?
10.a Yes; install a test CPC. Go to step 11.
10.b No; Refer to section “Thermostat Operation” of the Optimized Idle User Manual (DDC-SVC-MAN-0019) .
Verify repair.
11. Will Optimized Idle work correctly with a test CPC?
11.a Yes; replace the CPC.
12. Set the Optimized Idle Thermostat mode to cool the cab and put the vehicle on Optimized Idle mode. Using
a heat gun, apply heat to the Optimized Idle Thermostat Skin Temperature sensor; refer to OEM literature
for sensor location. Did Optimized Idle start the engine to cool the cab?
12.a Yes; Refer to section "Optimized Idle" of the A&I Manual for proper Optimized Idle parameter configuration.
13. Monitor the Optimized Idle Thermostat temperature reading while applying heat to the sensor. Is the
reading on the Thermostat display accurate?
13.a Yes; replace the Optimized Idle Thermostat.
14. Disconnect the Optimized Idle Thermostat electrical connector and measure the resistance between the
Optimized Idle Thermostat connector and the Skin Temperature sensor harness side connector. Is the
resistance less than 10 ohms?
14.a Yes; replace the Skin Temperature sensor.
14.b No; repair the circuit.
7
28.3 Optimized Idle will arm but will not restart the engine
Check as follows:
3. Using DiagnosticLink, verify the operation of the Optimized Idle Safety Loop and the Vehicle Speed Sensor
(VSS). Under Instrumentation, go to the Chart tab and select the following on the chart:
• ASL: Road Speed
8
Verify repair.
6. Will Optimized Idle work correctly with the test CPC?
9

9. Disconnect the Optimized Idle Thermostat electrical connector and measure the resistance between pin 3
of the Optimized Idle Thermostat connector, harness side and the sensor ground circuit of the Skin
Temperature sensor harness side connector. Is the resistance less than five ohms?

10. Measure the resistance between pin 1 of the Optimized Idle Thermostat connector, harness side and the
sensor signal circuit of the Skin Temperature sensor harness side connector. Is the resistance less than
five ohms?
10
28.4 Optimized Idle does not work on Thermostat Mode
Check as follows:
11

2.a Yes; check for proper CPC parameter settings, Refer to section "Optimized Idle" of the A&I Manual.
4. Disconnect the Optimized Idle Thermostat. Check for voltage at pin 4, harness side. Is voltage greater than
two volts?
4.a Yes; repair a short to power between CPC connector 3, pin 1 and pin 4 of the Optimized Idle
Thermostat connector.
5. Check the Optimized Idle Thermostat settings; Refer to section “ Thermostat Operation” of the Optimized
Verify repair.
12
13
28.5 Optimized Idle does not go into Continuous Run

Mode under Extreme Ambient Conditions
Check as follows:
1. Does the HVAC work on the vehicle?
1.b No; repair the HVAC system first. Refer to chassis OEM guidelines.
2. Check CPC parameters to make sure the Continuous Run feature is enabled; Refer to section "Optimized Idle" of
the A&I Manual. Is Continuous Run Mode properly configured?
2.b No; this feature is available but not set up on the vehicle.
3. Is the Optimized Idle Thermostat Skin Temperature sensor properly adhered onto an outside metal wall,
secured and wired to the Thermostat? Refer to OEM literature for sensor location.
14

15
28.6 Optimized Idle does not go into Continuous Battery

Run Mode
Check as follows:
1.a Yes; install a test CPC.
16
28.7 Optimized Idle will intermittently not restart the

engine
Check as follows:
• ASL: Road Speed
17
for sensor location. Monitor the Optimized Idle Thermostat temperature reading while applying heat to the
sensor. Is the reading on the Thermostat display accurate?
6.b No; repair the circuit. Go to step 7.
18
7. Run the vehicle through an Optimized Idle cycle. Did Optimized Idle work correctly?
function while connected to DiagnosticLink, go to "Actions", click on "Engine Idle Shutdown" from the drop- down
9. Under Instrumentation, go to the Chart tab and select on the following on the chart :
• ASL: Road Speed
19
These chart selections will display the last five known reasons for Opt Idle to fail. The value column will
display the last known reason for an Optimized Idle failure. Repair as necessary.
20
Symptom Diagnostics - Optimized Idle
28.1 Optimized Idle Thermostat does not power up
Check as follows:
1. Disconnect the Optimized Idle Thermostat connector.
3. Turn the key to the on position, engine off.
4. Measure the voltage between pin 5 of the Optimized Idle Thermostat harness side connector, and ground.
Is the voltage within 1.5 volts of battery voltage.
4.b No, repair the circuit short between pin 5 of the Optimized Idle Thermostat connector and ignition feed.
21
5. Measure the resistance between pin 6 of Optimized Idle Thermostat harness side connector and ground. Is
the resistance greater than 5 ohms?
5.a Yes, repair the open circuit between pin 6 of Optimized Idle Thermostat connector and vehicle ground.
5.b No, replace the Optimized Idle Thermostat.
22
28.2 Optimized Idle does not Arm
Check as follows:
function while connected to DiagnosticLink®, go to "Actions", click on "Engine Idle Shutdown" from the drop-down
23

4. Test the functionality of Battery Run Mode; Refer to section "Optimized Idle" of the A&I Manual. Does Optimized
Idle start the engine for Battery Run mode?
• ASL: Road Speed
24
function while connected to DiagnosticLink, go to "Actions", click on "Engine Idle Shutdown" from the drop-down
8. Under Instrumentation, go to the Chart tab and select the following on the chart:
• ASL: Road Speed
25

9. Under Instrumentation, go to the Chart tab and select the following on the chart :
These chart selections will display the last five known reasons for Optimized Idle to fail. The value column
will display the last known reason for an Optimized Idle failure. Repair as necessary. If no failure is found,
Go to step 10.
26
Verify repair.
11. Will Optimized Idle work correctly with a test CPC?
27
28.3 Optimized Idle will arm but will not restart the engine
Check as follows:
3. Using DiagnosticLink, verify the operation of the Optimized Idle Safety Loop and the Vehicle Speed Sensor
(VSS). Under Instrumentation, go to the Chart tab and select the following on the chart:
• ASL: Road Speed
28
Verify repair.
29

9. Disconnect the Optimized Idle Thermostat electrical connector and measure the resistance between pin 3
of the Optimized Idle Thermostat connector, harness side and the sensor ground circuit of the Skin
Temperature sensor harness side connector. Is the resistance less than five ohms?

10. Measure the resistance between pin 1 of the Optimized Idle Thermostat connector, harness side and the
sensor signal circuit of the Skin Temperature sensor harness side connector. Is the resistance less than
five ohms?
30
28.4 Optimized Idle does not work on Thermostat Mode
Check as follows:
31

2.a Yes; check for proper CPC parameter settings, Refer to section "Optimized Idle" of the A&I Manual.
4. Disconnect the Optimized Idle Thermostat. Check for voltage at pin 4, harness side. Is voltage greater than
two volts?
4.a Yes; repair a short to power between CPC connector 3, pin 1 and pin 4 of the Optimized Idle
Thermostat connector.
5. Check the Optimized Idle Thermostat settings; Refer to section “ Thermostat Operation” of the Optimized
Verify repair.
32
33
28.5 Optimized Idle does not go into Continuous Run

Mode under Extreme Ambient Conditions
Check as follows:
1. Does the HVAC work on the vehicle?
1.b No; repair the HVAC system first. Refer to chassis OEM guidelines.
34

35
28.6 Optimized Idle does not go into Continuous Battery

Run Mode
Check as follows:
1.a Yes; install a test CPC.
36
28.7 Optimized Idle will intermittently not restart the

engine
Check as follows:
• ASL: Road Speed
37
for sensor location. Monitor the Optimized Idle Thermostat temperature reading while applying heat to the
sensor. Is the reading on the Thermostat display accurate?
6.b No; repair the circuit. Go to step 7.
38
7. Run the vehicle through an Optimized Idle cycle. Did Optimized Idle work correctly?
function while connected to DiagnosticLink, go to "Actions", click on "Engine Idle Shutdown" from the drop- down
• ASL: Road Speed
39
These chart selections will display the last five known reasons for Opt Idle to fail. The value column will
display the last known reason for an Optimized Idle failure. Repair as necessary.
40
29.1 Low Engine Coolant Temperature
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
Check as follows:
1. Verify the complaint. The engine coolant temperature should rise while the engine is operated under a load
or during a Parked Regeneration. If there is no heat in the cab but the engine temperature does rise to
normal operating temperature, diagnose the HVAC system.
3. Inspect the vehicle for aftermarket cooling system components plumbed into the engine cooling system.
Are any aftermarket cooling system components present?
4. Bypass the aftermarket cooling system component and verify the complaint. Is the low engine coolant
temperature still present?
4.b No; no further troubleshooting is required. Shut down the engine.
5. Inspect thermostat for correct operation. Refer to section "Inspection of the Coolant Thermostat and Seal" . Is the
thermostat faulty or damaged?
5.a Yes; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" . Verify repair.
5.b No; review the results of the above troubleshooting steps to see if all results are consistent and
accurate. Replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" . Verify
repair.
1
29.1 Low Engine Coolant Temperature
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
Check as follows:
Note : In extremely cold ambient temperatures, it may take longer than 20 minutes of driving to reach operating
temperature. In these cases, performing a Parked Regeneration is preferred.
Note : Use DiagnosticLink to monitor engine coolant temperature.
1. Verify the complaint by driving the vehicle for 20 minutes or performing a Parked Regeneration. Does the
engine coolant temperature reach and maintain a minimum of 85°C (185°F)?
1.a Yes; the vehicle is performing as intended; no further troubleshooting is required. Shut down the
engine.
1.b No; shut down the engine. Go to step 2.
Note : If there is no heat in the cab but the engine temperature does rise to normal operating temperature,
diagnose the Heating Ventilation and Air Conditioning (HVAC) system.
2. Check engine coolant fan operation. Does the fan function and cycle correctly?
2.b No; diagnose the engine fan operation.
3. Inspect the vehicle for aftermarket cooling system components plumbed into the engine cooling system.
Are any aftermarket cooling system components present?
Note : Use DiagnosticLink to monitor engine coolant temperature.
4. Bypass the aftermarket cooling system component and verify the complaint by driving the vehicle for 20
minutes or performing a Parked Regeneration. Does the engine coolant temperature reach and maintain a
minimum of 85°C (185°F)?
4.a Yes; no further engine troubleshooting is required. Shut down the engine. Troubleshoot the aftermarket
cooling system component.
5. Remove the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
6. Inspect the thermostat. Refer to section "Inspection of the Coolant Thermostat and Seal" . Is the thermostat faulty or
damaged?
6.a Yes; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" . Verify repair.
6.b No; review the results of the above troubleshooting steps to see if all results are consistent and
accurate. Replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" . Verify
repair.
2
Symptom Diagnostics - Low Engine Coolant Temperature
3
30.1 Checking for Low Wheel Horsepower

Check as follows:
Note : Have operator fill out the Engine Diagnostic Questionnaire.
1. Check for active/inactive codes. Are there any active codes present?
1.a Yes; troubleshoot those codes first.
2. Using DiagnosticLink , check the following DDEC parameters for correct values:
Progressive shift: Refer to section "Progressive Shift" .
Low gear torque reduction: Refer to section "Low Gear Torque Reduction" .
Do the parameters have the correct values?
2.b No; update to the correct values, and then retest for low wheel horsepower. If low wheel horsepower is
still present, Go to step 3.
Note : All engines will incorporate a 10% derate when a fan code becomes active. This is important to know when
dyno testing a truck and unplugging a fan to lock it ON. You either must compensate for the derate on the
calculation, or find another method to lock the fan ON. Consider using Fan Override switch, if equipped.
3. Check that the dyno-measured power is within Detroit™ specifications as for minimum acceptable wheel
HP data. Refer to section "Power Verification With Chassis Dynamometer" . Does the vehicle make correct horsepower
for its specifications?
3.a Yes; no concern found, release vehicle.
4. Acquire a fuel sample from the vehicle fuel tank(s).
5. Submit fuel sample for an ASTM test analysis. Does the fuel sample meet specifications?
5.b No; drain the fuel tanks referring to OEM guidelines and dispose of properly. Refill the fuel tanks with
new ultra-low sulfur diesel fuel.
6. Turn the ignition ON (key ON, engine OFF). Using DiagnosticLink , under instrumentation, record the
barometric pressure value. Compare the barometric pressure value with barometric pressure versus
altitude chart. Refer to section "Barometric Pressure vs Altitude Chart" . Compare the barometric pressure value to the
inlet manifold pressure value. Is the barometric pressure value within 28 kPa (4 psi) of the barometric
pressure versus altitude chart value and inlet manifold pressure value?
6.b No; repair or replace as necessary.
7. Check the air filter. Is the air filter restricted?
7.a Yes; replace air filter as necessary.
8. Perform crankcase pressure test. Refer to section "Crankcase Pressure Test" . Did the crankcase pressure test
pass?
9. Attach air-to-air Charge Air Cooler (CAC) test kit, J-41473; refer to OEM guidelines.
10. Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing.
11. Attach the CAC test kit adaptor plug to fit into the hose at the compressor connector; refer to OEM
guidelines.
1
WARNING
EYE INJURY
12. Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the air inlet system to
a pressure of 205 kPa (30 psi).
13. Apply a water and soap solution to each hose connection, across the face of the CAC.
14. Apply a water and soap solution to the air intake manifold and cylinder head mating surface area.
15. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks. Are any
leaks present?
15.a Yes; repair or replace as necessary.
16. Check the following exhaust system components (exhaust manifold, turbocharger, interstage duct) for
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
17. Start and run the engine at idle with no-load for approximately five minutes, allowing the engine coolant to
reach normal operating range, 88 to 96°C (190 to 205°F).
18. On the chassis dynamometer, run the engine speed to full load. Is the exhaust backpressure at full load
less than 10.1 kPa (3.0 in. Hg)?
19. Visually examine the charge air cooler. Look for any obstruction or damage. Is damage or obstructions
present?
2
20. Initiate a parked regeneration. Is the DOC inlet pressure starting above the pressures specified in the box
below?
Engine Specification
GHG17 6 kPa (.89 psi)
GHG17 DD15 AT Only 7 kPa (1.01 psi)
20.a Yes; the DOC is plugged, causing the low power condition due to an exhaust restriction.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
21. Start and run the engine.

22. Run the engine at idle with a no-load for approximately five minutes, allowing the engine coolant to reach
normal operating range, 88 to 96°C (190 to 205°F). Is the return fuel temperature less than or equal to 60°C
(140°F)?
22.b No; replace the fuel filters.
23. Using DiagnosticLink® , run an FSIC routine.
24. Review the FSIC routine log file using DiagnosticLink® and monitor fuel compensation pressure. Refer to
section "Normal Fuel System Pressures - Two-Filter System" Refer to section "Normal Fuel System Pressures – Two-
Filter System". Is fuel compensation pressure low?
25. Review the FSIC routine log file using DiagnosticLink® and monitor Low Pressure Pump Out (LPPO)
pressure. Refer to section "Normal Fuel System Pressures - Two-Filter System" Is LPPO pressure low?
3
25.b No; correct the cause of low fuel compensation pressure, then re-test for low wheel horsepower. If low
wheel horsepower is still present, Go to step 26.
26. Verify the fuel injector(s) part number is correct for the engine application. Is the fuel injector(s) part number
correct?

26.b No; install the correct fuel injector(s).
27. Compare the calibration code(s) shown on the DiagnosticLink display with the six digit calibration code(s)
on the fuel injector(s). Do the calibration codes match?
4
27.a Yes; check compression pressure. Refer to section "Relative Cylinder Compression Test" .
27.b No; the fuel injector setting must be reset using DiagnosticLink .
5
30.2 Factors That Affect Wheel Horsepower

The factors affecting wheel horsepower are listed in the following table.
6
Factors Considerations
Fan Operation All engines will incorporate a 10% derate when a fan code becomes active. This is
important to know when dyno testing a truck and unplugging a fan to lock it ON. You
either must compensate for the derate on the calculation, or find another method to lock
the fan ON. Consider using Fan Override switch, if equipped.
Throttle Position Using DDDL 7.X, verify that you have 100% throttle position.
DDEC Power Rating Is the correct power rating programmed into the MCM? Is the driver aware of the effects
that cruise power, or the lack of cruise power has on perceived power?
Road Speed Setting Is the road speed setting causing a perceived lack of power?
Crank Case Overfilled If the crank case level is too high, there will be a loss of power due to churning losses
created by the crank shaft throws contacting the oil.
Fuel Temperature Make sure there is sufficient fuel supply (at least 1/3 of normal capacity) in the fuel tanks.
Check fuel temperature. For every 10°F increase in fuel inlet temperature above 100°F,
the engine will experience a power loss of up to one percent and could have a possible
Amber Warning Light and derate situation.
Fuel Blend (specific gravity) Check the specific gravity in the fuel/vehicle system. A typical D2 ULSD fuel has a
specific gravity raging from 0.830 to 0.85 @ 60°F. It should be noted that No. 1 diesel fuel
can reduce horsepower to 3.5 to 4 % HP less than No. 2 fuel. Blends of No. 1 and No. 2
(common in winter) will produce less horsepower, depending on the percent of the blend.
This is a common concern when dealing with low power complaints in cold climate
locations.
Fuel Filter Restriction Check for fuel flow restrictions which can be caused by undersize or improperly
routed/damaged fuel lines, faulty check valves, or contaminated fuel filters. Check the
restriction gauge or fuel pressure to determine filter condition.
Fuel Shut-Off Valve Position Make sure the fuel shut-off valve is fully open.
Fuel System Leak Fuel system leaks which result in aerated fuel are normally caused by a leak at the
connections and /or filters between the suction side of the fuel pump to the supply tank
and not between the pressure side of the pump and engine.
Fuel Tank Vent Restriction A plugged fuel tank vent will create a vacuum in the tank and result in a loss in fuel
pressure at the fuel injectors. This will reduce fuel delivery rate.
Air in Fuel Aerated fuel, caused by a fuel system leak, will result in reduced fuel delivery and late
injection timing.
Plugged or Cracked Fuel Tank If the fuel tank stand pipe is plugged by a shop rag or other debris, fuel delivery will be
Stand Pipe restricted. A cracked stand pipe will allow air to enter the fuel system and reduce fuel flow
and cause late injection timing.
Faulty Fuel Injector A faulty fuel injector will limit fuel delivery and alter the combustion process such that
power is compromised.
Fuel Injector Codes Incorrect fuel injector codes will limit fuel delivery.
Valve Lash Incorrect valve lash will alter the combustion process such that power is compromised.
Camshaft Timing Incorrect cam timing will alter the combustion process such that power is compromised.
Air Flow Restriction Air flow must not be inhibited by plugged filter, or inadequate inlet air duct shrouding.
Faulty Turbocharger A turbocharger that has wheel rubbing, oil leaks, bent blades, etc. will not provide
adequate air supply.
Temperature Controlled Fan A faulty thermo control will cause the fan to be locked on and drain power on a
continuous basis.
Air System Leaks (gaskets and Air system leaks will result in insufficient air for optimum combustion.
seals) or/and Charge Air System
Leak
Climate (fresh air temp) The maximum allowable temperature rise from ambient air to engine inlet is 30°F.
Undersized or dirty air cleaner element, as well as damaged or obstructed air inlet piping
can cause low power. Make sure under-hood hot air is not being taken in. Pressure drop
across the air to air charge cooler should be checked (3.0 in. Hg maximum from
turbocharger discharge to intake manifold). Check turbocharger boost pressure and
compare to specification.
Altitude Performance Site altitude has an effect on engine horsepower. Expect approximately 2% loss in power
when operating at an altitude of 5280 feet (1 mile), relative to sea level.
DDEC Parameter Settings Make sure vehicle settings such as: axle ratio, tire size, top gear ratio, etc. are set
correctly to avoid a false sense of engine performance.
EGR Valve A misadjusted or malfunctioning EGR valve will alter the amount of oxygen available for
combustion as well as introduce inert gas that does not promote combustion.
Exhaust Restriction A damaged, undersized, or otherwise restricted ATS or exhaust system can result in high
exhaust back pressure. Refer to the engine specification sheets for maximum allowable
pressure.
7
Delta P Sensor The Delta P sensor, along with the exhaust temperature, determines EGR flow rate. A
faulty Delta P sensor will cause the EGR system to malfunction and alter the amount of
oxygen available for combustion as well as introduce inert gas that will not promote
combustion.
Barometric Pressure Sensor The engine will reduce horsepower as a function of altitude to protect critical engine
components. Power reduction starts at approximately 8700 ft. on power ratings greater
than 500 hp. Altitude is determined by barometric pressure. A faulty Barometric Pressure
sensor could start a premature power reduction.
Air Compressor Leak An air compressor leak will cause the air compressor to work more and increase the
parasitic load on the engine.
Air Conditioner Leak An air conditioner leak will cause the air conditioner to work more and increase the
Excessive Play in Power Steering Continuous movement of the steering wheel will call for continuous work by the power
System steering unit. This will increase the parasitic load on the engine.
Alternator Load Excessive use of vehicle electrical power will cause increased use of the alternator. This
will increase the parasitic load on the engine.
Tire Pressure Under inflated tires will significantly increase driveline resistance to rotation.
Trailer Aerodynamics/Alignment A trailer that has poor aerodynamics or has misaligned axles (causing dog tailing) will
significantly increase vehicle inertia and resistance to forward motion.
Exhaust Leaks These leaks will cause low power and black smoke.
Vehicle Payload As vehicle loading increases, vehicle inertia and resistance to forward motion increases.
Winter-front Installation Improper installation or usage of a winter-front will result in extremely high intake air
temperatures and reduced mass flow of air into the combustion chamber.
Vehicle Application Unusual applications such as triple drive axles, PTO's, pumps, high air compressor duty
cycle, etc., will have higher parasitic loses resulting in less horsepower at the wheels.
Axial Power Turbine Failure Damage to turbine causing low power
8
30.3 Low Power Troubleshooting

Symptoms
Possible Excessive
Causes Loss of Poor Black Oil
Misfires Erratic Idle Engine Dies
Power Acceleration Smoke Consumptio
n
Fuel Filter X X X X X — —
Restriction
Fuel Shut-Off
Valve not X X X X X — —
Open
Air in the Fuel X X X X X — —
Faulty fuel X X X X X X —
injector
Faulty X — X — — X X
Turbocharger
EGR Valve X — X X — X —
Delta P sensor
or Plugged X — X X — X —
Lines
Charge Air X — X — — X —
Cooler Leak
Intake or
Exhaust X — X — — X —
Manifold Leak
Quality/Grade X X X — — X —
of Fuel
High Fuel
Temperature - X — X — — — —
Above 130°F
Restricted Air X — X — — X —
Intake
Crankcase X — X — — — X
Overfilled
Faulty Fan
Operation, X — X — — X —
Always On
Debris in Fuel
Tank - Air X X X X X X —
Vent Plugged
9
30.4 Engine Diagnostic Questionnaire

Engine Diagnostic Questionnaire is seen below:
10
30.5 Barometric Pressure vs Altitude Chart

The engine will reduce horsepower as a function of altitude to protect critical engine components. Power reduction
starts at approximately 8700 ft. on power ratings greater than 500 hp. Altitude is determined by barometric
pressure. A faulty barometric pressure sensor could start a premature power reduction. Check the barometric
pressure sensor.
If your vehicle is operating above sea level, a loss of power will be encountered, no further troubleshooting is
required. If your vehicle is operating at or below sea level and there is a lack of power, .
Barometric Pressure vs Altitude

Altitude Altitude Altitude Altitude Altitude Altitude
Baro (kPa) Baro (kPa) Baro (kPa)
(Ft) (M) (Ft) (M) (Ft) (M)
100.01 0 0 83.1 5400 1636 67.9 10800 3273
99.4 200 61 82.5 5600 1697 67.3 11000 3333
98.7 400 121 81.9 5800 1758 66.8 11200 3394
98.0 600 182 81.3 6000 1818 66.3 11400 3455
97.4 800 242 80.7 6200 1879 65.8 11600 3515
96.7 1000 303 80.1 6400 1939 65.2 11800 3576
96.1 1200 364 79.5 6600 2000 64.7 12000 3636
95.4 1400 424 79.0 6800 2061 64.2 12200 3697
94.8 1600 485 78.4 7000 2121 63.7 12400 3758
94.2 1800 545 77.8 7200 2182 63.2 12600 3818
93.5 2000 606 77.2 7400 2242 62.7 12800 3879
92.9 2200 667 76.7 7600 2303 62.2 13000 3939
92.3 2400 727 76.1 7800 2364 61.7 13200 4000
91.6 2600 788 75.5 8000 2424 61.2 13400 4061
91.0 2800 848 75.0 8200 2485 60.7 13600 4121
90.4 3000 909 74.4 8400 2545 60.2 13800 4182
89.8 3200 970 73.8 8600 2606 59.7 14000 4242
89.1 3400 1030 73.3 8800 2667 59.2 14200 4303
88.5 3600 1091 72.7 9000 2727 58.7 14400 4364
87.9 3800 1152 72.2 9200 2788 58.2 14600 4424
87.3 4000 1212 71.6 9400 2848 57.7 14800 4485
86.7 4200 1273 71.1 9600 2909 57.3 15000 4545
86.1 4400 1333 70.6 9800 2970 56.8 15200 4606
85.5 4600 1394 70.0 10000 3030 56.3 15400 4667
84.9 4800 1455 69.5 10200 3091 55.8 15600 4727
84.3 5000 1515 68.9 10400 3152 55.4 15800 4788
83.7 5200 1576 68.4 10600 3212 54.9 16000 4848
11
Symptom Diagnostics - Low Wheel Horsepower
30.1 Checking for Low Wheel Horsepower

Check as follows:
Note : Have operator fill out the Engine Diagnostic Questionnaire.
1. Check for active/inactive codes. Are there any active codes present?
2. Using DiagnosticLink , check the following DDEC parameters for correct values:
Progressive shift: Refer to section "Progressive Shift" .
Low gear torque reduction: Refer to section "Low Gear Torque Reduction" .
Do the parameters have the correct values?
2.b No; update to the correct values, and then retest for low wheel horsepower. If low wheel horsepower is
still present, Go to step 3.
Note : All engines will incorporate a 10% derate when a fan code becomes active. This is important to know when
dyno testing a truck and unplugging a fan to lock it ON. You either must compensate for the derate on the
calculation, or find another method to lock the fan ON. Consider using Fan Override switch, if equipped.
3. Check that the dyno-measured power is within Detroit™ specifications as for minimum acceptable wheel
HP data. Refer to section "Power Verification With Chassis Dynamometer" . Does the vehicle make correct horsepower
for its specifications?
3.a Yes; no concern found, release vehicle.
4. Acquire a fuel sample from the vehicle fuel tank(s).
5. Submit fuel sample for an ASTM test analysis. Does the fuel sample meet specifications?
5.b No; drain the fuel tanks referring to OEM guidelines and dispose of properly. Refill the fuel tanks with
new ultra-low sulfur diesel fuel.
6. Turn the ignition ON (key ON, engine OFF). Using DiagnosticLink , under instrumentation, record the
barometric pressure value. Compare the barometric pressure value with barometric pressure versus
altitude chart. Refer to section "Barometric Pressure vs Altitude Chart" . Compare the barometric pressure value to the
inlet manifold pressure value. Is the barometric pressure value within 28 kPa (4 psi) of the barometric
pressure versus altitude chart value and inlet manifold pressure value?
7. Check the air filter. Is the air filter restricted?
7.a Yes; replace air filter as necessary.
8. Perform crankcase pressure test. Refer to section "Crankcase Pressure Test" . Did the crankcase pressure test
pass?
9. Attach air-to-air Charge Air Cooler (CAC) test kit, J-41473; refer to OEM guidelines.
11. Attach the CAC test kit adaptor plug to fit into the hose at the compressor connector; refer to OEM
guidelines.
12
WARNING
EYE INJURY
13. Apply a water and soap solution to each hose connection, across the face of the CAC.
15. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks. Are any
leaks present?
15.a Yes; repair or replace as necessary.
16. Check the following exhaust system components (exhaust manifold, turbocharger, interstage duct) for
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
17. Start and run the engine at idle with no-load for approximately five minutes, allowing the engine coolant to
reach normal operating range, 88 to 96°C (190 to 205°F).
18. On the chassis dynamometer, run the engine speed to full load. Is the exhaust backpressure at full load
less than 10.1 kPa (3.0 in. Hg)?
19. Visually examine the charge air cooler. Look for any obstruction or damage. Is damage or obstructions
present?
13
20. Initiate a parked regeneration. Is the DOC inlet pressure starting above the pressures specified in the box
below?
Engine Specification
GHG17 6 kPa (.89 psi)
GHG17 DD15 AT Only 7 kPa (1.01 psi)
20.a Yes; the DOC is plugged, causing the low power condition due to an exhaust restriction.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

22. Run the engine at idle with a no-load for approximately five minutes, allowing the engine coolant to reach
normal operating range, 88 to 96°C (190 to 205°F). Is the return fuel temperature less than or equal to 60°C
(140°F)?
22.b No; replace the fuel filters.
23. Using DiagnosticLink® , run an FSIC routine.
24. Review the FSIC routine log file using DiagnosticLink® and monitor fuel compensation pressure. Refer to
section "Normal Fuel System Pressures - Two-Filter System" Refer to section "Normal Fuel System Pressures – Two-
Filter System". Is fuel compensation pressure low?
25. Review the FSIC routine log file using DiagnosticLink® and monitor Low Pressure Pump Out (LPPO)
pressure. Refer to section "Normal Fuel System Pressures - Two-Filter System" Is LPPO pressure low?
14

25.b No; correct the cause of low fuel compensation pressure, then re-test for low wheel horsepower. If low
wheel horsepower is still present, Go to step 26.
26. Verify the fuel injector(s) part number is correct for the engine application. Is the fuel injector(s) part number
correct?

26.b No; install the correct fuel injector(s).
27. Compare the calibration code(s) shown on the DiagnosticLink display with the six digit calibration code(s)
on the fuel injector(s). Do the calibration codes match?
15
27.a Yes; check compression pressure. Refer to section "Relative Cylinder Compression Test" .
27.b No; the fuel injector setting must be reset using DiagnosticLink .
16
30.2 Factors That Affect Wheel Horsepower

The factors affecting wheel horsepower are listed in the following table.
17
Factors Considerations
Fan Operation All engines will incorporate a 10% derate when a fan code becomes active. This is
important to know when dyno testing a truck and unplugging a fan to lock it ON. You
either must compensate for the derate on the calculation, or find another method to lock
the fan ON. Consider using Fan Override switch, if equipped.
Throttle Position Using DDDL 7.X, verify that you have 100% throttle position.
DDEC Power Rating Is the correct power rating programmed into the MCM? Is the driver aware of the effects
that cruise power, or the lack of cruise power has on perceived power?
Road Speed Setting Is the road speed setting causing a perceived lack of power?
Crank Case Overfilled If the crank case level is too high, there will be a loss of power due to churning losses
created by the crank shaft throws contacting the oil.
Fuel Temperature Make sure there is sufficient fuel supply (at least 1/3 of normal capacity) in the fuel tanks.
Check fuel temperature. For every 10°F increase in fuel inlet temperature above 100°F,
the engine will experience a power loss of up to one percent and could have a possible
Amber Warning Light and derate situation.
Fuel Blend (specific gravity) Check the specific gravity in the fuel/vehicle system. A typical D2 ULSD fuel has a
specific gravity raging from 0.830 to 0.85 @ 60°F. It should be noted that No. 1 diesel fuel
can reduce horsepower to 3.5 to 4 % HP less than No. 2 fuel. Blends of No. 1 and No. 2
(common in winter) will produce less horsepower, depending on the percent of the blend.
This is a common concern when dealing with low power complaints in cold climate
locations.
Fuel Filter Restriction Check for fuel flow restrictions which can be caused by undersize or improperly
routed/damaged fuel lines, faulty check valves, or contaminated fuel filters. Check the
restriction gauge or fuel pressure to determine filter condition.
Fuel Shut-Off Valve Position Make sure the fuel shut-off valve is fully open.
Fuel System Leak Fuel system leaks which result in aerated fuel are normally caused by a leak at the
connections and /or filters between the suction side of the fuel pump to the supply tank
and not between the pressure side of the pump and engine.
Fuel Tank Vent Restriction A plugged fuel tank vent will create a vacuum in the tank and result in a loss in fuel
pressure at the fuel injectors. This will reduce fuel delivery rate.
Air in Fuel Aerated fuel, caused by a fuel system leak, will result in reduced fuel delivery and late
injection timing.
Plugged or Cracked Fuel Tank If the fuel tank stand pipe is plugged by a shop rag or other debris, fuel delivery will be
Stand Pipe restricted. A cracked stand pipe will allow air to enter the fuel system and reduce fuel flow
and cause late injection timing.
Faulty Fuel Injector A faulty fuel injector will limit fuel delivery and alter the combustion process such that
power is compromised.
Fuel Injector Codes Incorrect fuel injector codes will limit fuel delivery.
Valve Lash Incorrect valve lash will alter the combustion process such that power is compromised.
Camshaft Timing Incorrect cam timing will alter the combustion process such that power is compromised.
Air Flow Restriction Air flow must not be inhibited by plugged filter, or inadequate inlet air duct shrouding.
Faulty Turbocharger A turbocharger that has wheel rubbing, oil leaks, bent blades, etc. will not provide
adequate air supply.
Temperature Controlled Fan A faulty thermo control will cause the fan to be locked on and drain power on a
continuous basis.
Air System Leaks (gaskets and Air system leaks will result in insufficient air for optimum combustion.
seals) or/and Charge Air System
Leak
Climate (fresh air temp) The maximum allowable temperature rise from ambient air to engine inlet is 30°F.
Undersized or dirty air cleaner element, as well as damaged or obstructed air inlet piping
can cause low power. Make sure under-hood hot air is not being taken in. Pressure drop
across the air to air charge cooler should be checked (3.0 in. Hg maximum from
turbocharger discharge to intake manifold). Check turbocharger boost pressure and
compare to specification.
Altitude Performance Site altitude has an effect on engine horsepower. Expect approximately 2% loss in power
when operating at an altitude of 5280 feet (1 mile), relative to sea level.
DDEC Parameter Settings Make sure vehicle settings such as: axle ratio, tire size, top gear ratio, etc. are set
correctly to avoid a false sense of engine performance.
EGR Valve A misadjusted or malfunctioning EGR valve will alter the amount of oxygen available for
combustion as well as introduce inert gas that does not promote combustion.
Exhaust Restriction A damaged, undersized, or otherwise restricted ATS or exhaust system can result in high
exhaust back pressure. Refer to the engine specification sheets for maximum allowable
pressure.
18
Delta P Sensor The Delta P sensor, along with the exhaust temperature, determines EGR flow rate. A
faulty Delta P sensor will cause the EGR system to malfunction and alter the amount of
oxygen available for combustion as well as introduce inert gas that will not promote
combustion.
Barometric Pressure Sensor The engine will reduce horsepower as a function of altitude to protect critical engine
components. Power reduction starts at approximately 8700 ft. on power ratings greater
than 500 hp. Altitude is determined by barometric pressure. A faulty Barometric Pressure
sensor could start a premature power reduction.
Air Compressor Leak An air compressor leak will cause the air compressor to work more and increase the
Air Conditioner Leak An air conditioner leak will cause the air conditioner to work more and increase the
Excessive Play in Power Steering Continuous movement of the steering wheel will call for continuous work by the power
System steering unit. This will increase the parasitic load on the engine.
Alternator Load Excessive use of vehicle electrical power will cause increased use of the alternator. This
will increase the parasitic load on the engine.
Tire Pressure Under inflated tires will significantly increase driveline resistance to rotation.
Trailer Aerodynamics/Alignment A trailer that has poor aerodynamics or has misaligned axles (causing dog tailing) will
significantly increase vehicle inertia and resistance to forward motion.
Exhaust Leaks These leaks will cause low power and black smoke.
Vehicle Payload As vehicle loading increases, vehicle inertia and resistance to forward motion increases.
Winter-front Installation Improper installation or usage of a winter-front will result in extremely high intake air
temperatures and reduced mass flow of air into the combustion chamber.
Vehicle Application Unusual applications such as triple drive axles, PTO's, pumps, high air compressor duty
cycle, etc., will have higher parasitic loses resulting in less horsepower at the wheels.
Axial Power Turbine Failure Damage to turbine causing low power
19
30.3 Low Power Troubleshooting

Symptoms
Possible Excessive
Causes Loss of Poor Black Oil
Misfires Erratic Idle Engine Dies
Power Acceleration Smoke Consumptio
n
Fuel Filter X X X X X — —
Restriction
Fuel Shut-Off
Valve not X X X X X — —
Open
Air in the Fuel X X X X X — —
Faulty fuel X X X X X X —
injector
Faulty X — X — — X X
Turbocharger
EGR Valve X — X X — X —
Delta P sensor
or Plugged X — X X — X —
Lines
Charge Air X — X — — X —
Cooler Leak
Intake or
Exhaust X — X — — X —
Manifold Leak
Quality/Grade X X X — — X —
of Fuel
High Fuel
Temperature - X — X — — — —
Above 130°F
Restricted Air X — X — — X —
Intake
Crankcase X — X — — — X
Overfilled
Faulty Fan
Operation, X — X — — X —
Always On
Debris in Fuel
Tank - Air X X X X X X —
Vent Plugged
20
30.4 Engine Diagnostic Questionnaire

Engine Diagnostic Questionnaire is seen below:
21
30.5 Barometric Pressure vs Altitude Chart

The engine will reduce horsepower as a function of altitude to protect critical engine components. Power reduction
starts at approximately 8700 ft. on power ratings greater than 500 hp. Altitude is determined by barometric
pressure. A faulty barometric pressure sensor could start a premature power reduction. Check the barometric
pressure sensor.
If your vehicle is operating above sea level, a loss of power will be encountered, no further troubleshooting is
required. If your vehicle is operating at or below sea level and there is a lack of power, .
Barometric Pressure vs Altitude

Altitude Altitude Altitude Altitude Altitude Altitude
Baro (kPa) Baro (kPa) Baro (kPa)
(Ft) (M) (Ft) (M) (Ft) (M)
100.01 0 0 83.1 5400 1636 67.9 10800 3273
99.4 200 61 82.5 5600 1697 67.3 11000 3333
98.7 400 121 81.9 5800 1758 66.8 11200 3394
98.0 600 182 81.3 6000 1818 66.3 11400 3455
97.4 800 242 80.7 6200 1879 65.8 11600 3515
96.7 1000 303 80.1 6400 1939 65.2 11800 3576
96.1 1200 364 79.5 6600 2000 64.7 12000 3636
95.4 1400 424 79.0 6800 2061 64.2 12200 3697
94.8 1600 485 78.4 7000 2121 63.7 12400 3758
94.2 1800 545 77.8 7200 2182 63.2 12600 3818
93.5 2000 606 77.2 7400 2242 62.7 12800 3879
92.9 2200 667 76.7 7600 2303 62.2 13000 3939
92.3 2400 727 76.1 7800 2364 61.7 13200 4000
91.6 2600 788 75.5 8000 2424 61.2 13400 4061
91.0 2800 848 75.0 8200 2485 60.7 13600 4121
90.4 3000 909 74.4 8400 2545 60.2 13800 4182
89.8 3200 970 73.8 8600 2606 59.7 14000 4242
89.1 3400 1030 73.3 8800 2667 59.2 14200 4303
88.5 3600 1091 72.7 9000 2727 58.7 14400 4364
87.9 3800 1152 72.2 9200 2788 58.2 14600 4424
87.3 4000 1212 71.6 9400 2848 57.7 14800 4485
86.7 4200 1273 71.1 9600 2909 57.3 15000 4545
86.1 4400 1333 70.6 9800 2970 56.8 15200 4606
85.5 4600 1394 70.0 10000 3030 56.3 15400 4667
84.9 4800 1455 69.5 10200 3091 55.8 15600 4727
84.3 5000 1515 68.9 10400 3152 55.4 15800 4788
83.7 5200 1576 68.4 10600 3212 54.9 16000 4848
22
31.1 Check for Excessive Oil Consumption

Check as follows:
1. Complete an Oil Consumption Report. Refer to the "Lube Oil Consumption Report" . Is oil consumption excessive?
1.b No; troubleshooting is complete. Release the vehicle.
2. Check first for external oil leaks. Are external oil leaks present?
3. Check for oil contamination in the coolant. Is there oil contamination in the coolant?
3.a Yes; Refer to section "Oil in Coolant" .
4. Perform a crankcase pressure test. Refer to section "Crankcase Pressure Test" . Is excessive crankcase pressure
found?
5. Using DiagnosticLink®, perform the Relative Compression test. Refer to section "Relative Cylinder Compression Test"
. Are the compression test results within specifications?
5.b No; inspect for cause of low compression, based on the Mechanical Cylinder Compression test results.
6. Check the interior of the exhaust S-pipe (Turbo Compound DD15 and DD16) or the exhaust flanged
manifold (DD13 and DD15 Asymmetrical Turbo DD15) for oil. Is excessive oil present?
WARNING
PERSONAL INJURY
7. Remove the turbocharger and inter-stage duct (if equipped), and inspect for oil in the exhaust manifold. Is
oil present in the exhaust manifold?
For the DD13 and DD15, Refer to section "Removal of the DD13 and DD15 Turbocharger" .
For the DD16, Refer to section "Removal of the DD16 Turbocharger" .
8. Is oil present in the inter-stage duct (DD15), or the exhaust flanged manifold (DD13)?
9. Inspect the turbocharger for damage. Is there damage to the turbocharger?
For the DD13 and DD15, Refer to section "Inspection of the DD13 and DD15 Turbocharger" .
For the DD16, Refer to section "Inspection of the DD16 Turbocharger" .
9.a Yes; replace the turbocharger.
1
9.b No; check for air inlet restrictions.

10. Check pressure output of the Axial Power Turbine (APT) air solenoid using an air pressure gauge. Is the
APT air pressure 21 to 48 kPa (3 to 7 psi)?
10.a Yes; replace the APT. Refer to section "Removal of the Axial Power Turbine" .
10.b No; if the air pressure is out of specification. Replace the APT air solenoid.
11. Remove the exhaust manifold to determine if the oil is coming from one cylinder or multiple cylinders. Is the
oil coming from multiple cylinders?
For DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Manifold"
For DD16: Refer to section "Removal of the DD16 Exhaust Manifold"
12. Look in the air inlet and Charge Air Cooler (CAC) pipes for excessive oil. Is excessive oil present?
12.a Yes; clean the oil presence in the CAC . Go to step 14.
13. Inspect the valve seals, stems, and guides for wear. Is wear found?
14. Remove the cylinder head and inspect cylinder(s) for damage. Repair as necessary.
For DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly"
2

Check as follows:
found?
WARNING
PERSONAL INJURY
3

4
Symptom Diagnostics - Excessive Oil Consumption

Check as follows:
found?
WARNING
PERSONAL INJURY
5
6
32.1 Excessive Black or Grey Smoke

To check for excessive black or grey smoke perform the following:
NOTICE
Use only Ultra-Low Sulfur Diesel (ULSD) fuel (15 ppm sulfur content maximum), based on
ASTM D2622 test procedure.
NOTICE
Always check the Aftertreatment Device for internal damage when experiencing exhaust
smoke. The Aftertreatment Device could be a secondary failure.
1. Verify proper ultra-low sulfur diesel fuel is being used. Is the correct fuel being used?
WARNING
ENGINE EXHAUST
2. Run engine from a known good fuel source. Go to step 3.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Run the engine at idle with no-load for approximately five minutes, allowing the engine coolant to reach
normal operating range.
5. Visually inspect exhaust pipe for excessive black or grey smoke.
5.a If the engine exhaust smoke emission appears normal, no further troubleshooting is required. Shut
down the engine.
5.b If the engine exhaust smoke is excessively black or gray, shut down the engine. Go to step 6.
6. Check the air cleaner for restriction.
6.a If the air cleaner is restricted, remove the air filter element from the air cleaner container; refer to OEM
guidelines.
1
6.b If the air cleaner is not restricted. Go to step 7.

7. Attach the air-to-air cooler test kit (J-41473); refer to OEM guidelines.
9. Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor connector. Refer to
OEM guidelines.
11. Apply a water and soap solution to each hose connection, across the face of the charge air cooler.
13. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks.
13.a If air leaks are present around the joints, replace the charge air cooler. Refer to OEM guidelines.
13.b If air leaks are present around the air intake manifold. Repair as necessary.
13.c If NO air leaks are present Go to step 14.
14. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section "Removal of the Exhaust Gas Recirculation Hot
Pipe" .
15. Using DDDL 7.X command the EGR valve from full open to full closed. Visually verify that the EGR valve
fully opens and fully closes.
15.a If the EGR valve fully opens and fully closes, Go to step 18.
15.b If the EGR valve does not fully open and fully close, Go to step 16.
16. With the ignition OFF, manually check the EGR valve and actuator by sweeping for smoothness. Is binding
is present?
16.a If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR pull rod binds, Go to
step 17.
16.b If no binding is present, reset the EGR Valve actuator end stops using DDDL 7.X.
17. Check the EGR valve for excessive soot buildup.
For the DD13 and DD15 Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" .
For the DD16 Refer to section "Removal of the DD16 Exhaust Manifold" .
17.a If buildup exists, clean or replace as necessary.
17.b If no buildup exists, Go to step 18.
18. Check for soot or buildup in the EGR venturi Refer to section "Removal of the Exhaust Gas Recirculation Venturi" .
18.a If soot is found, clean the EGR venturi.
18.b If no soot is found, Go to step 19.
19. Check the Delta P sensor for leaks and blockage.
19.a If the Delta P sensor leaks or has blockage, clean or replace the Delta P sensor. Refer to section "Removal
of the Delta P Sensor"
19.b If the Delta P does not leak or have blockage, check for a cracked or leaking intake manifold or
gaskets. Repair as necessary.
2
32.2 Excessive Blue Smoke

Check as follows:
Note : Always check the Aftertreatment Device for internal damage when experiencing exhaust smoke. The
Aftertreatment Device could be a secondary failure.
1. Perform a crankcase pressure test. Refer to section "Crankcase Pressure Test" .
1.a Is excessive crankcase pressure is found, Go to step 2.
1.b Is excessive crankcase pressure is not found, Go to step 3.
2. Perform the relative compression test with DDDL 7.X or higher. Refer to section "Relative Cylinder Compression Test"
.
2.a If relative compression test shows no cylinders with low compression, Go to step 3.
2.b If relative compression test reveals a cylinder with low compression, inspect for a worn or damaged
cylinder kit. Repair as necessary.
3. Check the interior of the exhaust S-pipe (DD15) or the exhaust flanged manifold (DD13) for oil.
3.a If oil is found, Go to step 4.
3.b If no oil is found, Go to step 7.
4. Remove the turbocharger and inter-stage duct (if equipped), inspect for oil in the exhaust manifold.
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Turbocharger" .
For the DD16: Refer to section "Removal of the DD16 Turbocharger" .
4.a If oil is found in the inter-stage duct (DD15) or the exhaust flanged manifold (DD13) and none is found
in the exhaust manifold, Go to step 5.
4.b If no oil is found in the inter-stage duct (if equipped), Go to step 6.
4.c If oil is found in the exhaust manifold, Go to step 7.
For the DD13 and DD15: Refer to section "Inspection of the DD13 and DD15 Turbocharger" .
For the DD16: Refer to section "Inspection of the DD16 Turbocharger" .
5.a If the turbocharger is OK, check for air inlet restrictions.
5.b If the turbocharger appears to be defective, replace the turbocharger.
For the DD13: Refer to section "Removal of the DD13 and DD15 Turbocharger" .
For the DD15 and DD16: Refer to section "Removal of the DD16 Turbocharger" .
APT air pressure between 3 and 7 psi?
6.b No; if the air pressure is out of specification, change the APT air solenoid.
7. Remove the exhaust manifold to determine if the oil is coming from one cylinder or multiple cylinders.
7.a If oil is coming out of a particular cylinder, check the valve seals, stems, and guides for wear. If the
valve seals, stems, and guides are OK, Go to step 8.
7.b If oil is coming from multiple cylinders, look in the air inlet and Charge Air Cooler (CAC) pipes for oil
from the compressor side of the turbocharger. If no oil is found Go to step 8.
8.a For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly" .
8.b For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
3
32.3 Excessive White Smoke

Check as follows:
1. Check for water in the exhaust pipe.
1.a If no water is found, Go to step 2.
1.b If water is found, drain water and retest. If excessive white smoke is still present, Go to step 2.
2. Check engine coolant level.
2.a If coolant level is low, repair source of coolant loss.
2.b If coolant within specification, Go to step 3.
Pipe" .
5. With the ignition OFF, manually check the EGR valve and EGR actuator by sweeping for smoothness. Is
binding is present?
5.a If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR pull rod binds,
replace as necessary.
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve" .
For the DD16: Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve" .
5.b If no binding is present, Go to step 6.
6.a If buildup exists, clean or replace the EGR valve.
6.b If no buildup exists, reset the EGR Valve actuator end stops using DDDL 7.X.
7. Perform an Idle Speed Balance (ISB) test. Refer to section "Checking Idle Speed Balance" .
7.a If ISB test fails, repair as necessary.
7.b If ISB passes, Go to step 8.
8. Verify camshaft and valve timing. Refer to section "Camshaft Timing Verification" .
8.a If camshaft and valve timing is OK, contact the Detroit™ Customer Support Center at 800–445–1980.
8.b If camshaft and valve timing is not OK, repair as necessary.
4
Symptom Diagnostics - Excessive Exhaust Smoke
32.1 Excessive Black or Grey Smoke

To check for excessive black or grey smoke perform the following:
NOTICE
Use only Ultra-Low Sulfur Diesel (ULSD) fuel (15 ppm sulfur content maximum), based on
ASTM D2622 test procedure.
NOTICE
Always check the Aftertreatment Device for internal damage when experiencing exhaust
smoke. The Aftertreatment Device could be a secondary failure.
1. Verify proper ultra-low sulfur diesel fuel is being used. Is the correct fuel being used?
WARNING
ENGINE EXHAUST
2. Run engine from a known good fuel source. Go to step 3.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Run the engine at idle with no-load for approximately five minutes, allowing the engine coolant to reach
normal operating range.
5. Visually inspect exhaust pipe for excessive black or grey smoke.
5.a If the engine exhaust smoke emission appears normal, no further troubleshooting is required. Shut
down the engine.
5.b If the engine exhaust smoke is excessively black or gray, shut down the engine. Go to step 6.
5
6. Check the air cleaner for restriction.

6.a If the air cleaner is restricted, remove the air filter element from the air cleaner container; refer to OEM
guidelines.
6.b If the air cleaner is not restricted. Go to step 7.
7. Attach the air-to-air cooler test kit (J-41473); refer to OEM guidelines.
9. Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor connector. Refer to
OEM guidelines.
11. Apply a water and soap solution to each hose connection, across the face of the charge air cooler.
13. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks.
13.a If air leaks are present around the joints, replace the charge air cooler. Refer to OEM guidelines.
13.b If air leaks are present around the air intake manifold. Repair as necessary.
13.c If NO air leaks are present Go to step 14.
Pipe" .
16. With the ignition OFF, manually check the EGR valve and actuator by sweeping for smoothness. Is binding
is present?
16.a If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR pull rod binds, Go to
step 17.
16.b If no binding is present, reset the EGR Valve actuator end stops using DDDL 7.X.
For the DD13 and DD15 Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" .
For the DD16 Refer to section "Removal of the DD16 Exhaust Manifold" .
17.a If buildup exists, clean or replace as necessary.
17.b If no buildup exists, Go to step 18.
18. Check for soot or buildup in the EGR venturi Refer to section "Removal of the Exhaust Gas Recirculation Venturi" .
18.a If soot is found, clean the EGR venturi.
18.b If no soot is found, Go to step 19.
19. Check the Delta P sensor for leaks and blockage.
19.a If the Delta P sensor leaks or has blockage, clean or replace the Delta P sensor. Refer to section "Removal
of the Delta P Sensor"
19.b If the Delta P does not leak or have blockage, check for a cracked or leaking intake manifold or
gaskets. Repair as necessary.
6
32.2 Excessive Blue Smoke

Check as follows:
1. Perform a crankcase pressure test. Refer to section "Crankcase Pressure Test" .
1.a Is excessive crankcase pressure is found, Go to step 2.
1.b Is excessive crankcase pressure is not found, Go to step 3.
2. Perform the relative compression test with DDDL 7.X or higher. Refer to section "Relative Cylinder Compression Test"
.
2.a If relative compression test shows no cylinders with low compression, Go to step 3.
2.b If relative compression test reveals a cylinder with low compression, inspect for a worn or damaged
cylinder kit. Repair as necessary.
3. Check the interior of the exhaust S-pipe (DD15) or the exhaust flanged manifold (DD13) for oil.
3.a If oil is found, Go to step 4.
3.b If no oil is found, Go to step 7.
4. Remove the turbocharger and inter-stage duct (if equipped), inspect for oil in the exhaust manifold.
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Turbocharger" .
For the DD16: Refer to section "Removal of the DD16 Turbocharger" .
4.a If oil is found in the inter-stage duct (DD15) or the exhaust flanged manifold (DD13) and none is found
in the exhaust manifold, Go to step 5.
4.b If no oil is found in the inter-stage duct (if equipped), Go to step 6.
4.c If oil is found in the exhaust manifold, Go to step 7.
For the DD13 and DD15: Refer to section "Inspection of the DD13 and DD15 Turbocharger" .
For the DD16: Refer to section "Inspection of the DD16 Turbocharger" .
5.a If the turbocharger is OK, check for air inlet restrictions.
5.b If the turbocharger appears to be defective, replace the turbocharger.
For the DD13: Refer to section "Removal of the DD13 and DD15 Turbocharger" .
For the DD15 and DD16: Refer to section "Removal of the DD16 Turbocharger" .
APT air pressure between 3 and 7 psi?
6.b No; if the air pressure is out of specification, change the APT air solenoid.
7. Remove the exhaust manifold to determine if the oil is coming from one cylinder or multiple cylinders.
7.a If oil is coming out of a particular cylinder, check the valve seals, stems, and guides for wear. If the
valve seals, stems, and guides are OK, Go to step 8.
7.b If oil is coming from multiple cylinders, look in the air inlet and Charge Air Cooler (CAC) pipes for oil
from the compressor side of the turbocharger. If no oil is found Go to step 8.
8.a For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly" .
8.b For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly" .
7
32.3 Excessive White Smoke

Check as follows:
1. Check for water in the exhaust pipe.
1.a If no water is found, Go to step 2.
1.b If water is found, drain water and retest. If excessive white smoke is still present, Go to step 2.
2. Check engine coolant level.
2.a If coolant level is low, repair source of coolant loss.
2.b If coolant within specification, Go to step 3.
Pipe" .
5. With the ignition OFF, manually check the EGR valve and EGR actuator by sweeping for smoothness. Is
binding is present?
5.a If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR pull rod binds,
replace as necessary.
5.b If no binding is present, Go to step 6.
6.a If buildup exists, clean or replace the EGR valve.
6.b If no buildup exists, reset the EGR Valve actuator end stops using DDDL 7.X.
7.a If ISB test fails, repair as necessary.
7.b If ISB passes, Go to step 8.
8. Verify camshaft and valve timing. Refer to section "Camshaft Timing Verification" .
8.a If camshaft and valve timing is OK, contact the Detroit™ Customer Support Center at 800–445–1980.
8.b If camshaft and valve timing is not OK, repair as necessary.
8
33.1 Rod Out of the Block

Note : This diagnostic will help to determine the Primary Failed Part (PFP) of the engine failure. This will help to
determine responsibility for the failure and avoid future failures.
2. Does this repair require a determination of the root cause and/or Primary Failed Part (PFP)?
2.b No; replace the failed engine.
3. Refer to "DD Platform Bearing Failure Guide, DDC-SVC-MAN-0196".
1
Symptom Diagnostics - Rod Out of the Block
33.1 Rod Out of the Block

Note : This diagnostic will help to determine the Primary Failed Part (PFP) of the engine failure. This will help to
determine responsibility for the failure and avoid future failures.
2. Does this repair require a determination of the root cause and/or Primary Failed Part (PFP)?
2.b No; replace the failed engine.
3. Refer to "DD Platform Bearing Failure Guide, DDC-SVC-MAN-0196".
2
34.1 Check for Rough Running or Stalling - Two-Filter Fuel

System
Check as follows:
1. Connect using DDDL 7.11 or newer.
• SPN 1077/FMI 7 Rail Pressure Deviation
• SPN 3250/FMI 0 DOC Outlet Temperature Very High
• SPN 3246/FMI 0 DFP Outlet Temperature Very High
4. Using DDDL 7.11 or newer, Key ON, Engine OFF (KOEO), monitor the EGR Delta P voltage with the
coolant temperature above 65°C (150°F). Is the EGR Delta P voltage between 0.55 to 0.82 volts?
4.b No; perform the troubleshooting for SPN411/FMI 13.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : Fault code 411/4 will become active with the Delta P sensor unplugged.
5. Disconnect the Delta P electrical sensor. Key ON Engine Running, idle the engine for 30 seconds, then
using the accelerator pedal, increase the engine to 1000 rpm. Did the engine stop surging?
5.a Yes; clean the Exhaust Gas Recirculation Venturi ports and verify repairs.
Note : If the fuel mass is over 50 mg/st at 600 rpm (engine at operating temperature), abort the FSIC routine and
Go to step 7.
Note : See examples of erratic pressure showing (1) ASL001 Rail pressure and (2) AS098 Desired rail pressure.
6. Run an automatic Fuel System Integrity Check (FSIC) test. Review the automatic FSIC log file. Does
ASL001 Rail Pressure have a saw tooth pattern or does the desired rail pressure and rail pressure deviate
by more than 50 bar?
1
2
6.a Yes; replace the Quantity Control Valve (QCV).

7. Review the automatic FSIC log file. At 600 rpm, is fuel mass over 50 mg/st?
7.a Yes; replace both engine brake solenoids.
8. Check the Idle Speed Balance (ISB) values. Refer to section "Idle Speed Balance Test" . Are there any cylinders
above 70% or below -70%?
8.a Yes; follow repair procedures in idle speed balance test and verify repairs. Refer to section "Verify Repairs" .
9. Check for aerated fuel. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Is fuel aerated?
9.a Yes; if fuel is aerated, repair or replace as necessary.
9.b No; if fuel is not aerated, Go to step 10.
3
10. Check for loose connections, kinked fuel lines or issues related to the fuel system.
10.a If fuel system issues were found, repair or replace as necessary.
10.b If fuel system issues were not found, Go to step 11.
Note : If rust is found in the filters Refer to section "Diesel Exhaust Fluid in Fuel".
11. Remove the Fuel Prefilter and Fuel Coalescer/Final Filter. Refer to section "Removal of the Fuel Prefilter – Two Filter
System" and Refer to section "Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter System" for further instruction.
Check for damaged or missing seals at the bottom of filters. Are damaged or missing seals at the bottom of
the filters?
11.a Yes; replace fuel filters as necessary.
12. Check air vents at the top of the Fuel Coalescer/Final filter for blockage.
12.a If Fuel Coalescer/Final filter has a blockage, replace the fuel filter as needed. Refer to section "Removal of
the Coalescer/Final Filter – Two Filter System "
12.b If no blockage is found, Go to step 13.

Note : Use e-Parts to verify injector part numbers.
13. Verify the fuel injector(s) part number is correct for engine application. Is the fuel injector(s) part number
correct?
4

13.b No; install correct fuel injector(s).
14. Compare calibration code(s) shown on the DDDL 7.X display with six-digit calibration code(s) on the fuel
injector(s).
5
14.a If calibration codes match, Go to step 15.

14.b If calibration code on display is different than the calibration code on suspect fuel injector for that
cylinder, the fuel injector setting must be reset using DDDL 7.X.
Note : If proper valve lash cannot be obtained, call the Customer Support Center at 800-445-1980.
15. Check valve lash and engine brake rocker lash.
15.a If the valve lash is within specification and the engine brake is in adjustment, Go to step 16.
15.b If either is out of adjustment, readjust lash and retest.
16. Using DiagnosticLink®, perform a relative compression test; Refer to section "Relative Cylinder Compression Test" .
Are the results in range?
16.a Yes; contact the Customer Support Center at 800-445-1980.
16.b No; perform a Mechanical Cylinder Compression Test.
6
34.1 Check for Rough Running or Stalling - Two-Filter Fuel

System
Check as follows:
1. Connect using DDDL 7.11 or newer.
• SPN 3250/FMI 0 DOC Outlet Temperature Very High
• SPN 3246/FMI 0 DFP Outlet Temperature Very High
4. Using DDDL 7.11 or newer, Key ON, Engine OFF (KOEO), monitor the EGR Delta P voltage with the
coolant temperature above 65°C (150°F). Is the EGR Delta P voltage between 0.55 to 0.82 volts?
4.b No; perform the troubleshooting for SPN411/FMI 13.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : Fault code 411/4 will become active with the Delta P sensor unplugged.
5. Disconnect the Delta P electrical sensor. Key ON Engine Running, idle the engine for 30 seconds, then
using the accelerator pedal, increase the engine to 1000 rpm. Did the engine stop surging?
5.a Yes; clean the Exhaust Gas Recirculation Venturi ports and verify repairs.
Note : If the fuel mass is over 50 mg/st at 600 rpm (engine at operating temperature), abort the FSIC routine and
Go to step 7.
6. Run an automatic Fuel System Integrity Check (FSIC) test. Review the automatic FSIC log file. Does
ASL001 Rail Pressure have a saw tooth pattern or does the desired rail pressure and rail pressure deviate
by more than 50 bar?
7
8
6.a Yes; replace the Quantity Control Valve (QCV).

7. Review the automatic FSIC log file. At 600 rpm, is fuel mass over 50 mg/st?
7.a Yes; replace both engine brake solenoids.
8.a Yes; follow repair procedures in idle speed balance test and verify repairs. Refer to section "Verify Repairs" .
9. Check for aerated fuel. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Is fuel aerated?
9.a Yes; if fuel is aerated, repair or replace as necessary.
9.b No; if fuel is not aerated, Go to step 10.
9
10. Check for loose connections, kinked fuel lines or issues related to the fuel system.
10.a If fuel system issues were found, repair or replace as necessary.
10.b If fuel system issues were not found, Go to step 11.
Note : If rust is found in the filters Refer to section "Diesel Exhaust Fluid in Fuel" .
11. Remove the Fuel Prefilter and Fuel Coalescer/Final Filter. Refer to section "Removal of the Fuel Prefilter" and Refer to
section "Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter System" for further instruction. Check for damaged
or missing seals at the bottom of filters. Are damaged or missing seals at the bottom of the filters?
11.a Yes; replace fuel filters as necessary.
12. Check air vents at the top of the Fuel Coalescer/Final filter for blockage.
12.a If Fuel Coalescer/Final filter has a blockage, replace the fuel filter as needed. Refer to section "Removal of
the Coalescer/Final Filter "

Note : Use e-Parts to verify injector part numbers.
13. Verify the fuel injector(s) part number is correct for engine application. Is the fuel injector(s) part number
correct?
10

13.b No; install correct fuel injector(s).
14. Compare calibration code(s) shown on the DDDL 7.X display with six-digit calibration code(s) on the fuel
injector(s).
11
14.a If calibration codes match, Go to step 15.

14.b If calibration code on display is different than the calibration code on suspect fuel injector for that
cylinder, the fuel injector setting must be reset using DDDL 7.X.
Note : If proper valve lash cannot be obtained, call the Customer Support Center at 800-445-1980.
15. Check valve lash and engine brake rocker lash.
15.a If the valve lash is within specification and the engine brake is in adjustment, Go to step 16.
15.b If either is out of adjustment, readjust lash and retest.
16. Using DiagnosticLink®, perform a relative compression test; Refer to section "Relative Cylinder Compression Test" .
Are the results in range?
16.a Yes; contact the Customer Support Center at 800-445-1980.
16.b No; perform a Mechanical Cylinder Compression Test.
12
Symptom Diagnostics - Rough Running or Stalling
13
35.1 Engine Manufacturer Diagnostics Definitions

Description - lists the service fault code description which is displayed on the service tool and the extreme value
which needs to be met for the fault to be set.
Monitored Parameter - the component which is being monitored.
Typical Enabling Conditions - conditions which also need to be true for enabling conditions to be active (i.e.
coolant temp greater than 100°F).
Monitor Sequence - additional unique conditions which also need to be true in order for enabling conditions to be
active (i.e. fault X must also be active in order to monitor a particular failure).
Execution Frequency - how often the fault is monitored when enabling condition (if any) are met.
Typical Duration - length of time fault needs to be present to become active. May also include number of drive
cycles which need to be completed for fault to become active.
Dash Lamp - List all dash lights that will be illuminated if this fault code is active.
Engine Reaction - If a reduction in horse power is mandated by the active fault the percentage will be displayed.
Verification - This describes the required steps a technician needs to perform and the conditions needed to verify
that the customer concern is no longer present, thus allowing the truck to be released back to the customer.
1
Engine Manufacturer Diagnostics
35.1 Engine Manufacturer Diagnostics Definitions

Description - lists the service fault code description which is displayed on the service tool and the extreme value
which needs to be met for the fault to be set.
Monitored Parameter - the component which is being monitored.
Typical Enabling Conditions - conditions which also need to be true for enabling conditions to be active (i.e.
coolant temp greater than 100°F).
Monitor Sequence - additional unique conditions which also need to be true in order for enabling conditions to be
active (i.e. fault X must also be active in order to monitor a particular failure).
Execution Frequency - how often the fault is monitored when enabling condition (if any) are met.
Typical Duration - length of time fault needs to be present to become active. May also include number of drive
cycles which need to be completed for fault to become active.
Dash Lamp - List all dash lights that will be illuminated if this fault code is active.
Engine Reaction - If a reduction in horse power is mandated by the active fault the percentage will be displayed.
Verification - This describes the required steps a technician needs to perform and the conditions needed to verify
that the customer concern is no longer present, thus allowing the truck to be released back to the customer.
2
36.1 Virtual Technician
36.1.1 Terms and Abbreviations

CSC - Customer Support Center
ECM - Engine Control Module
ECU - Electronic Control Unit
FMI - Failure Mode Indicator. The part of a J1587, J1939, and CAN fault code that identifies how part of a device,
or item on a device, failed.
GPS - Global Positioning System
GSM - Global System for Mobile Communications; the cellular telephone network.
LED - Light-Emitting Diode
OTA - Over the Air; OTA refers to software updates made to the Virtual Technician system over the GPS system.
Parameter - A parameter is a specific value that is assigned to a feature or function of the vehicle, and allows the
customer to choose how that particular feature or function will work on the vehicle.
SA - Source Address, indicates any device that communicates on J1939.
SPN - Suspect Parameter Number. The part of a J1939 or CAN fault code that identifies how part of a device, or
item on a device, failed.
VT - Virtual Technician
36.1.2 General Information

The Virtual Technician (VT) ECU generates diagnostic information to aid Detroit™ and the technician in
diagnosing complex engine control issues. The system creates sensor log files, captures fault codes, and sends
alert messages and other advanced diagnostic information to the Detroit™ Customer Support Center. The ECU
utilizes GPS navigation, GSM (cellular telephone) communication, and a J1939 connection for databus
monitoring. Virtual Technician does not require any driver input to function.
36.1.3 Component Locations

On Cascadia vehicles, the ECU is located behind the sunglass holder on the passenger side of the overhead
console.
1
1. Dome Light (For Reference)

2. Virtual Technician ECU
Fig 0.1, Virtual Technician ECU, Cascadia Installation
On Western Star vehicles, the ECU is located behind the glove box along the cab side. The ECU can safely be
removed from the mount while remaining wired to the vehicle for visual diagnostic purposes.
2

2. Open Glove Box Door (Glove Box Removed)
3. Passenger Side Door (For Reference)
Fig 0.2, Virtual Technician ECU, Western Star Installation
36.1.4 Diagnostic Overview

All testing of the GPS and cellular reception must be done outside, and at a distance of at least 40 feet (12
meters) from any buildings. This ensures adequate GPS signal strength and good cellular reception.
Diagnosing Virtual Technician requires access to the ECU to view the LEDs on the unit. The LEDs provide
diagnostic information needed by the technician and the CSC (Customer Support Center). To access the unit,
remove the sunglass holder from the passenger side of the overhead console and detach the VT box from the
hook-and-loop tape mounting. To diagnose the unit, turn the ignition to the ON position.
There are seven LEDs visible on the VT ECU module. If no LEDs light up with the ignition ON, diagnose supplied
power and ground to the unit.
3
Diagnostic LEDs
Name Color Function Action
DL1 Red Red Blink (1Hz): J1708 Red is the normal and
connectivity (disabled). expected state. There is no
J1708 databus connection.
DL2 Red and Green Red Blink (1Hz): J1939 Green blink is expected. If
connectivity. No J1939 activity LED is blinking red, diagnose
detected (device is awake). J1939 connectivity issue at
the terminals. The LED will
Green Blink (1Hz): (1Hz): blink red when the VT is
J1939 activity detected awake but the ignition if OFF.
(device is awake). The VT remains awake for 2
minutes after the ignition is
tuned OFF and will flash red
during this time.
GSM Green Solid: GPS connection Solid is expected – if
successful. otherwise, call the CSC for
further instruction.
One Blink: Initializing.
Two Blinks: Acquiring time
zone information.
Three Blinks: Attempting to
make a GPS connection.
GPS Green Solid: Satellites acquired. Solid green when the satellite
is aquired with the external
One Blink: Acquiring antenna, and solid amber
satellites. when the satellite is acquired
with teh internal antenna.
Amber when no external
antenna is connected.
Status Green Solid: Engine running. Refer to J1939 fault codes if
problem is suspected.
One Blink: Engine not
running; no data to send.
Two Blinks: Data is
available to be sent.
Four Blinks: GPS storage
log is full.
AUX Red Solid: GSM Modem Comm. Refer to J1939 fault codes if
Error, or panic line is active. problem is suspected.
Two Blinks: Not Used.
Three Blinks: GSM modem
is not starting up.
Four Blinks: SIM Card read
error.
Five Blinks: GSM CTS
(clear-to-send) line is active.
Tamper Red Disabled N/A
36.1.5 Fault Codes
4
Fault Codes
Fault SPN FMI Details Action
SIM Card Error 524283 11 Installed SIM Card Contact CSC/Replace
cannot be read. ECU.
GPS Shorted 524286 4 Center lead shorted to Check the antenna
ground or cable ground. cable; replace GPS
Antenna if necessary.
GPS Not Connected 524286 5 Antenna open or cut. Attach GPS Antenna.
Replace Antenna if
wiring damaged.
NAND Full 524285 0 Full Contact CSC/Replace
ECU.
NAND ++Checksum 524285 2 Error Contact CSC/Replace
Error ECU.
uSD Full 524284 0 Full Contact CSC/Replace
ECU.
uSD Checksum Error 524284 2 Read/write error. Contact CSC/Replace
ECU.
uSD I/O Error (micro 524284 11 Cannot read/write – not Contact CSC/Replace
SD) present. ECU.
RTC Error (real time 524282 11 VTECU RTC out of Contact CSC/Replace
clock) range ECU.
36.1.6 DL1 and DL2 Alternate Functionality

These LEDs indicate other behavior than those indicated at startup:
• Fast-alternating red DL1 and DL2 blinks: indicates that the device is booting.
• Fast-alternating green DL1 and DL2 blinks: indicates that a new firmware file is detected and is being
loaded.
• Solid red DL1 and OFF (dark) DL2: indicates that the device is updating the vehicle interface firmware.
36.1.7 External Antennas

There are two coaxial (SMA) connectors on the VT ECU module. One connector is for an external GPS antenna,
and the other is for an external GSM antenna. The GSM antenna is mounted directly to the ECU.
36.1.8 Vehicle Fault Monitoring

When the VT ECU receives a new fault code, it compares the received message to a list stored internally. If the
fault code is already on the list, it will be ignored. New fault codes are added to the list and the appropriate
information is uploaded to the Zonar server. If the fault code is a ring buffer trigger, a ring buffer will be created
and uploaded along with the normal fault data.
36.1.9 Ring Buffer Files

The VT ECU is capable of generating diagnostic ring buffer files. A ring buffer file is a recording of J1939 databus
activity over a predefined period. This information is sent directly to the CSC for analysis.
36.1.10 Virtual Technician ECU Connector Reference
5
Fig 0.3, ECU Connector Reference
Power Connector
Connector Pin Name Type Minimum Maximum Notes
4-Pin 1 Power Input 8 VDC 30 VDC Requires
External Fuse
2 Ignition Input 0 VDC 30 VDC 0 VDC = Logic 0
1.8 VDC = Logic
1
Requires
External Fuse
3 Ground – 0 VCD 0 VDC –
4 -- -- -- -- --
6
Vehicle Communication Connector

Connector Pin Name
10-Pin 1 J1939 –H
2 CAN-Shield
3 J1708 (–)
4 NC
5 NC
6 J1939 –L
7 J1708 (+)
8 NC
9 NC
10 Ground
7
Virtual Technician
36.1 Virtual Technician
36.1.1 Terms and Abbreviations

CSC - Customer Support Center
ECM - Engine Control Module
ECU - Electronic Control Unit
FMI - Failure Mode Indicator. The part of a J1587, J1939, and CAN fault code that identifies how part of a device,
or item on a device, failed.
GPS - Global Positioning System
GSM - Global System for Mobile Communications; the cellular telephone network.
LED - Light-Emitting Diode
OTA - Over the Air; OTA refers to software updates made to the Virtual Technician system over the GPS system.
Parameter - A parameter is a specific value that is assigned to a feature or function of the vehicle, and allows the
customer to choose how that particular feature or function will work on the vehicle.
SA - Source Address, indicates any device that communicates on J1939.
SPN - Suspect Parameter Number. The part of a J1939 or CAN fault code that identifies how part of a device, or
item on a device, failed.
VT - Virtual Technician
36.1.2 General Information

The Virtual Technician (VT) ECU generates diagnostic information to aid Detroit™ and the technician in
diagnosing complex engine control issues. The system creates sensor log files, captures fault codes, and sends
alert messages and other advanced diagnostic information to the Detroit™ Customer Support Center. The ECU
utilizes GPS navigation, GSM (cellular telephone) communication, and a J1939 connection for databus
monitoring. Virtual Technician does not require any driver input to function.
36.1.3 Component Locations

On Cascadia vehicles, the ECU is located behind the sunglass holder on the passenger side of the overhead
console.
8
1. Dome Light (For Reference)

Fig 36.4, Virtual Technician ECU, Cascadia Installation
On Western Star vehicles, the ECU is located behind the glove box along the cab side. The ECU can safely be
removed from the mount while remaining wired to the vehicle for visual diagnostic purposes.
9

2. Open Glove Box Door (Glove Box Removed)
3. Passenger Side Door (For Reference)
Fig 36.5, Virtual Technician ECU, Western Star Installation
36.1.4 Diagnostic Overview

All testing of the GPS and cellular reception must be done outside, and at a distance of at least 40 feet (12
meters) from any buildings. This ensures adequate GPS signal strength and good cellular reception.
Diagnosing Virtual Technician requires access to the ECU to view the LEDs on the unit. The LEDs provide
diagnostic information needed by the technician and the CSC (Customer Support Center). To access the unit,
remove the sunglass holder from the passenger side of the overhead console and detach the VT box from the
hook-and-loop tape mounting. To diagnose the unit, turn the ignition to the ON position.
There are seven LEDs visible on the VT ECU module. If no LEDs light up with the ignition ON, diagnose supplied
power and ground to the unit.
10
Diagnostic LEDs
Name Color Function Action
DL1 Red Red Blink (1Hz): J1708 Red is the normal and
connectivity (disabled). expected state. There is no
J1708 databus connection.
DL2 Red and Green Red Blink (1Hz): J1939 Green blink is expected. If
connectivity. No J1939 activity LED is blinking red, diagnose
detected (device is awake). J1939 connectivity issue at
the terminals. The LED will
Green Blink (1Hz): (1Hz): blink red when the VT is
J1939 activity detected awake but the ignition if OFF.
(device is awake). The VT remains awake for 2
minutes after the ignition is
tuned OFF and will flash red
during this time.
GSM Green Solid: GPS connection Solid is expected – if
successful. otherwise, call the CSC for
further instruction.
One Blink: Initializing.
Two Blinks: Acquiring time
zone information.
Three Blinks: Attempting to
make a GPS connection.
GPS Green Solid: Satellites acquired. Solid green when the satellite
is aquired with the external
One Blink: Acquiring antenna, and solid amber
satellites. when the satellite is acquired
with teh internal antenna.
Amber when no external
antenna is connected.
Status Green Solid: Engine running. Refer to J1939 fault codes if
problem is suspected.
One Blink: Engine not
running; no data to send.
Two Blinks: Data is
available to be sent.
Four Blinks: GPS storage
log is full.
AUX Red Solid: GSM Modem Comm. Refer to J1939 fault codes if
Error, or panic line is active. problem is suspected.
Two Blinks: Not Used.
Three Blinks: GSM modem
is not starting up.
Four Blinks: SIM Card read
error.
Five Blinks: GSM CTS
(clear-to-send) line is active.
Tamper Red Disabled N/A
36.1.5 Fault Codes
11
Fault Codes
Fault SPN FMI Details Action
SIM Card Error 524283 11 Installed SIM Card Contact CSC/Replace
cannot be read. ECU.
GPS Shorted 524286 4 Center lead shorted to Check the antenna
ground or cable ground. cable; replace GPS
Antenna if necessary.
GPS Not Connected 524286 5 Antenna open or cut. Attach GPS Antenna.
Replace Antenna if
wiring damaged.
NAND Full 524285 0 Full Contact CSC/Replace
ECU.
NAND ++Checksum 524285 2 Error Contact CSC/Replace
Error ECU.
uSD Full 524284 0 Full Contact CSC/Replace
ECU.
uSD Checksum Error 524284 2 Read/write error. Contact CSC/Replace
ECU.
uSD I/O Error (micro 524284 11 Cannot read/write – not Contact CSC/Replace
SD) present. ECU.
RTC Error (real time 524282 11 VTECU RTC out of Contact CSC/Replace
clock) range ECU.
36.1.6 DL1 and DL2 Alternate Functionality

These LEDs indicate other behavior than those indicated at startup:
• Fast-alternating red DL1 and DL2 blinks: indicates that the device is booting.
• Fast-alternating green DL1 and DL2 blinks: indicates that a new firmware file is detected and is being
loaded.
• Solid red DL1 and OFF (dark) DL2: indicates that the device is updating the vehicle interface firmware.
36.1.7 External Antennas

There are two coaxial (SMA) connectors on the VT ECU module. One connector is for an external GPS antenna,
and the other is for an external GSM antenna. The GSM antenna is mounted directly to the ECU.
36.1.8 Vehicle Fault Monitoring

When the VT ECU receives a new fault code, it compares the received message to a list stored internally. If the
fault code is already on the list, it will be ignored. New fault codes are added to the list and the appropriate
information is uploaded to the Zonar server. If the fault code is a ring buffer trigger, a ring buffer will be created
and uploaded along with the normal fault data.
36.1.9 Ring Buffer Files

The VT ECU is capable of generating diagnostic ring buffer files. A ring buffer file is a recording of J1939 databus
activity over a predefined period. This information is sent directly to the CSC for analysis.
36.1.10 Virtual Technician ECU Connector Reference
12
Fig 36.6, ECU Connector Reference
Power Connector
Connector Pin Name Type Minimum Maximum Notes
4-Pin 1 Power Input 8 VDC 30 VDC Requires
External Fuse
2 Ignition Input 0 VDC 30 VDC 0 VDC = Logic 0
1.8 VDC = Logic
1
Requires
External Fuse
3 Ground – 0 VCD 0 VDC –
4 -- -- -- -- --
13
Vehicle Communication Connector

Connector Pin Name
10-Pin 1 J1939 –H
2 CAN-Shield
3 J1708 (–)
4 NC
5 NC
6 J1939 –L
7 J1708 (+)
8 NC
9 NC
10 Ground
14
SPN 51 (MCM) (GHG17)
37.1 SPN 51/FMI 2 - GHG17

Intake Throttle Position Deviation Error
SPN 51/FMI 2
Description This Code Sets When The Intake Throttle Valve Position Has
A 15% Deviation From The Position Commanded By The
Motor Control Module (MCM) When The Engine Coolant
Temperature Is Above 60°C (140°F)
Monitored Parameter Intake Throttle Valve (ITV)
Typical Enabling Conditions Coolant Temperature Is Greater Than 60°C (140°F)
Monitor Sequence None
Execution Frequency Continuous When Enabling Conditions Met
Typical Duration Five Seconds
Dash Lamps MIL, CEL
Engine Reaction 10% Derate
Verification Engine rpm = 600 rpm or Higher
Possible causes:
1
• Faulty ITV motor

• Faulty ITV position sensor
• Sticking ITV
Check as follows:
2. Remove the hose from the Charge Air Cooler (CAC) to the ITV.
3. Visually inspect the ITV butterfly valve. Is there damage to the butterfly valve?
3.a Yes; replace the ITV. Refer to section "Removal of the Intake Throttle Valve and Adaptor" . Verify repair.
4. Connect Diagnostic Link .
6. Using DiagnosticLink, command the ITV by clicking the "full open" and "full closed" buttons while watching
the ITV flap. Does the ITV butterfly valve fully close and fully open when commanded?

6.b No; replace the ITV. Refer to section "Removal of the Intake Throttle Valve and Adaptor" .
7. Using the Air Intake Throttle service routine, command the ITV to 20% while monitoring the ITV actual
position. Is the actual valve position between 14% and 26%?
2

7.b No; replace the ITV. Refer to section "Removal of the Intake Throttle Valve and Adaptor" . Verify repair.
8. Command the ITV to 50% while monitoring the ITV actual position. Is the actual valve position between
44% and 56%?

9. Command the ITV to 90% while monitoring the ITV actual position. Is the actual valve position between
84% and 96%?
3

11. Disconnect and inspect the ITV 5-pin connector. Are there any damaged pins, spread pins, corrosion
present or is the retainer clip missing?
12. Measure the resistance across pins 4 and 5, component side, of the ITV motor connector. Is the resistance
less than 10 ohms?
12.b No; replace the ITV due to a shorted motor. Refer to section "Removal of the Intake Throttle Valve and Adaptor" .
Verify repair.
less than 10 ohms?
Verify repair.
14. Disconnect the 120-pin MCM connector.
15. Measure the resistance between pin 4 of the 5-pin Intake Throttle Valve electrical connector harness side
and pin 100 of the 120-pin MCM electrical connector harness side. Is the resistance less than 5 ohms?
15.a Yes; replace the ITV. Verify repair.
15.b No; replace the MCM. Verify repair.
16. Measure the resistance between pin 5 of the 5-pin Intake Throttle Valve electrical connector harness side
and pin 101 of the 120-pin MCM electrical connector harness side. Is the resistance less than 5 ohms?
16.b No; repair the circuit between pin 5 of the 5-pin Intake Throttle Valve electrical connector harness side
and pin 101 of the 120-pin MCM electrical connector harness side.
17. Install a test MCM.
4
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
18. Start and run the engine until the engine coolant temperature is above 60°C (140°F).
19. Erase fault code SPN 51/FMI 2.
20. Road test the vehicle. Does code SPN 51/FMI 2 return?
20.a Yes; replace the ITV. Refer to section "Removal of the Intake Throttle Valve and Adaptor" .
20.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" .
5
37.2 SPN 51/FMI 3 - GHG17

Intake Throttle Valve Circuit Failed High
SPN 51/FMI 3
Description This Fault Code Sets When There Is A Short To Voltage On
The Intake Throttle Valve Circuit
Monitored Parameter Intake Air Throttle
Typical Enabling Conditions Key On
Execution Frequency Always Enabled
Typical Duration 2 Seconds
Dash Lamps MIL, CEL
Engine Reaction Derate 10%
Verification Engine Idle (1 minute)
Check as follows:
3. Check for multiple fault codes. Is fault code 3509 FMI 3 also present?
6
3.a Yes; diagnose fault code SPN 3509/FMI 3.

4. Disconnect and inspect the Intake Throttle Valve (ITV) electrical connector. Is there any damage or
corrosion present?
6. Recheck for the fault code. Did SPN 51 FMI 3 become inactive and fault code SPN 51 FMI 4 become
active?
6.a Yes; replace the ITV. Refer to section "Removal of the Intake Throttle Valve and Adaptor" .
8. Disconnect and inspect the MCM 120-pin electrical connector. Is the MCM connector damaged?
10. Recheck for the fault code. Is SPN 31 FMI 3 still present?
10.a No; replace the MCM. Refer to section "Removal of the Motor Control Module" .
10.b No; repair the circuit between pin 1 of the ITV electrical connector harness side and pin 90 of the 120-
pin MCM electrical connector harness side.
7
37.3 SPN 51/FMI 4 - GHG17

Intake Throttle Valve Circuit Failed Low
SPN 51/FMI 4
Description This Fault Code Sets When There Is an open On The Intake
Throttle Valve Circuit
Monitored Parameter Intake Air Throttle
Typical Enabling Conditions Key On
Dash Lamps MIL, CEL
Check as follows:
3. Check for multiple fault codes. Is fault code SPN 3509 FMI 4 also present?
8

4. Turn the ignition off.
5. Disconnect and inspect the ITV electrical connector. Is there damage or corrosion present?
less than 10 ohms?
less than 10 ohms?
7.a If resistance is greater than 5 ohms, repair open circuit between pin 90 of the MCM 120-pin connector
and pin 1 of the ITV connector.
7.b If resistance is less than 5 ohms, replace the ITV.
8. Turn the ignition ON.
9. Measure the voltage between pin 2 and pin 3 of the ITV electrical connector harness side. Is the voltage
between 4.5 and 5.5 volts?
11. Disconnect and inspect the MCM 120-pin electrical connector. Is there damage or corrosion present?
12. Measure resistance between pin 1 of the ITV electrical connector harness side and pin 90 of the 120-pin
MCM electrical connector harness side. Is the resistance less than 5 ohms?
12.a Yes; replace the MCM. Refer to section "Removal of the Motor Control Module" .
12.b No; repair the circuit between pin 1 of the ITV electrical connector harness side and pin 90 of the 120-
pin MCM electrical connector harness side.
13. Measure the voltage between pin 3 and ground. Is the voltage between 4.5 and 5.5 volts?
13.a Yes; repair the circuit between pin 2 of the ITV electrical connector harness side and the splice.
13.b No; repair the circuit between pin 3 of the ITV electrical connector harness side and the splice.
9
37.4 SPN 51/FMI 10 - GHG17

Intake Throttle Position Abnormal Rate of Change
This code sets when the Intake Throttle Valve (ITV) position is not within 30% of the commanded position during
freezing conditions.
SPN 51/FMI 10
Description Intake Throttle Position Abnormal Rate Of Change
Monitored Parameter Intake Throttle Valve
Typical Enabling Conditions Engine rpm = idle or higher
Execution Frequency Continuous when enabling conditions met
Typical Duration Five seconds
Dash Lamps None
Engine Reaction No Derate
Verification Engine rpm = idle or higher
Possible causes:
• Faulty ITV motor
• Faulty ITV position
• Frozen (ice buildup) ITV butterfly
Note : With the new strategy when the ignition key is turned on, the ITV will cycle two full times and then the ITV
will be commanded short increments.
Check as follows:
10
1. Connect Diagnostic Link™. Go to step 2.

2. Turn ignition ON (key ON, engine OFF). Go to step 3.
3. Check the Engine Coolant Temperature and Ambient Air Temperature in the Motor Control Module (MCM)
when the fault code is set. Were temperatures below freezing when the code set?
4. Turn the ignition OFF. Go to step 5.
5. Remove the hose from the charge air cooler to the ITV. Go to step 6.
6. Inspect the hose and the ITV for signs of ice or moisture. Are there signs of ice or moisture?
6.a Yes; clean the hose and ITV as necessary. Inspect the air intake system/air cleaner for signs of water
intrusion. Repair as necessary. Verify repair.
7. Turn the ignition ON (key ON, engine OFF). Go to step 8.
8. Remove the hose from the charge air cooler to the ITV. Go to step 9.
9. Use the Service Routines greater than Intake Throttle Valve in DiagnosticLink to command the Intake
Throttle Valve fully open and fully closed while watching the ITV flap. Does the ITV butterfly valve fully
close and fully open when commanded?
10. Using the Intake Throttle Valve service routine, command the ITV to 20% while monitoring the ITV actual
position. Is the actual valve position within +/- 5% of the commanded position?
11. Command the ITV to 50% while monitoring the ITV actual position. Is the actual valve position within +/- 5%
of the commanded position?
14. Disconnect and inspect the ITV 5-pin connector. Are there any damaged pins, spread pins or the retainer
clip missing?
14.a Yes; repair as necessary. Verify repair.
15. Measure the resistance across pins 4 and 5 of the component side of the ITV motor connector. Is the
Verify repair.
16. Install a test Motor Control Module (MCM). Go to step 17.
17. Road test the vehicle. Is code SPN 51/FMI 2 still present?
17.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repair.
11
37.5 SPN 51/FMI 18 - GHG17

Intake Throttle Position Rationality Error
SPN 51/FMI 18
Description This Fault Sets When Intake Throttle Position Does Not Match
Requested Range
Monitored Parameter Intake Throttle Valve (ITV)
Dash Lamps MIL
Possible causes:
• Damaged ITV Butterfly Flap
• Faulty ITV Motor
• Faulty ITV Sensor
WARNING
PERSONAL INJURY
Check as follows:
1. Remove the hose from the Charge Air Cooler (CAC) to the ITV.
2. Visually inspect the ITV butterfly valve. Is there damage to the butterfly valve?
5. Use the ITV service routine in DiagnosticLink to command the ITV fully open and fully closed while
watching the ITV flap. Does the ITV butterfly valve fully close and fully open when commanded?
6. Using the ITV service routine, command the ITV to 20% while monitoring the ITV actual position. Is the
actual valve position within +/- 5% of the commanded position?
12

10. Disconnect and inspect the ITV 5-pin connector. Are there any damaged pins, spread pins or the retainer
clip missing?
less than 10 ohms?
Verify repair.
12. Install a test Motor Control Module (MCM). Go to step 13.
13. Road test the vehicle. Is code SPN 51/FMI 18 still present?
13
SPN 70 (CPC) (GHG17)
38.1 SPN 70/FMI 2 - GHG17

J1939 Park Brake Switch Signal from Source #1, #2, or #3 Data Erratic, Intermittent or Incorrect
SPN 70/FMI 2
Description Park Brake Switch Signal Data Incorrect
Monitored Parameter Park Brake Switch
Typical Enabling Conditions Always On
Monitor Sequence Key ON
Execution Frequency Continuous When Enabling Conditions are Met
Typical Duration Two Seconds
Dash Lamps MIL
Engine Reaction None
Verification Key ON, Engine OFF
1. Check for multiple codes; are fault codes (CPC) SPN 168/FMI 0/14/18 present?
1.a Yes; troubleshoot and repair these first.
2. Is (MCM) SPN 625/FMI 9 present?
2.a Yes; troubleshoot and repair the Controller Area Network (CAN) line.
3. Has the CPC been recently reprogrammed?
3.a Yes; check the proper configuration of the CPC.
3.b No; determine which modules are configured for the vehicle and their communication status. Once this
is done, follow the appropriate module communication troubleshooting procedures for the affected
module.
1
38.2 SPN 70/FMI 13 - GHG17

J1939 Park Brake Switch Signal from Source #1, #2, or #3 is Missing
SPN 70/FMI 13
Description Park Brake Switch Signal Data Missing
Dash Lamps MIL
module.
2
38.3 SPN 70/FMI 19 - GHG17

J1939 Park Brake Switch Signal from Source #1, #2, or #3 is Erratic
SPN 70/FMI 19
Description Park Brake Switch Signal Erratic
Dash Lamps MIL
module.
3
39.1 SPN 84/FMI 0 - GHG17

Vehicle Speed Above Programmable Threshold 1 While Driving
Note : This is an information-only fault. It indicates that vehicle speed is above a programmable threshold. It may
be necessary to contact the truck owner or fleet manager to see if they have this feature enabled.
1. Does the fleet operator have this feature enabled?
1.a Yes, note the fault code in the repair order and clear the code only if the fleet or owner requests it.
Release the vehicle.
2. Using DiagnosticLink , change the Common Powertrain Controller (CPC) parameters highlighted below to
99 (actual value which will be displayed in window is 98.92).
1
39.2 SPN 84/FMI 2 - GHG17
1. Are there any battery faults (SPN 168/FMI any) or Controller Area Network (CAN) faults (SPN 625/FMI any)
present?
1.a Yes; repair those faults first.
2. Has the Common Powertrain Controller (CPC) been recently reprogrammed?
2.a Yes; ensure the VSS parameters are configured correctly for the vehicle application. If OK, Go to step 3.
3. Disconnect the VSS harness connector. Refer to Original Equipment Manufacturer (OEM) literature for
location.
4. Inspect the VSS harness connector for bent, spread, or corroded pins. Is any pin damage found?
4.a Yes; repair as necessary. Verify repairs.
5. Is the vehicle equipped with a Hall Effect sensor? Refer to OEM literature for application.
7. Measure the voltage between pin 3 of the VSS harness connector and ground. Is the voltage greater than
4.5 volts?
2
8. Disconnect CPC #3 connector.

9. Measure the voltage between pin 8 of the CPC #1 connector component side and ground. Is the voltage
greater than 4.5 volts?
9.a Yes; repair wire between pin 8 of the CPC #1 harness connector and pin 3 of the VSS harness
connector. Verify repairs.
9.b No; replace the CPC. Refer to OEM literature.
10. Turn the ignition OFF (key OFF, engine OFF).
11. Disconnect CPC #3 connector.
12. Measure the resistance between pins 13 and 14 of the CPC #3 harness connector. Is resistance greater
than 10K ohms?
12.b No; repair short between pins 13 and 14 of the CPC #3 harness connector to the VSS harness
13. Measure the resistance between pin 13 of the CPC #3 harness connector and the VSS + harness
connector. Is resistance less than 5 ohms?
13.b No; repair wire between pin 13 of the CPC #3 connector and the VSS + harness connector. Verify
repairs.
14. Measure the resistance between pin 14 of the CPC #3 harness connector and the VSS - harness
connector. Is resistance less than 5 ohms?
14.a Yes; refer to OEM literature for VSS sensor and sensor wheel diagnostics.
14.b No; repair wire between pin 14 of the CPC #3 harness connector and the VSS - harness connector.
Verify repairs.
3
39.3 SPN 84/FMI 3 - GHG17

SPN 84/FMI 3
Description Vehicle Speed Sensor Circuit Short to Voltage
Monitored Parameter Vehicle Speed Sensor
Typical Enabling Conditions Key ON and Engine ON
Typical Duration Three Seconds
Dash Lamps MIL, CEL
Verification rpm greater than 600
Check as follows:
1. Disconnect the Vehicle Speed Sensor (VSS).
2. Measure the resistance between pin 13 of the Common Powertrain Controller (CPC) #3 21-pin connector
and pin 1 of the VSS. Is the resistance greater than three ohms?
2.a Yes; repair the open between pin 13 of the CPC #3 21-pin connector and pin 1 of the VSS.
3. Measure the resistance between pin 14 of the CPC #3 21-pin connector and pin 2 of the VSS sensor. Is the
resistance greater than three ohms?
3.a Yes; repair the open wire between pin 14 of the CPC #3 21-pin connector and pin 2 of the VSS.
4. Measure the resistance between pins 13 and 14 of the CPC #3 21-pin connector. Is the resistance greater
than three ohms?
4.a Yes; replace the VSS.
4.b No; repair the short in the harness between pins 13 and 14 of the CPC #3 21-pin connector.
4
39.4 SPN 84/FMI 4 - GHG17

SPN 84/FMI 4
Description Vehicle Speed Sensor Circuit Short to Ground
Dash Lamps MIL, CEL
Check as follows:
1. Disconnect the Vehicle Speed Sensor (VSS) connector.
2. Disconnect the Common Powertrain Controller (CPC) #3 21-pin connector.
3. Measure the resistance between pins 1 and 2 of the VSS harness connector. Is the resistance
measurement less than five ohms?
3.a Yes; repair the short between pins 13 and 14 of the CPC #3 21-pin connector.
4. Measure the resistance between pin 1 of the VSS harness connector and ground. Is the resistance
4.a Yes; repair the short to ground between pin 13 of the CPC #3 21-pin connector and pin 1 of the VSS
harness connector.
5. Measure the resistance between pin 2 of the VSS harness connector and ground. Is the resistance
5.a Yes; repair the short to ground between pin 14 of the CPC #3 21-pin connector and pin 2 of the VSS
harness connector.
5.b No; replace the VSS.
5
39.5 SPN 84/FMI 5 - GHG17

SPN 84/FMI 5
Description Vehicle Speed Sensor Circuit Open
Dash Lamps MIL, CEL
Check as follows:
Note : This SPN is broadcast to the Motor Control Module (MCM) via the Common Powertrain Controller (CPC).
2. Measure the resistance between pin 13 of the Common Powertrain Controller (CPC) #3 21-pin connector
and pin 1 of the VSS. Is the resistance greater than three ohms?
2.a Yes; repair the open between pin 13 of the CPC #3 21-pin connector and pin 1 of the VSS.
3. Measure the resistance between pin 14 of the CPC #3 21-pin connector and pin 2 of the VSS sensor. Is the
resistance greater than three ohms?
3.a Yes; repair the open wire between pin 14 of the CPC #3 21-pin connector and pin 2 of the VSS.
4. Measure the resistance between pins 13 and 14 of the CPC #3 21-pin connector. Is the resistance greater
than 10K ohms?
4.a Yes; replace the VSS.
4.b No; repair the short in the harness between pins 13 and 14 of the CPC #3 21-pin connector.
6
39.6 SPN 84/FMI 6 - GHG17

Vehicle Speed Sensor Anti-Tamper Detection via Antilock Brake System Vehicle Speed Comparison
This fault code indicates a missing message from the Antilock Brake System (ABS) module. Refer to Original
Equipment Manufacturer (OEM) material for J1939 troubleshooting for the ABS module.
7
39.7 SPN 84/FMI 7 - GHG17

SPN 84/FMI 7
Description Vehicle Speed Sensor Rationality Fault
Dash Lamps MIL, CEL
Check as follows:
1. Check for multiple codes. Is (CPC) SPN 168/FMI 0/14/18 (battery voltage) present?
2. Is (MCM) SPN 625/FMI 9 code present?
is done, follow the appropriate wiring schematic information. Refer to Original Equipment Manufacturer
(OEM) literature.
8
39.8 SPN 84/FMI 11 - GHG17

Note : This is an information-only fault. It indicates the vehicle speed is above a programmable threshold. It may
be necessary to contact the truck owner or fleet operator to see if they have this feature enabled.
1. Does the fleet operator have this feature enabled?
1.a Yes; note the fault code in the repair order and clear the code only if the fleet or owner requests it.
Release the vehicle.
2. Using DiagnosticLink®, change the Common Powertrain Controller (CPC) parameters highlighted below to
99 (actual value which will be displayed in window is 98.92).
9
39.9 SPN 84/FMI 13 - GHG17

SPN 84/FMI 13
Description Vehicle Speed Over PTCAN SNA
Monitored Parameter Vehicle Speed Sensor (VSS)
Typical Enabling Conditions Key ON Engine ON
Dash Lamps MIL, CEL
Verification rpm Greater Than 600
1. Connect DiagnosticLink and check for other fault codes. Are fault codes SPN 168/FMI 0 or 18 (battery
voltage) fault codes present?
1.a Yes; troubleshoot these fault codes first.
2. Is the Motor Control Module (MCM) SPN 625/FMI 9 present?
2.a Yes; repair the Controller Area Network (CAN) line faults.
3. Has the Common Powertrain Controller (CPC) been recently reprogramed?
3.a Yes; check proper configuration of the CPC.
WARNING
ENGINE EXHAUST
4. Reprogram MCM and verify repairs. Did the code return?

4.b No; release the vehicle.
5. Replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs. Did the code return?
6. Check the other vehicle modules for Communication or VSS related faults. Follow the appropriate module
troubleshooting procedures for the fault.
10
39.10 SPN 84/FMI 14 - GHG17

SPN 84/FMI 14
Description Vehicle Speed Sensor Signal Missing
Dash Lamps MIL, CEL
1. Check for multiple codes: Are (CPC) SPN 168/FMI 0/14/18 (battery voltage) codes present?
is done, follow the appropriate wiring schematic information. Refer to Original Equipment Manufacturer
(OEM) literature.
11
39.11 SPN 84/FMI 19 - GHG17

J1939 Wheel-based Vehicle Speed Signal from Source #1, #2, or #3 is Erratic
SPN 84/FMI 19
Description J1939 Wheel-Based Vehicle Speed Signal from Source#1, #2,
or #3 is erratic
Typical Enabling Conditions rpm greater than1500, Torque Demand On
Dash Lamps MIL
Engine Reaction
Verification rpm greater than 1500, Torque Demand On
1. Check for multiple codes. Are fault codes SPN 168/FMI 0/14/18 (CPC) present?
2. Is SPN 625/FMI 9 (MCM) present?
3.b No; connect ServiceLink to determine which modules are configured for the vehicle and their
communication status. Once this is done, follow the appropriate module communication
troubleshooting procedures for the affected module.
12
39.12 SPN 84/FMI 20 - GHG17

Vehicle Speed Sensor Erratic
SPN 84/FMI 20
Description Vehicle Speed Sensor Erratic
Typical Enabling Conditions RPM greater than 1500, Torque Demand On
Dash Lamps MIL
Verification RPM greater than 1500, Torque Demand On
1. Are there any battery (SPN 168/FMI any) or Controller Area Network (CAN) (SPN 625/FMI any) faults
present?
2.a Yes; insure the VSS parameters are configured correctly for the vehicle application. If OK, Go to step 3.
3. Is the VSS hardwired?
3.b No; refer to the Application and Installation manual for the correct parameter configuration. If
configuration is correct, refer to the Original Equipment Manufacturer (OEM) material for J1939
troubleshooting.
4. Disconnect the VSS harness connector; refer to OEM literature for location.
5. Inspect the VSS harness connector for bent, spread, or corroded pins. Is damage found?
6. Disconnect CPC connector #3.
7. Measure the resistance between pins 13 and 14 of the CPC connector #3. Is the resistance less than 1K
ohms?
7.a Yes; repair the short between pins 13 and 14 of the CPC connector #3 and the VSS connector.
8. Measure the resistance between pin 13 of the CPC connector #3 and the VSS+ harness connector. Is the
resistance less than 1K ohms?
8.a Yes; repair the wire between pin 13 of the CPC connector #3 and the VSS+ harness connection.
9. Measure the resistance between pin 14 of the CPC connector #3 and the VSS- harness connector. Is the
resistance less than 1k ohms?
9.a Yes; repair the wire between pin 14 of the CPC connector #3 and the VSS- harness connection.
9.b No; refer to OEM literature for VSS sensor diagnostics.
13
39.13 SPN 84/FMI 21 - GHG17

Vehicle Speed Sensor Erratic
SPN 84/FMI 21
Description Vehicle Speed Sensor Erratic
Typical Enabling Conditions rpm greater than 1500, Torque Demand On
Dash Lamps MIL
Verification rpm Greater than 1500, Torque Demand On
1. Are there any battery (SPN 168/FMI any) or Controller Area Network (CAN) (SPN 625/FMI any) faults
present?
2.a Yes; ensure the VSS parameters are configured correctly for the vehicle application, if OK Go to step 3.
3. Is the VSS hardwired?
3.b No; refer to the Application and Installation manual for the correct parameter configuration. If
troubleshooting.
4. Disconnect the VSS harness connector, refer to OEM literature for location.
5. Inspect the VSS harness connector for bent, spread, or corroded pins. Is damage found?
7. Measure the resistance between pins 13 and 14 of the CPC connector #3 . Is the resistance less than 1K
ohms?
7.a Yes; repair the short between pins 13 and 14 of the CPC connector #3 and the VSS connector.
8. Measure the resistance between pin 13 of the CPC connector #3 and the VSS+ harness connector. Is the
8.a Yes; repair the wire between pin 13 of the CPC connector #3 and the VSS+ harness connection.
9. Measure the resistance between pin 14 of the CPC connector #3 and the VSS- harness connector. Is the
resistance less than 1k ohms?
9.a Yes; repair the wire between pin 14 of the CPC connector #3 and the VSS- harness connection.
9.b No; refer to OEM literature for VSS sensor diagnostics.
14
SPN 84 (CPC3) (GHG17)
40.1 SPN 84/FMI 0 - GHG17

This is an information only code that indicates the vehicle speed exceeded its programmable limit while in drive.
No action required.
1
40.2 SPN 84/FMI 6 - GHG17

VSS Anti-Tamper Detection via ABS Vehicle Speed Comparison
This fault only occurs on vehicles equipped with a manual transmission. It indicates the Vehicle Speed Sensor
(VSS) speed is different than Antilock Brake (ABS) wheel speed.
Check as follows:
1. Connect DiagnosticLink 8.04 SP2 or higher.
2. Are any ABS system faults also present?
2.a Yes, repair those faults first.
3. Inspect VSS harness for defeat devices such as signal generators or added resistors in the harness. If
found return vehicle to original factory configuration.
2
40.3 SPN 84/FMI 11 - GHG17

Vehicle Speed Above Programmable Threshold2 While Driving
This is an information-only code that indicates the vehicle speed exceeded its programmable limit while coasting.
No action required.
3
40.4 SPN 84/FMI 20 - GHG17

Check as follows:
1. Disconnect the VSS.
2. Inspect the VSS harness connector for bent, spread or corroded pins. Is pin damage found?
3. Remove the VSS, inspect sensor magnetic tip and the tone wheel for damage. Is damage found?
3.a Yes; replace the VSS and tone wheel.
4
40.5 SPN 84/FMI 21 - GHG17

Vehicle Speed Sensor Failure
Check as follows:
2. Inspect the VSS harness connector for bent, spread or corroded pins. Is pin damage found?
3. Remove the VSS, inspect sensor magnetic tip and the tone wheel for damage. Is damage found?
3.a Yes; replace the VSS and tone wheel.
5
41.1 SPN 84/FMI 13 - GHG17

SPN 84/FMI 13
Description Vehicle Speed Over PTCAN SNA
Typical Enabling Conditions Key ON Engine ON
Dash Lamps MIL, CEL
Verification rpm Greater Than 600
Check as follows:
1. Connect DiagnosticLink and check for other fault codes. Are there any TCM faults or fault codes SPN
168/FMI 0 or 18 (battery voltage) fault codes present?
1.a Yes; troubleshoot these fault codes first.
2. Is the Motor Control Module (MCM) SPN 625/FMI 9 present?
3. Has the Common Powertrain Controller (CPC) been recently reprogramed?
3.a Yes; check proper configuration of the CPC.
WARNING
ENGINE EXHAUST
4. Reprogram MCM and verify repairs. Did the code return?

4.b No; release the vehicle
5. Replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs. Did the code return?
6. Check the other vehicle modules for Communication or VSS related faults. Follow the appropriate module
troubleshooting procedures for the fault.
1
41.2 SPN 84/FMI 19 - GHG17

Vehicle Speed outside the Allowable range
SPN 84/FMI 19
Description This fault code sets when the vehicle speed sensor reads the
maximum value 255kph (185 mph)
Dash Lamps MIL
Note : OEM VSS connectors may vary. Refer to OEM literature for details
Check as follows:
1. Connect DiagnosticLink and check for other fault codes. Are there any TCM codes present?
1.a Yes; troubleshoot the other codes first.
2

5. Disconnect the VSS harness connector. Refer to OEM literature for location.
6. Inspect the VSS harness connector for bent, spread, or corroded pins. Is any damage found?
8. Measure the resistance between pins 13 and 14 of the CPC connector #3. Is the resistance greater than
10k ohms?
8.b No; repair short between pins 13 and 14 of the CPC connector #3 and the VSS connector. Verify
repairs.
9. Measure the resistance between pin 13 of the CPC connector #3, harness side and battery ground. Is the
resistance greater than 10k ohms?
9.b No; repair the short to ground between pin 13 of the CPC connector #3 and the VSS+ harness
connection. Verify repairs.
10.b No; repair the short to ground between pin 14 of the CPC connector #3 and the VSS- connector. Verify
repairs.
11. Measure the resistance between pin 13 of the CPC connector #3 and the VSS(+) harness connection. Is
the resistance less than five ohms?
11.b No; repair the wire between pin 13 of the CPC connector #3 and the VSS (+) harness connection.
Verify repairs.
12. Measure the resistance between pin 14 of the CPC connector #3 and the VSS (-) harness connection. Is
12.a Yes; refer to OEM literature for VSS sensor diagnostics.
12.b No; repair the wire between pin 14 of the CPC connector #3 and the VSS(-) harness connection. Verify
repairs.
3
41.3 SPN 84/FMI 21 - GHG17

Vehicle Speed Sensor Failure
SPN 84/FMI 21
Description Vehicle Speed Sensor Rationality
Typical Enabling Conditions RPM greater than 1500, Torque Demand On
Dash Lamps MIL
Verification RPM greater than 1500, Torque Demand On
Check as follows:
Note : OEM VSS connectors may vary. Refer to OEM literature for details.
1. Connect DiagnosticLink and check for other fault codes. Are there any TCM codes present?
4

5. VSS programming options are either hardwired or transmitted via J1939. Is the VSS hardwired?
5.b No; refer to the Application and Installation Manual for the correct parameter configuration. If
configuration is correct, refer to Original Equipment Manufacturer (OEM) material for J1939 VSS
troubleshooting.
6. Disconnect the VSS harness connector. Refer to OEM literature for location.
7. Inspect the VSS harness connector for bent, spread, or corroded pins. Is any damage found?
10K ohms?
9.b No; repair short between pins 13 and 14 of the CPC connector #3 and the VSS connector. Verify
repairs.
10. Measure the resistance between pin 13 of the CPC connector #3 and battery ground. Is the resistance
greater than 10K ohms?
10.b No; repair the short to ground between pin 13 of the CPC connector #3 and the VSS+ harness
connection. Verify repairs.
11. Measure the resistance between pin 14 of the CPC connector #3 and battery ground. Is the resistance
11.b No; repair the short to ground between pin 14 of the CPC connector #3 and the VSS- connector. Verify
repairs.
12. Measure the resistance between pin 13 of the CPC connector #3 and the VSS+ harness connection. Is the
resistance less than five ohms?
12.b No; repair the wire between pin 13 of the CPC connector #3 and the VSS+ harness connection. Verify
repairs.
13. Measure the resistance between pin 14 of the CPC connector #3 and the VSS- harness connection. Is the
13.a Yes; refer to OEM literature for VSS sensor diagnostics.
13.b No; repair the wire between pin 14 of the CPC connector #3 and the VSS- harness connection. Verify
repairs.
5
42.1 SPN 91/FMI 0 – GHG17

SPN 91/FMI 0
Description Pedal Sensor Supply Signal Short Or Open Ground Circuit
Monitored Parameter Pedal Position
Dash Lamps CEL
Verification Key Cycle - Ignition ON
Fig 42.1, Analog Pedal Type
1
Fig 42.2, Williams Dual-Channel Analog Pedal
Williams Dual-Channel Pedal Connector and Pinout

Function CPC pinout Connector Pinout Comments Harness
Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
VCC1 (+5V) 1/8 C APS1 Power Supply
VCC2 (+5V) 3/3 D APS2 Power Supply
GND2 3/2 E APS2 GND The image
above is
the front
side
looking
into the
pins on the
Harness
Connector.
APS2 4/14 F SENSOR 2 Harness
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
2
WARNING
ENGINE EXHAUST
Check as follows:
1. Disconnect the Accelerator Pedal (AP).
2. Inspect the AP and harness side connectors for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Is any
damage found?
4. Measure the voltage between pin A of the AP harness connector and ground. Is voltage present?
4.a Yes; repair the short to voltage between pin A of the AP harness connector and pin 7 of the CPC # 1
connector. Verify repair.
5. Measure the voltage between pin B of the AP harness connector and ground. Is the voltage greater than
five volts?
5.a Yes; repair the short to voltage between pin B of the AP harness connector and pin 4 of the CPC # 1
7. Measure the resistance between pin B of the AP harness connector and ground. Is the resistance greater
than five ohms?
7.a Yes; repair the open circuit between pin B of the AP harness connector and pin 4 of the CPC #1
7.b No; replace the Accelerator Pedal. Refer to Original Equipment Manufacturer (OEM) literature.
3
42.2 SPN 91/FMI 2 - GHG17

SPN 91/FMI 2
Description Pedal Sensor Supply Signal Erratic
Dash Lamps CEL
4

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
5
WARNING
ENGINE EXHAUST
Check as follows:
2. Check for multiple codes. Are SPN 91 / FMI 0, or 8 present?
4. Gently wiggle the pedal and harness connector to simulate road vibrations. Go to step 5.
5. While wiggling the circuit, measure the voltage between pin C of the AP harness connector and ground. Is
voltage consistently present?
5.b No; repair an open between pin C of the AP harness connector and pin 8 of the CPC #1 connector.
Verify repair.
6. While wiggling the circuit, measure the voltage between pins C and B of the AP harness connector. Is
voltage consistently present?
6.b No; repair an open between pin B of the AP harness connector and pin 4 of the CPC #1 connector.
Verify repair.
7. Check for proper configuration of the CPC against the server information. Does the CPC pedal type have
the proper configuration?
7.a Yes; replace the Accelerator Pedal. Refer to Original Equipment Manufacturer (OEM) literature.
7.b No; reprogram the CPC with the correct information as necessary. Verify repair.
6
42.3 SPN 91/FMI 4 - GHG17

SPN 91/FMI 4
Description Accelerator Pedal Sensor Shorted or Open Circuit
Dash Lamps CEL
7

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
8
WARNING
ENGINE EXHAUST
Check as follows:
1. Has the CPC been recently programmed ?
2.b No; reprogram the CPC with the correct information as necessary. Verify repair .
damage found?
6. Is the vehicle equipped with a Williams Dual-Channel Analog Pedal?
7. Measure the voltage between pin E of the AP harness connector and ground. Is voltage present?
7.a Yes; repair a short to voltage between pin E of the AP harness connector and pin 2 of the CPC #3
9. Measure the voltage between pin F of the AP harness connector and ground. Is voltage present?
9.a Yes; repair a short to voltage between pin F of the AP harness connector and pin 2 of the CPC #2
10. Measure the voltage between pin B of the AP harness connector and ground. Is voltage present?
10.a Yes; repair a short to voltage between pin B of the AP harness connector and pin 4 of the CPC # 1
11. Measure the resistance between pin B of the AP harness connector and ground. Is the resistance greater
than 10 ohms?
11.b No; repair the short to ground between pin B of the AP harness connector and pin 4 of the CPC #1
12. Measure the resistance between pin A of the AP harness connector and ground. Is the resistance less than
five ohms?
9
12.a Yes; repair a short to ground between pin A of the AP harness connector and pin 7 of the CPC #1
13. Measure the resistance between pin C of the AP harness connector and ground. Is the resistance less than
five ohms?
13.a Yes; repair a short to ground between pin C of the AP harness connector and pin 8 of the CPC #1
15. Disconnect the CPC #1 connector.
16. Inspect the CPC and the harness connector for signs of damaged, bent, spread, corroded or unseated
damage found?
17. Measure the resistance between pin A of the AP harness connector and pin 7 of the CPC #1 connector. Is
17.b No; repair an open between pin A of the AP harness connector and pin 7 of the CPC #1 connector.
Verify repair.
18. Measure the resistance between pin C of the AP harness connector and pin 8 of the CPC #1 connector. Is
18.b No; repair an open between pin C of the AP harness connector and pin 8 of the CPC #1 connector.
Verify repair.
10
42.4 SPN 91/FMI 7 - GHG17

2-Channel Accelerator Pedal Idle Not Recognized
SPN 91/FMI 7
Description Pedal Idle Position Not Reached Two Minutes After Ignition
On.
Dash Lamps None
Verification Key Cycle - Ignition ON for Two Minutes
11

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
12
WARNING
ENGINE EXHAUST
Check as follows:
2. Connect DiagnosticLink ; are any other SPN 91/FMI 0, FMI 2, FMI 4, or FMI 8 fault codes active?
2.a Yes; troubleshoot any other faults first.
4. Using DiagnosticLink, monitor PWM Pedal Signal GAS1 and PWM Pedal Signal GAS2 under the
Instrumentation/Chart tab.
5. Cycle Accelerator Pedal (AP) slowly several times with a full sweep from top to bottom of travel. Does
voltage sweep smoothly in relation to pedal travel?
5.b No; replace the AP. Refer to Original Equipment Manufacturer (OEM) literature.
6. Clear codes and cycle ignition off.
8. Does the code return?
9. Gently wiggle pedal and harness connector to simulate road vibration. Go to step 10.
Note : Do not disconnect the Accelerator Pedal (AP) connector at this time.
NOTICE
Do not tap on AP with metal object or tool as this may damage component.
Note : A second technician may be required to monitor values during wiggle testing.
10. While performing wiggle test, monitor PWM Pedal Signal GAS1 and PWM Pedal Signal GAS2 under the
DiagnosticLink Instrumentation/Chart tab.
11. Cycle Accelerator Pedal (AP) slowly several times with a full sweep from top to bottom of travel. Do the
percentages sweep smoothly in relation to pedal travel?
11.b No; isolate that section of harness and inspect for wire chaffing, corrosion, improper connections or
physical damage and repair as necessary . Verify repair.
damage found?
13.b No; reconnect the AP. Go to step 14.
13
14. Gently wiggle CPC harness connectors to simulate road vibration. Go to step 15.
15. While performing wiggle test , monitor PWM Pedal Signal GAS1 and PWM Pedal Signal GAS2 under the
DiagnosticLink Instrumentation/Chart tab. Go to step 16.
physical damage and repair as necessary . Verify repair.
20. Inspect the CPaC and the harness connectors for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connectors. Is any
damage found?
20.b No; replace the Common Powertrain Controller (CPC). Verify repair.
14
42.5 SPN 91/FMI 8 - GHG17

2-Channel Accelerator Pedal Signal 1 Missing
SPN 91/FMI 8
Description Accelerator Pedal Sensor Signal Missing
Monitored Parameter GAS1
Dash Lamps CEL
15

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
16
WARNING
ENGINE EXHAUST
Check as follows:
1. Turn the ignition ON (key ON, engine OFF) and connect DiagnosticLink®.
damage found?
7.a Yes; repair a short to power between pin E of the AP harness connector and pin 2 of the CPC #3
8.a Yes: repair a short to power between pin F of the AP harness connector and pin 2 of the CPC #2
9.a Yes; repair the short to power between pin B of the AP harness connector and pin 4 of the CPC #1
10. Measure the voltage between pin C of the AP harness connector and ground. Is the voltage greater than
5.5 volts?
10.a Yes; repair a short to 12 volt battery power between pin C of the AP harness connector and pin 8 of the
CPC #1 connector. Verify repair.
11.a Yes; repair a short to power between pin A of the AP harness connector and pin 7 of the CPC #1
12. Measure the resistance between pin A of the AP harness connector and ground. Is the resistance less than
five ohms?
12.a Yes; repair a short to ground between pin A of the AP harness connector and pin 7 of the CPC #1
17

15. Inspect the CPC and the harness connector for signs of damaged, bent, spread, corroded or unseated
damage found?
16. Measure the resistance between pin B of the AP harness connector and pin 4 of the CPC #1 connector. Is
16.b No; repair the open circuit between pin B of the AP harness connector and pin 4 of the CPC #1
17. Measure the resistance between pin A of the AP harness connector and pin 7 of the CPC #1 connector. Is
17.b No; repair the open circuit between pin A of the AP harness connector and pin 7 of the CPC #1
18. Measure the resistance between pin C of the AP harness connector and pin 8 of the CPC #1 connector. Is
18.b No; repair the open circuit between pin C of the AP harness connector and pin 8 of the CPC #1
18
42.6 SPN 91/FMI 10 - GHG17

SPN 91/FMI 10
Description Pedal Sensor Signal Data Abnormal
Dash Lamps CEL
19

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
20
WARNING
ENGINE EXHAUST
Check as follows:
2. Connect DiagnosticLink®; are any other SPN 91/FMI 0, FMI 2, FMI 4, or FMI 8 fault codes active?
NOTICE
physical damage and repair as necessary. Verify repair.
damage found?
21
20. Inspect the CPC and the harness connectors for signs of damaged, bent, spread, corroded or unseated
damage found?
22
42.7 SPN 91/FMI 13 – GHG17

J1939 EEC2 Message is Missing or Not Available
SPN 91/FMI 13
Description Pedal Sensor Signal Out of Calibration
Dash Lamps CEL
23

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
24
WARNING
ENGINE EXHAUST
Check as follows:
NOTICE
damage found?
25
damage found?
26
42.8 SPN 91/FMI 14 - GHG17

2-Channel Accelerator Pedal Not Learned
SPN 91/FMI 14
Description Pedal Sensor Signal Not Recognized
Dash Lamps CEL
27

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
28
WARNING
ENGINE EXHAUST
Check as follows:
percentage sweep smoothly in relation to pedal travel and return to idle (zero percent)?
8.a Yes; replace the AP, clear codes and verify repair. Refer to Original Equipment Manufacturer (OEM)
literature.
NOTICE
10. While performing wiggle test , monitor PWM Pedal Signal GAS1 and PWM Pedal Signal GAS2 under the
Diagnostic Link Instrumentation/Chart tab.
damage found?
29

damage found?
20.b No; replace the AP, clear codes and verify repair. Refer to Original Equipment Manufacturer (OEM)
literature. Verify repair.
30
42.9 SPN 91/FMI 31 - GHG17

2-Channel Accelerator Pedal Learned Range to Large
SPN 91/FMI 31
Description Pedal Sensor Signal Outside of Learned Range
Dash Lamps CEL
31

Connecto
r Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
32
WARNING
ENGINE EXHAUST
Check as follows:
2. Connect DiagnosticLink ; are any other SPN 91/FMI 0, FMI 2, FMI 4, or FMI 8 fault codes active?
8.a Yes; replace the AP, clear codes and verify repairs. Refer to Original Equipment Manufacturer (OEM)
literature.
NOTICE
damage found?
33

damage found?
34
43.1 SPN 91/FMI 7 - GHG17

SPN 91/FMI 7
Description Pedal Idle Position Not Reached Two Minutes After Ignition
On
Dash Lamps None
Verification Key Cycle - Ignition ON for Two Minutes

damage found?
2.a Yes; repair as necessary. Verify the repair.

Function CPC3 Cavity Pedal Connector Pin Comments Ped
al
Har
nes
s
Con
nect
or
Bod
y
APS1 2/3 A SENSOR 1
GND1 2/20 B APS1 GND
GND2 2/14 E APS2 GND
APS2 2/4 F SENSOR 2
4. Measure the voltage between pin C and B of the AP harness connector. Is the voltage between 4.5 and 5.5
volts?
5. Measure the voltage between pin C of the AP harness connector and ground. Is the voltage between 4.5
and 5.5 volts?
5.a Yes; repair the open circuit between pin B of the AP harness connector and pin 20 of the CPC3 #2
connector. Verify the repair.
5.b No; repair the circuit between pin C of the AP harness connector and pin 15 of the CPC3 #2 connector.
Verify the repair.
1
6. Measure the voltage between pin A of the AP harness connector and ground. Is any voltage present?
6.a Yes; repair the short to power between pin A of the AP harness connector and pin 3 of the CPC3 #2
connector. Verify the repair.
8. Disconnect the CPC3 #2 connector.
9. Inspect the CPC3 #2 connector and the harness connector for signs of damaged, bent, spread, corroded or
unseated (pushed out) pins and signs of moisture in the connector or wire damage near the connector. Is
any damage found?
9.a Yes; repair as necessary. Verify the repair.
10. Measure the resistance between pin A of the AP harness connector and pin 3 of the CPC3 #2 connector. Is
10.b No; repair the circuit between pin A of the AP harness connector and pin 3 of the CPC3 #2 connector.
Verify the repair.
11. Measure the resistance between pin A of the AP harness connector and ground. Is the resistance greater
than 10K ohms?
11.a Yes; replace the Accelerator Pedal. Verify the repair.
11.b No; repair the shorted circuit between pin A of the AP harness connector and pin 3 of the CPC3 #2
connector.
2
43.2 SPN 91/FMI 8 - GHG17

SPN 91/FMI 8
Description Accelerator Pedal Sensor Signal Missing
Dash Lamps CEL

damage found?

al
Har
nes
s
Con
nect
or
Bod
y
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
4. Measure the voltage between pin C and B of the AP harness connector. Is the voltage between 4.5 and 5.5
volts?
and 5.5 volts?
5.a Yes; repair the open circuit between pin B of the AP harness connector and pin 20 of the CPC3 #2
5.b No; repair the circuit between pin C of the AP harness connector and pin 15 of the CPC3 #2 connector.
Verify repair.
6.a Yes; repair the short to power between pin A of the AP harness connector and pin 3 of the CPC3 #2
3

8. Disconnect the CPC3 #2 connector.
9. Inspect the CPC3 #2 and the harness connector for signs of damaged, bent, spread, corroded or unseated
damage found?
10. Measure the resistance between pin A of the AP harness connector and pin 3 of the CPC3 #2 connector. Is
10.b No; repair the circuit between pin A of the AP harness connector and pin 3 of the CPC3 #2 connector.
Verify repair.
11. Measure the resistance between pin A of the AP harness connector and ground. Is the resistance greater
than 10K ohms?
11.a Yes; replace the Accelerator Pedal. Verify repair.
11.b No; repair the shorted circuit between pin A of the AP harness connector and pin 3 of the CPC3 #2
connector.
4
43.3 SPN 91/FMI 12 - GHG17

Check as follows:
1. Connect DiagnosticLink SP2 or higher.
2. Turn the ignition ON (key ON engine OFF).
3. Is SPN 91/FMI 12 active?
3.b No; no action required.
4. Are CPC2 SPN 91/FMI 8/13 or CPC3 SPN 2623/FMI 8 also present?
4.a Yes; repair those fault codes first.
5. Physically inspect accelerator pedal for any obstructions, binding, loose mounting bracket, and that pedal
has full travel. Is any damage found?
5.b No; replace accelerator pedal.
5
43.4 SPN 91/FMI 13 - GHG17

Accelerator Pedal Incorrect Parameterization
This fault indicates the Accelerator Pedal is incorrectly parameterized. Reprogram the CPC3 to the latest server
settings.
6
44.1 SPN 94/FMI 2 – GHG17

SPN 94/FMI 2
Description Low Side Fuel Pressure Out of Range
Monitored Parameter Low Side Fuel Pressure Sensor Circuit
Typical Enabling Conditions Always Enabled
Dash Lamps MIL, CEL
Verification Engine Idle (One minute)
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1
Check as follows:
1. Check and record fuel level using parameter AS044 Fuel Tank Level. Is the fuel level under ¼ tank (25%)?
1.a Yes; add fuel and road test vehicle. If code does not become active during road test, release the truck.
If code becomes active during the road test with over ¼ tank of fuel, Go to step 3.
2. Check fuel tank level in the extended fault code data. Was fuel tank level over ¼ tank (25%) when the code
logged?
2.b No; fuel sloshing in the tank may have caused aerated fuel and set this code. Road test vehicle. If code
does not come active during road test, release the truck. If code does come active, Go to step 3.
3. Disconnect the Low Pressure Pump Output (LPPO) fuel pressure sensor.
5. Measure the voltage between pins 2 and 3 on the harness side of the LPPO fuel pressure sensor
connector. Is the voltage between 4.75 and 5 volts?
6. Measure the voltage between pin 3 on the harness side of the LPPO fuel pressure sensor connector and
battery ground. Is the voltage between 4.75 and 5 volts?
6.a Yes; repair the wire between pin 2 of the LPPO fuel pressure sensor harness connector and pin 102 of
the MCM 120-pin connector.
6.b No; repair the wire between pin 3 of the LPPO fuel pressure sensor harness connector and pin 117 of
8. Disconnect the MCM 120-pin connector.
9. Measure the resistance between pin 1 of the LPPO fuel pressure sensor harness connector and pin 113 of
the MCM 120- pin connector. Is the resistance less than three ohms?
2
9.a Yes; replace the LPPO fuel pressure sensor.

9.b No; repair the wire between pin 1 of the LPPO fuel pressure sensor harness connector and pin 113 of
3
44.2 SPN 94/FMI 3 - GHG17

SPN 94/FMI 3
Description Low Side Fuel Pressure Circuit Short to Voltage
Dash Lamps MIL, CEL
Check as follows:
WARNING
PERSONAL INJURY
4
WARNING
PERSONAL INJURY
1. Check for multiple codes. Are the following codes present?

• SPN 100/FMI 3
• SPN 4077/FMI 3
• SPN 94/FMI 3
1.a Yes; repair short to power between pin 82 of the Motor Control Module (MCM) 120-pin connector and
the engine oil pressure, fuel line, and fuel compensation pressure sensors.
2. Are the following codes present?
• SPN 4407/FMI 3
• SPN 94/FMI 3
2.a Yes; repair short to power between pin 104 of the MCM 120-pin connector and the fuel line and fuel
compensation pressure sensors.
3. Disconnect FCP sensor electrical harness connector.
5. Measure the resistance across pins 1 and 2 of the FLP sensor connector. Is the resistance less than five
ohms?
5.a Yes; repair the short between wires 82 and 84 of the MCM 120-pin connector.
5.b No; repair the short to power on circuit between pin 84 of the MCM 120-pin connector and pin 4 of the
FCP sensor connector.
5
44.3 SPN 94/FMI 4 - GHG17

SPN 94/FMI 4
Description Low Side Fuel Pressure Sensor Circuit Short to Ground
Dash Lamps MIL, CEL
Check as follows:
WARNING
PERSONAL INJURY
6
WARNING
PERSONAL INJURY
3. Check for multiple codes. Are the following codes also present?
• SPN 411/FMI 4
• SPN 51/FMI 4
• SPN 94/FMI 4
3.a Yes; repair open 5V supply between pin 117 of the Motor Control Module (MCM) 120- pin connector
and the Low Pressure Pump Output (LPPO) fuel pressure sensor, EGR delta P sensor, and the intake
throttle harness connectors. Clear codes. Verify repairs.
4. Disconnect the LPPO sensor.
5. Inspect the LPPO sensor harness connector for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Is damage
present?
6. Measure the voltage between pins 3 and 2 of the LPPO sensor harness side connector (5V supply from
MCM) and (ground circuit to MCM). Is the voltage greater than 4.5 volts?
7. Measure the voltage between pin 3 of the LPPO sensor harness side connector (5V supply from MCM) and
ground (battery ground lug by starter). Is the voltage greater than 4.5 volts?
7.a Yes; repair open wire between pin 102 of the MCM 120-pin connector and the Oil Separator speed
sensor, the Intake Manifold Pressure/Temperature sensor, and the LPPO sensor harness connectors.
Go to step 14.
7.b No; repair open wire between pin 117 of the MCM 120-pin connector and the EGR delta P sensor, and
the intake throttle, and LPPO sensor harness connectors. Go to step 14.
10. Inspect the MCM harness connector for signs of damaged, bent, spread, corroded or unseated (pushed
out) pins and signs of moisture in the connector or wire damage near the connector. Is damage present?
11. Measure the resistance between (signal circuit) pin 113 from MCM harness connector to pin 1 of the LPPO
sensor harness connector. Is the resistance less than five ohms?
11.b No; repair open wire between pin 113 of the MCM 120-pin harness side connector and the LPPO
sensor harness side connector. Go to step 14.
12. Measure the resistance between pins 1 and 2 of the LPPO sensor harness connector (signal and ground
circuits). Is the resistance less than 10K ohms?
12.a Yes; repair short between pins 113 and 102 of the MCM 120-pin harness side connector and the LPPO
sensor harness side connector. Go to step 14.
7
13. Measure the resistance between pin 1 of the LPPO sensor harness side connector (signal circuit) and
ground (battery ground lug by starter). Is resistance less than 10K ohms?
13.a Yes; repair short to ground between pin 113 of the MCM 120-pin harness side connector and the
LPPO sensor harness side connector. Go to step 14.
13.b No; replace the LPPO sensor. Refer to section "Removal of the Low Pressure Fuel Sensor" . Go to step 14.
14. Clear codes and verify repairs. If fault returns, install a test MCM and retest. If code does not return,
replace MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs.
8
44.4 SPN 94/FMI 15 - GHG17

Fuel Filter Service Warning
1. Replace fuel filters. Refer to section "Removal of the Coalescer/Final Filter – Two Filter System " .
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2. Start engine and check Low Pressure Pump Out (LPPO) fuel pressure. Is fuel pressure within specified
range? Refer to section "Normal Fuel System Pressures - Two-Filter System" .
2.a Yes; release vehicle.
3. Using Fuel Filter Module Inlet/Outlet Hoses (J-48707) and Fuel Flow Tool (J-48708-1), run the supply and
return lines to the Fuel Flow Tool. Prime the fuel system and start the engine. Is LPPO fuel pressure within
specified range? Refer to section "Normal Fuel System Pressures - Two-Filter System" .
3.a Yes; repair the restriction on the OEM fuel system.
damage found?
5. Remove and inspect the high pressure flange and all low pressure fuel lines. Refer to section "Removal of the High
Pressure Fuel Flange - Two-Filter System" . Was damage or a restriction found?
5.a Yes; replace damaged component.

5.b No; replace fuel filter module. Refer to section "Removal of the Fuel Filter Module - Two-Filter System" .
9
44.5 SPN 94/FMI 16 - GHG17

Fuel Filter Replacement Required
1. Refer to section "SPN 94/FMI 15 - GHG17" .
10
45.1 SPN 96/FMI 13 - GHG17

Fuel Level Sensor Received Network Data in Error
SPN 96/FMI 13
Description This Fault Indicates an Error in the Fuel Level Signal at the
Common Powertrain Controller (CPC).
Monitored Parameter Fuel Level Status Byte
Dash Lamps CEL
Verification Key Cycle
Check as follows:
Note : Fuel level sensor is hardwired to instrument cluster. Fuel level signal is multiplexed from instrument cluster
to the CPC.
1. Check for multiple codes. Are there any SPN 168 (battery voltage) fault codes present?
1.a Yes; repair the battery voltage concern. Verify repair.
2. Is SPN 625/FMI 9 fault code present?
2.a Yes; repair the Controller Area Network (CAN) line. Verify repair.
3. Has the Common Powertrain Controller (CPC) been recently programmed?
3.b No; refer to Original Equipment Manufacturer (OEM) literature for instrument cluster troubleshooting.
1
45.2 SPN 96/FMI 19 - GHG17

Fuel Level Sensor Missing or Not Available
SPN 96/FMI 19
Description This Fault Indicates a Missing Fuel Level Signal at the
Common Powertrain Controller (CPC).
Monitored Parameter Fuel Level Status Byte
Dash Lamps CEL
Check as follows:
Note : Fuel level sensor is usually hardwired to instrument cluster. Fuel level signal is multiplexed from instrument
cluster to the CPC.
3.b No; refer to Original Equipment Manufacturer (OEM) literature for instrument cluster troubleshooting.
2
46.1 SPN 96/FMI 2 - GHG17

Fuel Tank Level Sensor Stuck in Position
Note : Obtain information from the customer about Check Engine Lamp (CEL) occurrences, performance
concerns or exhaust smoke.
SPN 96/FMI 2
Description Fuel Tank Level Sensor Stuck in Position
Monitored Parameter Fuel Tank Level
Dash Lamps MIL
Check as follows:
1. Did SPN 96/FMI 2 appear after the fuel system was repaired or fuel filter maintenance was performed?
1.a Yes; clear codes and road test to verify complaint. If code does not set, release the vehicle. If code
sets, Go to step 2.
3. Check and record fuel level in all fuel tanks. Is the fuel level below ¼ tank (25%)?
If the code becomes active during the road test with over ¼ tank (25%) of fuel, Go to step 4.
3.b No; question the driver about the fuel level when the code was set. If the level was under ¼ tank
(25%), fuel sloshing in the tank could create aerated fuel that could cause this code. If the fuel level
was over ¼ tank (25%) when the code was set, Go to step 4.
4. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, kerosene, or coolant.
Is any contamination found?
4.a Yes; refer to section "Contaminated Fluids" in this manual.
5. Visually inspect for external fuel leaks on the engine and on the chassis. Are fuel leaks present?
5.a Yes; repair leak. Refer to section "Verify Repairs" .
5.b No; replace fuel level sensor. For additional information, refer to the OEM service procedures.
1
46.2 SPN 96/FMI 13 - GHG17

Fuel Level Sensor Missing or Not Available
SPN 96/FMI 13
Description This Fault indicates the Motor Controller Module (MCM) is not
receiving Fuel Tank Level signal from another device.
Execution Frequency Always
Dash Lamps MIL, CEL
Verification Key ON Engine OFF
Check as follows:
Note : Fuel level sensor is hardwired to instrument cluster. Fuel level signal is multiplexed from instrument cluster
to the MCM.
Note : Faults are listed in diagnostic priority from top to bottom.
2. Are there any of the following faults present in the CPC, MCM, or instrument cluster?
• SPN 168/FMI any
• SPN 625/FMI any
2.a Yes; repair fault with the highest priority listed above.
2.b No; refer to Original Equipment Manufacturer (OEM) literature for proper Fuel Tank Level sensor
installation and wiring.
2
46.3 SPN 96/FMI 19 - GHG17

Fuel Level Sensor Signal Error
SPN 96/FMI 19
Description This fault indicates Motor Control Module (MCM) has received
an error indicator from the ECU transmitting fuel level signal
source.
Dash Lamps MIL, CEL
Check as follows:
Note : Fuel level sensor is usually hardwired to instrument cluster. Fuel level signal is multiplexed from instrument
cluster to the CPC.
2. Are there any of the following faults present in the CPC, MCM, or instrument cluster?
• SPN 168/FMI any
• SPN 625/FMI any
2.a Yes, repair fault with the highest priority listed above.
2.b No; refer to Original Equipment Manufacturer (OEM) literature for troubleshooting circuits between Fuel
Level Sensor and Vehicle instrument cluster.
3
47.1 Electronic Diagram
1
47.2 SPN 97/FMI 3 - GHG17

Water-in-Fuel Circuit Failed High
SPN 97/FMI 3
Description Short to Voltage or Open on Water-In-Fuel (WIF) Sensor
Circuit
Monitored Parameter Water in Fuel Sensor
Execution Frequency Continuous
Dash Lamps CEL
Verification Two Minute Idle
Check as follows:
2
1. Check for multiple codes. Is SPN 2791/FMI 3 also active?

1.a Yes; repair the open circuit from pin 67 of the MCM 120-pin connector to pin 4 of the WIF sensor
harness connector and Pin 2 of the Exhaust Gas Recirculation (EGR) actuator harness connector.
3. Disconnect the WIF sensor harness connector.
4. Inspect the sensor harness connector for signs of damage, water intrusion, bent, spread, corroded, pushed
out (unseated) pins or frayed wiring. Is damage present?
6. Measure the voltage between pins 1 and 4 of the WIF sensor harness connector. Is the voltage greater
than 11.5 volts?
7. Measure the voltage between pins 2 and 4 of the WIF sensor harness connector. Is the voltage greater
than 5.5 volts?
8. Was the voltage in Step 7 less than 4.5 volts?
8.a Yes; repair the wire between pin 2 of the harness side of the WIF sensor and pin 57 of the MCM 120-
pin connector. Verify repairs.
8.b No; replace the WIF sensor referring to the proper procedure for the engine being serviced. Refer to
section "Removal of the Water-in-Fuel Sensor" .
9. Measure the voltage between pin 1 of the WIF sensor harness connector and engine ground (Battery
Ground). Is the voltage greater than 11.5 volts?
9.a Yes; repair the wire between pin 4 of the WIF sensor harness connector and pin 67 of the MCM 120-
9.b No; repair the wire between pin 1 of the WIF sensor harness connector and pin 71 of the MCM 120-pin
12. Inspect the MCM 120-pin connector and harness connector for signs of damage, water intrusion, bent,
spread, corroded or pushed out (unseated) pins. Is damage present?
13. Measure resistance between the following pins on the MCM 120-pin harness connector and pins on the
WIF sensor harness connector.
• Signal circuit wire; 120-pin connector pin 57 and WIF harness connector pin 2
• Ground circuit wire; 120-pin connector pin 67 and WIF harness connector pin 4
• Power circuit wire; 120-pin connector pin 71 and WIF harness connector pin 1
Is the resistance value greater than five ohms in any of the above tests?
13.a Yes; repair the wire for the pin pairs tested. Verify repairs.
13.b No; replace the Water-In-Fuel sensor.
3
47.3 SPN 97/FMI 4 - GHG17

SPN 97/FMI 4
Description Short to Ground on Water-in-Fuel (WIF) Sensor Circuit
Dash Lamps CEL
Check as follows:
1. Check for multiple codes. Is SPN 168/FMI 1 also active?
1.a Yes; active troubleshoot that fault first.
4

3. Disconnect the WIF sensor.
4. Inspect the sensor harness connector for signs of damage, water intrusion, bent, spread, corroded, pushed
out (unseated) pins or frayed wiring. Is damage present?
5. Disconnect the Motor Control Module (MCM) 120-pin connector.
6. Inspect the MCM 120-pin connector and harness connector for signs of damage, water intrusion, bent,
spread, corroded, pushed out (unseated) pins or frayed wiring. Is damage present?
7. Check for shorted power wire: Measure the resistance between pin 1 of the WIF sensor connector and
ground. Is resistance less than 10K ohms?
7.a Yes; repair the wire between pin 1 of the WIF sensor harness and pin 71 of the MCM 120-pin
connector.
8. Check for shorted signal wire: Measure the resistance between pin 2 of the WIF sensor harness connector
and ground. Is resistance less than 10K ohms?
connector.
9. Check for shorted ground wire. Measure the resistance between pin 3 of the WIF sensor harness connector
and ground. Is resistance less than 10K ohms?
connector.
10. Check for a short between the power and ground wires. Measure the resistance between pins 1 and 4 of
the WIF sensor harness connector. Is resistance less than 10K ohms?
10.a Yes; repair the short circuit between pins 1 and 4 of the WIF sensor harness.
10.b No; replace the WIF sensor.
5
47.4 SPN 97/FMI 14 – GHG17

SPN 97/FMI 14
Description Fault Logs Once the Water In Fuel Sensor Detects a Certain
Level of Water
Dash Lamps WIF Light
Note : This fault code will set if Water in Fuel (WIF) sensor detects water in the fuel after a five-hour driving cycle
or three engine-start, key-ON cycles.
NOTICE
Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve
may cause damage to the water drain valve and housing.
6
Check as follows:
2. Take a one-quart fuel sample from the fuel filter module by opening the water bowl drain valve and fully
draining the fuel filter in to a clear container.
3. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), gasoline, kerosene, or coolant. Is the
fuel sample contaminated?
3.a Yes; refer to section "Contaminated Fluids".
3.b No; close the water drain valve. Go to step 4.
7
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Prime the fuel filter module via hand pump (approximately 250 times). Clear the fault code, start the engine
and let it run for 15 minutes. Does the fault become active?
4.a Yes; repeat steps 1 through 4. If the fault code is still active after steps 1 through 4 have been
performed, drain all water from fuel tank(s) and if equipped, drain the frame-mounted filter. Refer to
appropriate OEM manual for fuel tank cleaning/flushing procedure. Clear fault codes, Verify repairs
with a 15-minute road test.
8
47.5 SPN 97/FMI 15 - GHG17

SPN 97/FMI 15
Level of Water
NOTICE
9
Check as follows:
3.a Yes; refer to section "Contaminated Fluids" of this manual.
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Prime the fuel filter module via hand pump (approximately 250 times) or using Detroit approved priming
tool. Clear the fault code, start the engine, and let the engine run for 15 minutes. Does the fault become
active?
11
47.6 SPN 97/FMI 16 - GHG17

SPN 97/FMI 16
Level of Water
Monitored Parameter Water in Fuel (WIF) Sensor
NOTICE
12
Check as follows:
1. Follow troubleshooting procedure for SPN 97/FMI 15 - GHG17. Refer to section "SPN 97/FMI 15 - GHG17" .
13
47.7 SPN 97/FMI 31 - GHG17

SPN 97/FMI 31
Level of Water
NOTICE
14
Check as follows:
3.a Yes; Refer to section "Contaminated Fluids"of this manual.
15
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Prime the fuel filter module via hand pump (approximately 250 times). Clear the fault code, start the engine
and let the engine run for 15 minutes. Does the fault become active?
16
48.1 SPN 98/FMI 0 - GHG17

Oil Level High
SPN 98/FMI 0
Description This Code is Not Configured for NAFTA Applications. If this
Code is Active, CPC Configuration is Incorrect.
Monitored Parameter Engine Oil Level Signal from MCM
Typical Enabling Conditions Not Enabled
Execution Frequency None
Dash Lamps CEL
Verification Key ON, engine OFF
2. Reprogram the CPC with the proper server configuration.
3. Clear fault codes. Turn ignition OFF and disconnect DiagnosticLink. Wait five minutes for all modules to
power down.
4. Connect DiagnosticLink and check for codes. Did SPN 98/FMI 0 return?
4.a Yes; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature.
1
48.2 SPN 98/FMI 1 - GHG17

Oil Level Very Low
SPN 98/FMI 1
Description This Code is Not Configured for NAFTA Applications. If this
Code is Active, CPC Configuration is Incorrect.
Monitored Parameter Engine Oil Level Signal from MCM
Dash Lamps CEL
Verification Key ON, engine OFF
2. Reprogram the CPC with the proper server configuration.
power down.
4. Connect DiagnosticLink and check for codes. Did SPN 98/FMI 1 return?
2
48.3 SPN 98/FMI 18 - GHG17

Low Engine Oil Level
SPN 98/FMI 18
Description This fault code sets when the engine oil level is low.
Monitored Parameter Engine Oil Level
Monitor Sequence Key On Engine Running
Execution Frequency Continuous When Enabling Conditions Are Met
Dash Lamps CEL
Engine Reaction None, Engine Derate or Engine Shut Down - Calibration
Dependent
Verification Key on engine off
1. Check for multiple codes. Are SPN 100/ FMI any active?
1.a Yes; diagnose the other codes first.
2. Inspect the engine for leaks. Are there any leaks present?
2.a Yes; refer to section "Symptom Diagnostics - Engine Oil Leaks".
Refer to section "Engine Oil Leaks" .
Refer to section "Engine Oil Leaks - Oil Developer Method" .
3. Inspect the engine for any signs of oil consumption, Refer to section "Check for Excessive Oil Consumption" . Are
there any oil consumption concerns present?
4. Check the oil level. Is the oil level low?
4.a Yes; fill oil to proper level.
5. Check the operation of the oil level gauge. Is the oil level reading erratic?
5.a Yes; repair or replace the oil gauge as required.
5.b No; replace the oil level sensor.
3
50.1 SPN 100/FMI 1 – GHG17

SPN 100/FMI 1
Description This fault code sets when the engine oil pressure is less than
a calibrated threshold.
Monitored Parameter Engine Oil Pressure
Dash Lamps CEL
Dependent
Verification Check At Engine Operating Temperature
This fault will illuminate the Check Engine Lamp (CEL) and Shutdown Engine Lamp (SEL).
Note : The Common Powertrain Controller (CPC) digital outputs have the same SPN as some Motor Control
Module (MCM) faults. DiagnosticLink® makes the distinction between the MCM and CPC when diagnosing a fault.
DD15TC and DD16 Minimum Oil Pressure at operating Temperature

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
DD15AT Minimum Oil Pressure at operating Temperature

rpm Bar psi
600 0.689 10
1200 1.65 24
1800 2.55 37
1
DD13 Minimum Oil Pressure at operating Temperature

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
Note : The oil gauge in the dash is NOT used to diagnose or verify low oil pressure concerns.
Note : If diagnostic leads to a mechanical (non-electrical) low oil pressure condition, all mains and connecting rods
should be inspected. Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis".
Check as follows:
1. Check for multiple codes. Are there multiple oil pressure sensor circuit fault codes?
1.a Yes; diagnose the oil pressure sensor circuit fault codes first.
2. With the vehicle parked on a flat, level surface, check the engine oil level after the engine has been shut off
for at least 20 minutes. Is the engine oil at the correct level?
Note : An increase in the oil level suggests that there may be fuel or coolant entering the engine oil.
3. Is the oil level overfilled?
4. Use the manufacturer recommended oil to fill the engine oil to the correct level. Check for external engine
oil leaks and repair as necessary. Verify repair.
5. Check the oil for signs of coolant intrusion. When there is coolant intrusion, the oil will exhibit a milky
appearance or become thick and sludgy. Are there signs of coolant in the oil?
5.a Yes; Refer to section "Coolant in Oil". Verify repair.
6. Check the oil for signs of fuel intrusion. When there is fuel intrusion into the oil, the oil becomes thin and
has a fuel odor. Are there signs of fuel in the oil?
6.a Yes; determine the cause of fuel in the oil. Change the oil and filter. Verify repair.
6.b No; the oil level may have been over filled by the customer. Correct the oil level. Go to step 7.
8. Connect DiagnosticLink® and check for a biased oil pressure sensor at key ON, engine OFF. Does the oil
pressure sensor read zero psi?
8.b No; replace the oil pressure sensor. Refer to section "Removal of the Engine Oil Pressure Sensor" . Verify repair.
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2
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9. Start the engine and observe the stability of the oil pressure using the chart. Is the oil pressure stable and
within normal operating range as per the chart?
9.a Yes; clear the code. Release the vehicle.
10. Inspect the vehicle for aftermarket components plumbed into the oil system. Are there any aftermarket
components installed?
10.a Yes; isolate the aftermarket components. Recheck the oil pressure.
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Note : A code will be set when the oil temperature sensor is unplugged.
11. Remove the oil temperature sensor and connect a manual gauge into the oil temperature sensor port. Refer
to section "Removal of the Engine Oil Temperature Sensor" . Start and run the engine at the rpm listed in the chart. Is
the oil pressure, observed on the manual gauge, stable and within normal operating range as per the
chart?
11.a Yes; reinstall the oil temperature sensor; Refer to section "Installation of the Engine Oil Temperature Sensor" .
Replace the oil pressure sensor. Refer to section "Removal of the Engine Oil Pressure Sensor" . Verify repair. Clear
the code. Release the vehicle.
12. Remove and inspect the inlet air temperature sensor, intake manifold pressure sensor, and charge air
temperature sensor for signs of damage. Is there damage present?
12.a Yes; Refer to section "Test-E - Two-Filter Fuel System" .
13. Remove the oil filter and verify that the correct oil filter is installed. Refer to section "Replacement of the Oil Filter" . Is
the correct oil filter installed?
13.b No; install the correct oil filter. Verify repair.
14. Inspect the outside of the oil filter for signs of metal or bearing material. Is there an excessive amount of
metal or bearing material present on the outside of the filter?
14.a Yes; determine the cause of the excessive metal in the oil. Repair as necessary.
3
15. Inspect the oil filter stand pipe and oil bypass valve (located on the top of the stand pipe) for damage. Is
there any damage present or is the oil bypass valve missing?
15.a Yes; replace the oil filter module. Verify repair.
16. Inspect the oil filter drain back valve located in the bottom of the oil filter housing. Is the oil filter drain back
valve damaged or missing?
16.b No; reinstall the oil filter . Refer to section "Replacement of the Oil Filter" . Go to step 17.
18. Use the oil system adapter J-49181 and oil primer pump tool J-45299 to check for leaks in the upper
portion of the engine. Refer to section "Priming the Engine Lubrication System" . Are there any leaks present?
19. Remove the oil pan. Refer to section "Removal of the Oil Pan" . Go to step 20.
20. Check the torque on the oil suction manifold bolts and oil pump using a torque wrench. Refer to section
"Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Are the bolts torqued to specification?

20.b No; Remove the oil suction manifold and the oil pump. Replace the O-rings, then reinstall the oil pump
and oil suction manifold. Refer to section "Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Verify repair.
21. Remove the oil pump, oil suction manifold, and oil lines. Refer to section "Removal of the Oil Pump, Oil Suction
Manifold, and Oil Lines" . Check the condition of the oil pump, oil suction manifold, suction lines, and O-rings. Is
there any damage present?
22. Inspect the rod and main bearings. Are the rod and main bearings excessively worn or damaged?
22.b No; replace the oil pump, Refer to section "Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Verify
repair.
4
50.2 SPN 100/FMI 18 – GHG17

SPN 100/FMI 18
Description This Fault Code Sets when the Engine Oil Pressure is Less
than a Calibrated Threshold
Monitor Sequence Key ON Engine Running
Dash Lamps CEL
Dependent
DD15TC and DD16 Minimum Oil Pressure at Operating Temperature

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
DD15AT Minimum Oil Pressure at Operating Temperature

rpm Bar psi
600 0.689 10
1200 1.65 24
1800 2.55 37
DD13 Minimum Oil Pressure at Operating Temperature

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
5
Check as follows:
1. Check for multiple codes. Are there multiple oil pressure sensor circuit fault codes?
4. Use the manufacturer recommended oil to fill the engine oil to the correct level. Check for external engine
oil leaks and repair as necessary. Verify repair.
5.a Yes; Refer to section "Coolant in Oil" . Verify repair.
6.a Yes; determine the cause of fuel in the oil. Change the oil and filter. Verify repair.
8. Connect DiagnosticLink and check for a biased oil pressure sensor at key ON, engine OFF. Does the oil
pressure sensor read zero psi?
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within normal operating range as per the chart?
9.a Yes; clear the code. Release the vehicle.
6
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to section "Removal of the Engine Oil Temperature Sensor" . Start and run the engine at the rpm listed in the chart. Is
the oil pressure, observed on the manual gauge, stable and within normal operating range as per the
chart?
7

20. Check the torque on the oil suction manifold bolts and oil pump using a torque wrench. Refer to section
"Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Are the bolts torqued to specification?

20.b No; Remove the oil suction manifold and the oil pump. Replace the O-rings, then reinstall the oil pump
and oil suction manifold. Refer to section "Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Verify repair.
22. Inspect the rod and main bearings; Refer to section "DD Platform Bearing Failure Guide" in the DDC-SVC-MAN-0196
"DD Platform Bearing Failure Guide." Are the rod and main bearings excessively worn or damaged?
repair.
8
49.1 SPN 100/FMI 0 - GHG17

Oil Pressure Stuck
SPN 100/FMI 0
Description This fault code sets when the engine oil pressure is higher
than a calibrated pressure for the specific RPM.
Dash Lamps CEL
Dependent
Verification While the engine is at normal operating temperature, road test
performing several decelerations.
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 100/FMI 3 or FMI 4 present?
4. With the ignition ON (key ON, engine OFF), go to Service Routines and click on the Voltages tab. Monitor
the engine oil pressure voltage. Does the engine oil pressure voltage read between 0.703 and 1.023 volts?
4.b No; replace the engine oil pressure sensor. Refer to section "Removal of the Engine Oil Pressure Sensor" .
6. Remove the engine oil temperature sensor; Refer to section "Removal of the Engine Oil Temperature Sensor" .
7. Reconnect the oil temperature sensor to the electrical connector while the engine oil temperature sensor is
still removed.
8. Plumb a manual gauge into the oil temperature sensor port.
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1
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9. Start and warm the engine to operating temperature.

10. Perform several neutral run-ups. Does the oil pressure reading on the manual gauge match the engine oil
pressure sensor reading in DiagnosticLink?
Reinstall the engine oil temperature sensor; Refer to section "Installation of the Engine Oil Temperature Sensor" and
verify repair.
11. Road test the vehicle. Does the engine oil pressure reading on the manual gauge match the engine oil
pressure reading in DiagnosticLink when the fault is present?
11.a Yes; replace the oil pump. Refer to section "Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Reinstall
the engine oil temperature sensor; Refer to section "Installation of the Engine Oil Temperature Sensor" and verify
repair.
Reinstall the engine oil temperature sensor; Refer to section "Installation of the Engine Oil Temperature Sensor" and
verify repair.
2
49.2 SPN 100/FMI 1 - GHG17

SPN 100/FMI 1
Description This Fault Code Sets When the Engine Oil Pressure is Less
Than a Calibrated Threshold
Typical Enabling Conditions Always ON
Monitor Sequence Key ON, Engine ON
Dash Lamps CEL
Dependent
Verification Check at Engine Operating Temperature

RPM BAR psi
600 0.689 10
1200 1.65 24
1800 2.55 37
DD13 and DD16 Minimum Oil Pressure at Operating Temperature

RPM BAR psi
600 0.758 11
1200 1.65 24
1800 2.55 37
Check as follows:
1. Check for multiple codes. Is either SPN 100/FMI 3, SPN 100/FMI 4 or SPN 100/FMI 5 also present?
3

4. For engine low on oil or exhibiting oil consumption concerns (including oil leaks), Refer to section "Check for
Excessive Oil Consumption" . After the oil consumption concern has been repaired, use the manufacturer-
recommended oil to fill the engine oil to the correct level. Verify repair.
5.a Yes; diagnose the cause of coolant in oil. Refer to section "Coolant in Oil" and replace the crankshaft main
bearings, the connecting rod bearings and the oil pump.
Refer to section "Installation of the Crankshaft" .
Refer to section "Installation of the Piston and Connecting Rod Assembly" .
Refer to section "Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" .
6.a Yes; diagnose the cause of fuel in the oil. Refer to section "Fuel in Oil" .
8. Connect DiagnosticLink® and check for a biased oil pressure sensor. With the ignition ON (key ON, engine
OFF), go to Service Routines and click on the Voltages tab. Monitor the engine oil pressure voltage. Does
the engine oil pressure voltage read between 0.703 and 1.023 volts?
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within normal operating range as per the chart at the top of this procedure?
4
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to section "Removal of the Engine Oil Temperature Sensor" . Start and allow the coolant temp to reach 77°C (170°F).
Run the engine at the rpm listed in the chart. Is the oil pressure, observed on the manual gauge, stable and
12.a Yes; the diagnostics in “Test E” will need to be performed. Refer to section "Test-E - Two-Filter Fuel System" .
5
21. Inspect the rod and main bearings; Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" . Are
the rod and main bearings excessively worn or damaged?
repair.
6
49.3 SPN 100/FMI 3 - GHG17

SPN 100/FMI 3
Description This Fault Sets When Either Short to Voltage or Open circuit
on Engine Oil Pressure (EOP) Sensor Circuit Are Present.
Dash Lamps CEL
Check as follows:
2. Check for multiple codes. Is SPN 3510/FMI 3 also present?
2.a Yes; diagnose 3510/FMI 3 fault first.
3. Disconnect the Engine Oil Pressure (EOP) sensor and inspect the electrical connector for damage,
corrosion or spread pins. Is damage, corrosion or spread pins present?
7
4. Measure the resistance between pin 2 of the EOP sensor harness connector and ground. Is the resistance
greater than five ohms?
4.a Yes; repair open between pin 2 of the EOP sensor and pin 105 of the MCM 120-pin connector.
5. Measure the voltage between pin 3 of the EOP sensor harness connector and ground. Is voltage present?
5.b No; repair open between pin 3 of the EOP sensor and pin 82 of the MCM 120-pin connector.
6. Is the voltage from previous step greater than five volts?
6.a Yes; repair short to battery power between pin 3 of the EOP sensor and pin 82 of the MCM 120-pin
connector.
7.a Yes; repair the short to power between pin 2 of the EOP sensor and pin 105 of the MCM 120-pin
connector.
8.a Yes; repair the short to power between pin 1 of the EOP sensor and pin 54 of the MCM 120-pin
connector.
9. Measure the resistance between pin 1 of the EOP sensor harness connector and pin 54 of the MCM 120-
pin connector. Is the resistance greater than five ohms?
9.a Yes; repair an open between pin 1 of the EOP sensor harness connector and pin 54 of the MCM 120-
pin connector.
9.b No; replace the EOP sensor. Refer to section "Removal of the Engine Oil Pressure Sensor" .
8
49.4 SPN 100/FMI 4 - GHG17

Engine Oil Pressure Sensor Circuit Failed Low
SPN 100/FMI 4
Description This Code Sets When a Short to Ground on Engine Oil
Pressure (EOP) Sensor Circuit is Present.
Dash Lamps CEL
Check as follows:
3. Check for multiple codes. Are there additional circuit failed low codes (FMI 4) for the Camshaft Position
(CMP) sensor, fuel line pressure sensor and fuel compensation pressure present?
9
5. Disconnect the EOP sensor harness connector.

6. Inspect the EOP connector and EOP harness connector for damage, bent, spread or unseated (pushed
out) pins, corrosion or wire damage. Is damage present?
7. Measure the resistance between pin 1 of the EOP sensor and ground. Is the resistance greater than 10k
ohms?
7.b No; repair the short to ground between pin 1 of the EOP sensor and ground.
8. Measure the resistance between pin 3 of the EOP sensor and ground. Is the resistance greater than 10k
ohms?
8.a Yes; replace the EOP sensor. Refer to section "Removal of the Engine Oil Pressure Sensor" .
8.b No; repair the short to ground between pin 3 of the EOP sensor and ground.
NOTE: This could include a short to ground on pin 3 of the EOP sensor, pin 1 of the camshaft position
sensor, pin 2 of the fuel line pressure sensor, and pin 2 of the fuel compensation pressure sensor.
10
49.5 SPN 100/FMI 5 - GHG17

SPN 100/FMI 5
Description This diagnosis is Typically Oil Pressure Stuck
Monitor Sequence Key On Engine Running at Speeds Below 625 rpm
Dash Lamps CEL
Dependent
Verification While the Engine is at Normal Operating Temperature, Road
Test Performing Several Decelerations
Check as follows:
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ENGINE EXHAUST
11

3. Check for multiple fault codes. Are fault codes SPN 100/FMI 3 or FMI 4 present?
4. Disconnect the engine oil pressure sensor. Inspect the connector for damage, bent, spread or unseated
(pushed out) pins, corrosion or wire damage. Is damage present?
4.a Yes; repair as necessary .
5. Measure the resistance between pin 2 of the engine oil pressure sensor and ground. Is the resistance
5.a Yes; repair the open circuit between pin 2 of the engine oil pressure sensor and pin 105 of the MCM
120-pin connector.
12
49.6 SPN 100/FMI 10 - GHG17

SPN 100/FMI 10
Description This Fault Code Sets When the Engine Power has Been
Limited to Prevent Engine Damage Due to a Low Oil Pressure
Condition
Dash Lamps CEL
Engine Reaction Engine Derate or Engine Shut Down - Calibration Dependent
Tools Used
• Failed oil pressure sensor

• Initial start after oil maintenance
• Vehicle is parked on a steep incline
• Improper oil level
• Oil dilution
• Leaks in the oil suction manifold
• Leaks at the oil suction pipes
• Failed oil pump

rpm Bar psi
600 0.689 10
1200 1.65 24
1800 2.55 37

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
Note : The oil gauge in the dashboard of the vehicle is NOT used to diagnose or verify low oil pressure concerns.
13
5.a Yes; diagnose the cause of coolant in oil. Refer to section "Coolant in Oil" . Replace the crankshaft main
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14
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15

16.b No; reinstall the oil filter. Refer to section "Replacement of the Oil Filter" . Go to step 17.
21. Inspect the rod and main bearings; Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" . Are
21.b No; replace the oil pump. Refer to section "Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" . Verify
repair.
16
49.7 SPN 100/FMI 17 - GHG17

SPN 100/FMI 17
Description Engine Oil Pressure Plausibility Error
Dash Lamps CEL
Dependent

rpm Bar psi
600 0.689 10
1200 1.65 24
1800 2.55 37

rpm Bar psi
600 0.758 11
1200 1.65 24
1800 2.55 37
Check as follows:
17

5.a Yes; diagnose the cause of coolant in oil. Refer to section "Coolant in Oil" . Replace the crankshaft main
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18
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19
21. Inspect the rod and main bearings. Refer to section "Inspection of the Main and Connecting Rod Bearings in Chassis" Are
repair.
20
51.1 SPN 103/FMI 0 - GHG17

Turbocharger Speed Below Threshold (Low Box)
SPN 103/FMI 0
Description Turbocharger Speed Below Threshold (Low Box)
Monitored Parameter
Typical Enabling Conditions Turbocharger Speed Below Threshold
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps MIL, CEL
Engine Reaction none
Verification
1. Inspect the entire air intake system for leaks and/or restrictions including air filter and CAC.
1.a If leaks or restrictions are found, repair as necessary.
1.b If no air intake system leaks or restrictions are found, Go to step 2.
2. Connect to DiagnosticLink
4. Road test vehicle and record a log file with Instrumentation Mechanical Panel data; Temperatures, Engine
and Road Speed, Torque, Manifold and Boost psi. Do all readings pass specification?
4.a Yes; replace the Turbocharger Speed Sensor (TSS).
4.b No; follow the appropriate component troubleshooting procedure for the affected component.
1
51.2 SPN 103/FMI 1 - GHG17

Turbocharger Speed Below Threshold (High Box)
SPN 103/FMI 1
Description Turbocharger Speed Below Threshold (High Box)
Monitored Parameter
Typical Enabling Conditions Turbocharger Speed Above Threshold
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps MIL,CEL
Verification
1. Inspect the entire air intake system for leaks and/or restrictions including air filter and CAC.
1.a If leaks or restrictions are found, repair as necessary.
1.b If no air intake system leaks or restrictions are found, Go to step 2.
and Road Speed, Torque, Manifold and Boost psi. Do all readings pass Specification?
2
51.3 SPN 103/FMI 2 - GHG17

Turbocharger Speed Not Plausible
SPN 103/FMI 2
Description Turbocharger Speed Not Plausible
Monitored Parameter Turbo speed sensor
Typical Enabling Conditions Turbocharger Speed Above Threshold
Execution Frequency Always enabled
Dash Lamps MIL, CEL
Verification Road test
1. Inspect the entire air intake system for leaks and/or restrictions including air filter and CAC. Were leaks or
restrictions found?
2. Visually inspect the EGR system for leaks, obstructions, loose clamps or damage. Were leaks,
obstructions, loose clamps or damage found?
3. Inspect the EGR valve for physical damage such as a broken butterfly. Was damage found?
3.a If EGR valve is damaged, replace the EGR valve. Go to step 4.
and Road Speed, Torque, Manifold and Boost psi. Do all readings pass specification?
3
51.4 SPN 103/FMI 4 - GHG17

SPN 103/FMI 4
Description This fault Sets when the Motor Control Module (MCM) Detects
a Short to Ground on the Turbocharger Speed Sensor Circuit.
Monitored Parameter Turbocharger Speed Sensor
Execution Frequency Continuous when Enabling Conditions Met
Dash Lamps CEL
Verification Cycle Key
Check as follows:
2. Disconnect and inspect the turbocharger speed sensor electrical connector harness side. Is there corrosion
present?
2.a Yes; replace the turbocharger speed sensor and the electrical connector. Refer to section "Removal of the
Turbocharger Speed Sensor" . Verify repair.

3. Are any of the pins or the connector damaged?
4. Inspect the turbocharger speed sensor electrical connector component side. Are any of the pins or the
connector damaged?
4.a Yes; replace the turbocharger speed sensor and the electrical connector. Refer to section "Removal of the
Turbocharger Speed Sensor" . Verify repair.
4
4.b No; replace the turbocharger speed sensor electrical connector harness side. Verify repair.
6. Is fault code SPN 103/FMI 4 active?
6.b No; replace the turbocharger speed sensor. Refer to section "Removal of the Turbocharger Speed Sensor" . Verify
repair.
8. Disconnect and inspect the MCM 120-pin electrical connector harness side. Is there corrosion present?
8.a Yes; replace the MCM and the engine harness. Refer to section "Removal of the Motor Control Module" . Verify
repair.
9. Is the connector damaged?
10. Inspect the MCM 120-pin electrical connector component side. Are any of the pins or the connector
damaged?
repair.
10.b No; replace the engine harness. Verify repair.
11. Measure the resistance between pin 2 of the turbocharger speed sensor electrical connector harness side
and pin 52 of the MCM 120-pin electrical connector harness side. Is the resistance less than 10k ohms?
11.a Yes; repair the circuit between pin 2 of the turbocharger speed sensor electrical connector harness
side and pin 52 of the MCM 120-pin electrical connector harness side.
5
52.1 SPN 107/FMI 0 - GHG17

Check as follows:
1. Check the air cleaner for restriction. Is the air filter restricted?
1.a Yes; repair or replace the air filter as necessary. Refer to Original Equipment Manufacturer (OEM)
procedures.
2. Check for multiple codes. Is CPC SPN 107/FMI 2, FMI 3, or FMI 4 present?
2.a Yes; repair other FMIs first.
WARNING
PRESSURIZED FUEL
test.
3. Perform pressure check/visual inspection of the following and repair as necessary.

• Plugged inlet air filters
• Charge air cooler leaks or restriction
• Leaking or plugged intake manifold
• Exhaust leaks/plugging
1
52.2 SPN 107/FMI 2 - GHG17

Air Filter Sensor plausibility error
Check as follows:
Note : This fault code is not calibrated for NAFTA Market. If this fault code is active, the Common Powertrain
Controller (CPC) parameter is incorrectly set.
2. Check for proper configuration of the CPC against the server information. Does the CPC have the proper
configuration?
2.b No; reprogram the CPC with the correct information as necessary. Go to step 3. to verify repair.
power down. Verify repair.
2
52.3 SPN 107/FMI 3 - GHG17

Air Filter Sensor failed high
Check as follows:
configuration?
3
52.4 SPN 107/FMI 4 - GHG17

Air Filter Sensor failed low
Check as follows:
configuration?
4
SPN 108 (ACM) (GHG17)
53.1 SPN 108/FMI 13 - GHG17

SPN 108/FMI 13
Description Ambient Air Pressure Signal Not Available via CAN
Monitored Parameter Barometric Pressure Sensor
Dash Lamps MIL, CEL
Verification Engine Idle (One Minute)
1. Has the ACM/MCM/CPC been recently reprogrammed?

1.a Yes; clear faults codes if they do not become active. Release vehicle.
2. Turn the ignition OFF and disconnect DiagnosticLink . Wait five minutes for all modules to power down.
4. Reconnect DiagnosticLink; are fault codes active?
4.a Yes; Refer to section "SPN 625/FMI 9 – GHG17" under ACM for further PT CAN troubleshooting.
4.b No; clear faults codes and release vehicle.
1
54.1 SPN 108/FMI 13 - GHG17

Ambient Air Pressure Signal Not Available via CAN
4.a Yes; Refer to section "SPN 625/FMI 9 - GHG17" for further PT CAN troubleshooting.
1
54.2 SPN 108/FMI 4 - GHG17

Barometric Pressure (BP) Sensor Circuit Failed Low
Note : The BP sensor is internal to the MCM.
SPN 108/FMI 4
Description Barometric Pressure Circuit Failed Low
Monitored Parameter Barometric Pressure Sensor
Dash Lamps MIL, CEL
Check as follows:
2. Are there other codes present?
2.a Yes; diagnose other codes first.
2.b No; if SPN 108/FMI 3 is the only code present, replace the Motor Control Module (MCM). Refer to section
"Removal of the Motor Control Module" . Verify repair.
2
57.1 SPN 110/FMI 9 – GHG17

Coolant Temperature Signal Not Available via Controller Area Network (CAN)
SPN 110/FMI 9
Description This fault code Sets when the Coolant Temperature Signal is
Not Received from the MCM.
Monitored Parameter Outlet Coolant Temperature
Dash Lamps MIL, CEL
Verification Ignition On
W470589036300
Check as follows:
3. Check the MCM software level. Is the MCM software level 6.4.0.5 ZGS 005 or greater?
3.b No; Update the MCM using the latest server information. Perform the repair verification. If the fault
returns, Go to step 4.
4. Has the Aftertreatment Control Module (ACM) or Motor Control Module (MCM) been reprogrammed?
1

5. Verify that the module has been programmed correctly using the server information. Are the modules
programmed correctly?
5.b No; program the modules using the latest server information. Go to step 6.
6. Clear the fault code.
7. Turn the ignition off for five minutes to let the modules power down.
9. Check the fault codes. Has fault code SPN 110/FMI 9 become active?
9.b No; the fault code was set during the module reprogram event. No further diagnostics or repairs are
needed. The vehicle can be released to the customer.
10. Check for multiple fault codes. Are any of the following fault codes present?
• SPN 110/FMI 2
• SPN 110/FMI 3
• SPN 110/FMI 4
• SPN 625/FMI 9
12. Install a test MCM; use the MCM extension harness W470589036300, if available. Refer to Tool Letter 13
TL-21 for more information.
13. Turn the ignition ON ( key ON, engine OFF).

14.a Yes; replace the ACM.
For the 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .
For the Two-Box (2V2) , Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .
2
56.1 SPN 110/FMI 0 - GHG17

SPN 110/FMI 0
Description This Code Sets Once the Motor Control Module (MCM)
Detects that the Outlet Coolant Temperature is Above 112°C
(234°F)
Monitored Parameter Engine Coolant Outlet Temperature Sensor
Dash Lamps MIL, CEL
Engine Reaction
Verification Outlet Coolant Temperature Above 112°C (234°F) Followed
by One Minute of Idling
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ENGINE EXHAUST
Check as follows:
1.b No; update the MCM using the latest server information. Perform the repair verification. If the fault
2. Check for multiple codes. Are codes SPN 110/FMI 3, SPN 110/FMI 4, SPN 4814/FMI any or SPN 5927/FMI
any present?
1
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PERSONAL INJURY
3. Compare coolant inlet and coolant outlet temperatures. Are the temperatures within 13.9°C (25°F) of each
other?
3.b No; replace both the coolant inlet and coolant outlet temperature sensors.
Refer to section "Removal of the Engine Coolant Inlet Temperature Sensor"
Refer to section "Removal of the Engine Coolant Outlet Temperature Sensor"
4. Visually check the engine coolant level in the surge tank. Is the coolant level within the specified range?
4.b No; determine the cause of low coolant level. Refer to section "Symptom Diagnostics - Coolant Loss" .
5. Visually inspect the engine belts. Refer to section "Inspection of the Poly-V-Belts" . Do the belts show damage or
signs of excessive wear?
5.a Yes; replace the damaged belt(s). Refer to section "Removal of the Poly-V-Belts" .
6. Inspect the radiator and Charge Air Cooler (CAC) for any external restrictions or clogged fins (winter fronts,
plows and other front vehicle accessories can sometimes create a restriction). Use a flashlight on one side
of the radiator/CAC assembly and check to see if the light can be seen through the other side of the
assembly. Was a restriction present?
6.a Yes; clear the restriction and/or clean the radiator/CAC assembly using compressed air or water from a
hose.
7. Check the fan shroud for proper installation or damage. Is fan shroud not properly installed or damaged?
7.a Yes; adjust or replace the fan shroud as necessary, refer to OEM literature for removal and installation
instructions.
8. Inspect the engine cooling fan operation, inspect the fan blades. Is damage present?
8.a Yes; replace the engine cooling fan, refer to OEM literature for removal and installation instructions.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
2
WARNING
ENGINE EXHAUST
9. Run the engine until temperature reaches 106°C (223°F). Does the engine cooling fan activate?
9.b No; verify proper fan parametrization and diagnose the faulty engine cooling fan.
10. Pressure test the radiator cap according to Original Equipment Manufacturer (OEM) procedure. Does the
radiator cap pass the pressure test?
10.b No; replace the radiator cap.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
11. Start the engine and inspect the belt and belt tensioner for excessive noise, chatter, or movement while
idling and at 100 rpm increments for 15 seconds each until you reach 1200 rpm. Is there an excessive
amount of noise, chatter, or movement?
11.a Yes; Refer to section "Belt Drive Noise" .
12. Check for proper radiator hose condition. Are the hoses damaged or collapsed?
12.a Yes; determine the cause of a damaged or collapsed coolant hose and repair, as necessary.
13. Is the vehicle equipped with a variable speed water pump?
13.a Yes; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" , then Go to step
15.

14. Inspect the fixed speed water pump. Refer to section "Inspection of the Water Pump" . Is damage present?
14.a Yes; replace the water pump. Refer to section "Removal of the Water Pump" .
3
14.b No; replace the thermostat, then Go to step 15. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
15. Bring the outlet coolant temperature to 112°C (234°F) or above and run the engine at idle for one minute
and check for codes. Is SPN 110 FMI 0 active?
15.a Yes; inspect the radiator for flow and thermal efficiency. Refer to OEM guidelines.
4
56.2 SPN 110/FMI 16 - GHG17

Coolant Temperature High
1. Check for multiple codes.
1.a If fault codes SPN 110/FMI 3 or SPN 110/FMI 4 are also present, repair those faults first.
Refer to section "SPN 110/FMI 3 - GHG17" .
1.b If fault codes SPN 110/FMI 3 or SPN 110/FMI 4 are not present, Go to step 2.
2. With engine cold, compare coolant inlet and coolant outlet temperatures. Are the temperatures within 25°F
of each other?
3. Check for coolant loss.
4. Check thermostat operation.
5. Check for blockage in radiator and charge air cooler.
6. Check fan belt condition (slippage).
7. Check for proper location of fan shroud.
8. Check for proper radiator hose condition (no collapsed hoses).
9. Check for proper viscous fan operation.
5
55.1 Coolant Sensor Resistance Chart

Resistance Resistance Resistance Nominal Voltage Low Voltage High
Temp (°C) Temp (°F) () Nominal Low () High () Voltage (V) (V) (V)
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
1
55.2 SPN 110/FMI 0 - GHG17

SPN 110/FMI 0
(234°F)
Dash Lamps MIL, CEL
Engine Reaction
Verification Outlet Coolant Temperature Above 112°C (234°F) Followed
by One Minute of Idling
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
2. Check for multiple codes. Are codes SPN 110/FMI 3, SPN 110/FMI 4, SPN 4814/FMI any or SPN 5927/FMI
any present?
2
WARNING
PERSONAL INJURY
other?
Refer to section "Removal of the Engine Coolant Inlet Temperature Sensor"
Refer to section "Removal of the Engine Coolant Outlet Temperature Sensor"
6. Inspect the radiator and Charge Air Cooler (CAC) for any external restrictions or clogged fins (winter fronts,
plows and other front vehicle accessories can sometimes create a restriction). Use a flashlight on one side
of the radiator/CAC assembly and check to see if the light can be seen through the other side of the
assembly. Was a restriction present?
6.a Yes; clear the restriction and/or clean the radiator/CAC assembly using compressed air or water from a
hose.
7. Check the fan shroud for proper installation or damage. Is fan shroud not properly installed or damaged?
7.a Yes; adjust or replace the fan shroud as necessary, refer to OEM literature for removal and installation
instructions.
8. Inspect the engine cooling fan operation, inspect the fan blades. Is damage present?
8.a Yes; replace the engine cooling fan, refer to OEM literature for removal and installation instructions.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
3
WARNING
ENGINE EXHAUST
9. Run the engine until temperature reaches 106°C (223°F). Does the engine cooling fan activate?
9.b No; verify proper fan parametrization and diagnose the faulty engine cooling fan.
10. Pressure test the radiator cap according to Original Equipment Manufacturer (OEM) procedure. Does the
radiator cap pass the pressure test?
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
11. Start the engine and inspect the belt and belt tensioner for excessive noise, chatter, or movement while
idling and at 100 rpm increments for 15 seconds each until you reach 1200 rpm. Is there an excessive
amount of noise, chatter, or movement?
12.a Yes; determine the cause of a damaged or collapsed coolant hose and repair, as necessary.
13. Is the vehicle equipped with a variable speed water pump?
13.a Yes; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" , then Go to step
15.

14. Inspect the fixed speed water pump. Refer to section "Inspection of the Water Pump" . Is damage present?
14.a Yes; replace the water pump. Refer to section "Removal of the Water Pump" .
4
14.b No; replace the thermostat, then Go to step 15. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
15. Bring the outlet coolant temperature to 112°C (234°F) or above and run the engine at idle for one minute
and check for codes. Is SPN 110 FMI 0 active?
15.a Yes; inspect the radiator for flow and thermal efficiency. Refer to OEM guidelines.
5
55.3 SPN 110/FMI 3 - GHG17

SPN 110/FMI 3
Description Engine Coolant Outlet Temperature Circuit Short to Voltage or
Open
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
6
3. Check for multiple codes. Are fault codes SPN 174/FMI 3, SPN 175/FMI 3 or SPN 4193/FMI 3 also
present?
3.a Yes; repair the circuit between pin 55 of the MCM 120-pin electrical connector harness side and the
circuit splice.
5. Disconnect and inspect the engine coolant outlet temperature sensor electrical connector harness side. Is
there corrosion present?
5.a Yes; replace the engine coolant temperature sensor and electrical connector. Refer to section "Removal of
the Engine Coolant Outlet Temperature Sensor" . Verify repair.

6. Inspect the engine coolant outlet temperature sensor electrical connector harness side. Is the connector or
any of the pins damaged?
7. Inspect the engine coolant outlet temperature sensor electrical connector component side. Is the connector
or any of the pins damaged?
7.a Yes; replace the engine coolant temperature sensor and electrical connector. Refer to section "Removal of
the Engine Coolant Outlet Temperature Sensor" . Verify repair.
7.b No; replace the engine coolant temperature sensor electrical connector. Refer to Technical Service
letter 13 TS-16 . Verify repair.
8. Use the correct flex probe to check the pins in the connector. Are there any spread pins?
8.a Yes; replace engine coolant temperature sensor electrical connector. Refer to Technical Service letter
13 TS-16 . Verify repair.

10. Measure the voltage between pins 1 and 2 of the engine coolant outlet temperature sensor harness
connector. Is the voltage greater than 3.5 volts?
10.a Yes; repair short to power between pin 2 of the engine coolant temperature sensor and pin 110 of the
MCM 120-pin connector.
11. Measure the voltage between pins 1 and 2 of the engine coolant outlet temperature sensor harness
connector. Is the voltage between 2.5 and 3.5 volts?
11.a Yes; replace the engine coolant outlet temperature sensor. Refer to section "Removal of the Engine Coolant
Outlet Temperature Sensor" .

12. Measure voltage between pin 2 of the engine coolant outlet temperature sensor and ground. Is the voltage
12.a Yes; repair the wire between pin 2 of the engine coolant outlet temperature sensor connector and pin
110 of the Motor Control Module (MCM) 120-pin connector.
12.b No; repair the wire between pin 1 of the engine coolant outlet temperature sensor connector and pin 55
of the MCM 120-pin connector.
7
55.4 SPN 110/FMI 4 - GHG17

Engine Coolant Outlet Temperature Circuit Failed Low
SPN 110/FMI 4
Description This Fault Code Sets when the Motor Control Module (MCM)
Detects a Short to Ground on the Engine Coolant
Temperature Sensor Circuit.
Dash Lamps MIL, CEL
Engine Reaction
WARNING
ENGINE EXHAUST
Check as follows:
8
2. Disconnect and inspect the engine coolant electrical connector harness side. Is there corrosion present?
2.a Yes; replace the engine coolant temperature sensor and the electrical connector. Refer to section "Removal
of the Engine Coolant Outlet Temperature Sensor" and Technical Service letter 13 TS-16 . Verify repair.

4. Inspect the engine coolant outlet electrical connector component side. Are any of the pins or the connector
damaged?
4.a Yes; replace the engine coolant temperature sensor and the electrical connector. Refer to section "Removal
of the Engine Coolant Outlet Temperature Sensor" and Technical Service letter 13 TS-16 . Verify repair.
4.b No; replace the engine coolant outlet temperature sensor electrical connector. Refer to Technical
Service letter 13 TS-16 . Verify repair.
6. Is fault code SPN 110/FMI 4 still active?
6.b No; replace the engine coolant temperature sensor. Refer to section "Removal of the Engine Coolant Outlet
Temperature Sensor" . Verify repair.

8. Disconnect and inspect MCM 120-pin electrical connector harness side. Is there corrosion present?
repair.
damaged?
repair.
11. Measure the resistance between pin 2 of the engine coolant electrical connector harness side and pin 110
of the MCM 120-pin electrical connector harness side. Is the resistance less than five ohms?
11.a Yes; replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repair.
11.b No; repair the circuit between pin 2 of the engine coolant electrical connector harness side and pin 110
of the MCM 120-pin electrical connector harness side. Verify repair.
9
55.5 SPN 110/FMI 16 - GHG17

SPN 110/FMI 16
(234°F)
Dash Lamps MIL, CEL
Engine Reaction
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
1. Check for multiple codes. Are codes SPN 110/FMI 3 or SPN 110/FMI 4 present?
WARNING
PERSONAL INJURY
other?
10

Refer to section "Removal of the Engine Coolant Inlet Temperature Sensor" .
Refer to section "Removal of the Engine Coolant Outlet Temperature Sensor" .
5. Inspect the radiator and Charge Air Cooler (CAC) for any external restrictions or clogged fins. Use a
flashlight on one side of the radiator/CAC assembly and check to see if light can be seen through the other
side of the assembly. Is a restriction present?
5.a Yes; clean the radiator/CAC assembly using compressed air or water from a hose.
6. Check the fan shroud for proper installation or damage. Is the fan shroud improperly installed or damaged?
6.a Yes; adjust or replace the fan shroud as necessary, refer to Original Equipment Manufacturer (OEM)
literature for removal and installation instructions.
7. Inspect the engine cooling fan operation; inspect the fan blades. Is damage present?
7.a Yes; replace the engine cooling fan. Refer to OEM literature for removal and installation instructions.
8. Pressure-test the radiator cap according to OEM procedure. Does the radiator cap pass the pressure test?
9. Start the engine and inspect the belt and belt tensioner for excessive noise, chatter, or movement from idle
and at 100 rpm increments for 15 seconds each until you reach 1200 rpm. Is there an excessive amount of
noise, chatter, or movement?
10.a Yes; determine the cause of a damaged or collapsed coolant hose. Repair as necessary.
11. Test the water pump operation. Connect a coolant pressure tester tool to the surge tank. Start and run the
engine at 1200 rpm. Monitor the pressure gauge for five minutes. Did the pressure in the cooling system
increase above 69 kPa (10 psi)?
11.a Yes; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
11.b No; replace the water pump. Refer to section "Removal of the Water Pump" .
11
55.6 SPN 110/FMI 18 – GHG17

SPN 110/FMI 18
Description This Fault Sets when the Engine Coolant Temperature has
not Increased to Match a Modeled Temperature Range
Monitored Parameter Engine Coolant Outlet Temperature
Typical Enabling Conditions
Ambient Temp greater than -8°C (18°F)
Ambient Pressure greater than 755 mbar (11 psi)
Vehicle Speed greater than 45 km/hr (27 mph)
Engine Run Time After Engine Start greater than 5 Minutes
Dash Lamps MIL
Verification Road Test the Vehicle for 40 Minutes
Check as follows:
2. Turn the ignition ON (key ON; engine OFF).
3. Check for multiple fault codes. Are fault codes SPN 110/FMI 3, FMI 4, FMI 14; SPN 4193/FMI 2, FMI 3, FMI
4, or FMI 17 present?
3.a Yes; diagnose the other fault codes first. Verify repair.
4. Is this vehicle a bus?
5.b No; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
6. Isolate the aftermarket components and retest. Does fault code SPN 110/FMI 18 become active?
6.b No; inform the customer that the aftermarket component(s) plumbed into the cooling system are the
cause of the concern.
12
58.1 SPN 111/FMI 1 - GHG17

SPN 111/FMI 1
Description Coolant Level Below Normal Range
Monitored Parameter Coolant Level
Dash Lamps CEL
1. Check for multiple codes. Are there any coolant level circuit codes?
1.a Yes; repair those codes first.
2. Check the coolant level in the reservoir. Is the coolant level in the reservoir below limit level 2.
2.a Yes; Refer to section "Symptom Diagnostics - Coolant Loss" .
1
Note : Make sure that the coolant is not overfilled. The min/low and max/full marks on the coolant surge tank
represent the acceptable operating range of the coolant level. During normal operation, the coolant level will
expand and contract between the two lines, depending on temperature. Overfilling the coolant reservoir will cause
the surge tank to push coolant out.
3. With the coolant filled to the proper level (1), clear the code and run the engine for five minutes. Check for
codes. Did SPN 111/FMI 1 return?
3.a Yes; replace the Engine Coolant Level (ECL) sensor and verify the repair.
3.b No; the code was likely cause by a previously low coolant level condition. Ask the driver about coolant
loss. If necessary, Refer to section "Symptom Diagnostics - Coolant Loss" .
2
58.2 SPN 111/FMI 3 - GHG17
1. Turn ignition OFF.

2. Disconnect the Engine Coolant Level (ECL) sensor.
3. Inspect sensor and harness connector for bent, spread, or corroded pins. Is any damage found?
4. Is ECL sensor a magnetic float type? Refer to Original Equipment Manufacturer (OEM) literature.
5. Measure the resistance between pins 1 and 2 of the ECL sensor with the sensor submerged (float up,
circuit closed). Is the resistance between 120 to 140 ohms?
5.b No; replace the ECL sensor. Refer to section "Description and Operation of the Engine Coolant Level Sensor" .
6. Measure the resistance between pins 1 and 2 of the ECL sensor. Is the resistance less than 600K ohms
while submerged?
6.b No; replace the ECL sensor. Refer to section "Description and Operation of the Engine Coolant Level Sensor" .
8. Measure the voltage between pin 1, or pin A for magnetic float type, of the ECL sensor harness connector
and ground. Is the voltage above 4.0 volts?
8.a Yes; repair the open circuit between pin 2 of the ECL sensor harness and ground. Verify repairs.
11. Inspect CPC #3 connector for bent, spread, or corroded pins. Is any damage found?
12. Measure the resistance between pin 1 of the ECL harness connector and pin 11 of the CPC #3 connector.
Is the resistance greater than five ohms?
12.a Yes; repair the open circuit between pin 1 of the ECL sensor harness connector and pin 11 of the CPC
#3 connector. Verify repairs.
12.b No; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature. Go to step 13.
13. Clear the code and cycle the ignition on and off. Is SPN 111/FMI 3 active?
13.a Yes; follow the appropriate Coolant Level Sensor testing service bulletin procedure, listed below:
• Freightliner Service Bulletin 20-70
• Western Star Service Bulletin 20-27
3
58.3 SPN 111/FMI 4 - GHG17

SPN 111/FMI 4
Description This Fault Sets when the Common Powertrain Controller
(CPC) Detects that there is a Short to Ground on the Coolant
Level Circuit or the Engine Coolant Level is Low.
Dash Lamps CEL
Check as follows:
2. Disconnect and inspect the engine coolant level sensor harness side. Is there corrosion present?
2.a Yes; replace the engine coolant level sensor and the electrical connector. Refer to Original Equipment
Manufacturer (OEM) literature for removal and installation procedures. Verify repair.
3. Inspect the engine coolant level sensor harness side. Are any of the pins or the connector damaged?
4. Inspect the engine coolant level sensor component side. Are any of the pins or the connector damaged?
4.a Yes; replace the engine coolant level sensor and electrical connector. Refer to Original Equipment
Manufacturer (OEM) literature for removal and installation procedures. Verify repair.
4.b No; replace the electrical connector. Refer to Original Equipment Manufacturer (OEM) literature for
removal and installation procedures. Verify repair.
6. Is fault code SPN 111/FMI 4 still present?
6.b No; replace the engine coolant level sensor. Refer to Original Equipment Manufacturer (OEM) literature
for removal and installation procedures. Verify repair.
8. Disconnect and inspect the brown CPC electrical connector #3 harness side. Is there any corrosion
present?
8.a Yes; replace the CPC and the engine harness. Refer to Original Equipment Manufacturer (OEM)
literature for removal and installation procedures. Verify repair.
10. Inspect the CPC electrical connector #3 component side. Is the connector or are the pins damaged?
10.a Yes; replace the CPC and the brown electrical connector #3. Refer to Original Equipment Manufacturer
(OEM) literature for removal and installation procedures. Verify repair.
10.b No; replace the brown electrical connector #3 harness side. Refer to Original Equipment Manufacturer
(OEM) literature for removal and installation procedures. Verify repair.
4
11. Measure the resistance between pin 2 of the engine coolant electrical connector harness side and pin 11 of
brown CPC electrical connector #3 harness side. Is the resistance less than 10k ohms?
11.a Yes; repair the circuit between pin 2 of the engine coolant electrical connector harness side and pin 11
of brown CPC electrical connector #3 harness side. Verify repair.
11.b No; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature for removal and
installation procedures. Verify repair.
5
58.4 SPN 111/FMI 6 - GHG17

SPN 111/FMI 6
Description Coolant Level Circuit Signal Below Normal Range
Dash Lamps CEL
6
Check as follows:
2. Disconnect the Engine Coolant Level (ECL) sensor.
3. Inspect sensor and harness connector for bent, spread, or corroded pins. Is any damage found?
4. Disconnect the Common Powertrain Controller (CPC) #3 21-pin connector.
5. Inspect CPC #3 connector for bent, spread, or corroded pins. Is any damage found?
6. Measure the resistance across pins 1 and 2 of the ECL sensor harness side connector. Is the resistance
6.b No; repair the short between pin 1 and pin 2 of the ECL sensor harness side connector.
7. Measure the resistance between pin 1 of the ECL sensor harness connector and ground. Is the resistance
7.a Yes; replace the ECL sensor. Refer to section "Description and Operation of the Engine Coolant Level Sensor" .
7.b No; repair the short to ground between pin 1(A) of the ECL sensor harness connector and pin 11 of the
CPC #3 connector. Verify repairs. If fault returns, replace the CPC. Refer to Original Equipment
Manufacturer (OEM) literature. Go to step 8.
8. Clear the code and cycle the ignition on and off. Is SPN 111/FMI 4 active?
8.a Yes; follow the appropriate Coolant Level Sensor testing service bulletin procedure, listed below:
• Freightliner Service Bulletin 20-70
7
• Western Star Service Bulletin 20-27

8
58.5 SPN 111/FMI 18 - GHG17
1. Check for multiple codes. Are there any coolant level circuit codes?
2. Check the coolant level in the reservoir. Is the coolant level in the reservoir below limit level 2?
2.a Yes; Refer to section "Symptom Diagnostics - Coolant Loss" .
Note : Make sure that the coolant is not overfilled. The min/low and max/full marks on the coolant surge tank
represent the acceptable operating range of the coolant level. During normal operation, the coolant level will
expand and contract between the two lines, depending on temperature. Overfilling the coolant reservoir will cause
9
the surge tank to push coolant out.

3. With the coolant filled to the proper level (1), clear the code and run the engine for five minutes. Check for
codes. Did SPN 111/FMI 18 return?
3.a Yes; replace the Engine Coolant Level (ECL) sensor and verify the repair.
3.b No; the code was likely cause by a previously low coolant level condition. Ask the driver about coolant
loss. If necessary, Refer to section "Symptom Diagnostics - Coolant Loss" .
10
59.1 SPN 111/FMI 1 - GHG17

Check as follows:
1. Are any coolant level circuit codes present?
2. Check the coolant level reservoir, is the coolant level within the Min/Max indicator lines on the reservoir?
2.a Yes; replace the coolant level sensor.
2.b No; fill reservoir to proper level. Go to step 3.
3. Check for coolant leak at cylinder head gasket. Verify repairs.
4. Check for coolant leak at air compressor head gasket. Verify repairs.
5. Check for external coolant leak at hose connections. Verify repairs.
6. Check for coolant in oil. Verify repairs.
7. Check for loose or faulty radiator cap. Verify repairs.
8. Check cab heating system for leaks. Verify repairs.
1
59.2 SPN 111/FMI 4 - GHG17

SPN 111/FMI 4
(CPC) Detects that there is a Short to Ground on the Coolant
Level Circuit or the Engine Coolant Level is Low
Dash Lamps CEL
1. Disconnect the coolant level sensor.

2. Inspect the coolant level sensor harness connector for bent spread or corroded terminals. Is pin damage
found?
4. Measure the voltage between pin 1 and 2 of the coolant level sensor harness connector. Is the voltage
5. Measure the voltage between pin 1 of the coolant level sensor harness connector and ground. Is the
voltage between 4.5 and 5.0 volts?
5.a Yes; repair wire between pin 2 of the coolant level sensor harness connector and connector 2 pin 11 of
the CPC3.
5.b No; repair wire between pin 1 of the coolant level sensor harness connector and connector 2 pin 22 of
the CPC3.
2
59.3 SPN 111/FMI 14 - GHG17

SPN 111/FMI 14
(CPC) Detects an Erratic Coolant Level Sensor Signal
Dash Lamps CEL

2. Inspect the coolant level sensor harness connector for bent spread or corroded terminals. Is pin damage
found?
4. Measure the voltage between pin 1 and 2 of the coolant level sensor harness connector. Is the voltage
5.a Yes; repair wire between pin 2 of the coolant level sensor harness connector and connector 2 pin 11 of
the CPC3.
5.b No; repair wire between pin 1 of the coolant level sensor harness connector and connector 2 pin 22 of
the CPC3.
3
59.4 SPN 111/FMI 18 - GHG17

SPN 111/FMI 18
(CPC) Detects Coolant Level is Low
Dash Lamps CEL
1. Are any coolant level circuit codes present?

2. Check the coolant level reservoir, is the coolant level within the Min/Max indicator lines on the reservoir?
2.b No; fill reservoir to proper level and then Go to step 3.
3. Check for coolant leak at cylinder head gasket. Verify repairs.
4. Check for coolant leak at air compressor head gasket. Verify repairs.
5. Check for external coolant leak at hose connections. Verify repairs.
6. Check for coolant in oil. Verify repairs.
7. Check for loose or faulty radiator cap. Verify repairs.
8. Check cab heating system for leaks. Verify repairs.
4
60.1 SPN 120/FMI 13 – GHG17

J1939 Retarder Fluid Message is Missing or Not Available
1. Check for multiple codes. Are (CPC) SPN 168/FMI 0/14/18 (battery voltage) codes present?
1.a Yes; troubleshoot these first.
module.
1
61.1 SPN 157/FMI 10 – GHG17

Under-Capacity in the High Pressure Circuit
The Motor Control Module (MCM) monitors the rail pressure and when rail pressure deviation is greater than 200
bar, the MCM sets the code. This fault can occur due to the conditions listed below:
• External fuel leakage between the high pressure pump and fuel injectors
• Pressure Limiting Valve (PLV) leakage (internal)
• Fuel filter integrity (loose caps, plugged filters)
• Fuel supply issues (fuel level, fuel aeration, leaking fuel lines, fuel restrictions)
• Intermittent loss of engine speed signal
• High pressure pump internal failure
• Fuel injector (amplifier or needle) leakage
• Fuel Contamination
• Rail pressure sensor failure
• Faulty Motor Control Module (MCM)

J-48876 Test Gauge, Primer Port, HDE
J-48704 Caps, HP Fuel Rail, HDE
DiagnosticLink® Electronic Diagnostic Tool
Note : It is important to obtain information from the customer regarding Check Engine Lamp occurrences,
performance concerns, or exhaust smoke.
1. Did SPN 157/FMI 16 or SPN 520268/FMI 18 appear after the fuel system was repaired or fuel filter
maintenance was performed?
1.a Yes; the code may be set due to air in the fuel system. Clear codes and road test to verify complaint. If
code does not set, release the vehicle. If code sets, Go to step 2.
Note : Fuel tank level at the time the fault triggered can be viewed in extended data #5, “Enhanced Environmental
Data” Fuel Tank Level.
3. Check and record fuel level in all fuel tanks.
3.a If fuel level is below ¼ tank (or 25%), add fuel and road test vehicle. If code does not become active
during road test, release the truck. If the code becomes active during the road test with over ¼ tank (or
25%) of fuel, Go to step 4.
3.b If the fuel level is over ¼ tank (or 25%), question the driver about the fuel level when the code was set.
If the level was under ¼ tank (or 25%), fuel sloshing in the tank could be the cause of aerated fuel that
could cause this code. If the fuel level was over ¼ tank (or 25%) when the code was set, Go to step 4.
4. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, kerosene, coolant, etc.
4.a If contamination is found, contact the Detroit™ Customer Support Center at 800-445-1980.
4.b If no contamination is found, Go to step 5.
5. Visually inspect for external fuel leaks on the engine and on the chassis.
5.a If a leak is found, repair leak. Refer to section "Verify Repairs" .
1
5.b If no leaks are found, Go to step 6.

6. Using DiagnosticLink , check for multiple codes.
6.a If any of the additional fault codes are active, perform the associated diagnostics first:
• SPN 94/FMI 15 Fuel Filter Plugged
• SPN 97/FMI 15 Water in the Fuel
• SPN 157/FMI 1 Rail Pressure Too High
• SPN 164/FMI (All) Rail pressure Sensor Faults
• SPN 174/FMI 0 Fuel Temperature Too High
• SPN 679/FMI 7 PLV Stuck Open
• SPN 723/FMI (all) Cam Sensor Codes
• SPN 636/FMI (all) Crank Sensor Codes
• SPN 1077/FMI 5, 6 or 14
6.b If only SPN 1077/7, SPN 157/FMI 16 or SPN 1077/FMI 31 is present, Go to step 7.
Note : Do not reset this counter unless the PLV is being replaced.
7. Using DiagnosticLink, check the value of Pressure Limiting Valve (PLV) openings. With the ignition ON (key
ON, engine OFF), select the Actions tab in the top tool bar. Select Fuel System, then Pressure Limiting
Valve (PLV). Change or view (E2P_RPG_CTR_PLV_OPEN) under “Extended Data Record Number 5th”
list. View and record the PLV open counts.
7.a If the counter is greater than 50, replace the PLV.
Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
Verify repairs. Refer to section "Verify Repairs" .
7.b If counter is less than 50, Go to step 8.
8. Perform automatic Fuel System Integrity Check (FSIC) routine using DDDL 7.09 SP2 or newer. With the
ignition ON (key ON, engine OFF), start the Automatic FSIC. The software/tool will ask to start the engine
when required. Once the engine is running, the software will have the engine enter and exit several engine
operating conditions. Once the engine shuts down, leave the key on for five minutes. Disconnect DDDL and
open the log file. The next part of the troubleshooting will require reviewing the FSIC log file. Go to step 9.
9. Monitor rail pressure bleed-off time.
9.a If bleed-off time is below 35 seconds, perform a low pressure leak test.
Refer to section "FIS Low Pressure Leak Test" .
9.b If bleed-off time is between 35 seconds and 2 minutes 30 seconds, Go to step 10.
9.c If bleed-off time is greater than 2 minutes 30 seconds with engine warm, Refer to section "Idle Speed Balance
Test" .
10. Does Kw/Nw show/stay “ON / Enabled / True” while the engine is running during the Automatic FSIC
routine?
10.b No; refer to troubleshooting for SPN 723/FMI 10.
11. Was the fuel temperature rise greater than 10 degrees?
12. At 600 rpm, is ASL003 Fuel Compensation Pressure within range per the fuel pressure chart?
Refer to section "Normal Fuel System Pressures - Two-Filter System" .
13. Monitor AS124 LPPO sensor (if equipped) or use manual gauge J-48706. Is the pressure in range at 600
and 1800 rpm?
2

13.b No; Repair cause of incorrect fuel pressure.
14. Monitor AS124 LPPO (if equipped) and ASL003 Fuel Compensation Pressure at all engine speeds. Are
pressures stable with no oscillations?
14.b No; pressures are unstable WITH oscillations of more than 1.5 psi at a steady rpm, check for aerated
fuel.
Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
15. Check the Idle Speed Balance (ISB) Values. Refer to section "Idle Speed Balance Test" . Are there any cylinders
15.a Yes; Follow repair procedures in “Idle Speed Balance (ISB) Test” and verify repairs. Refer to section "Verify
Repairs" .

16. Is ASL001 Rail Pressure erratic or does it have a saw-tooth pattern?
3
4

17. Perform the aerated fuel test. Was fuel aerated?
Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
17.a Yes; repair cause of aerated fuel.
17.b No; replace the Quantity Control Valve (QCV).
Refer to section "Removal of the Quantity Control Valve - Two-Filter System" .
18. Perform Pressure Limiting Valve (PLV) flow test. Did the PLV flow test pass?
Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System"
5
18.b No; replace the PLV.

Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System"
Note : Prime the fuel system after performing the low pressure fuel system leak test.
19. Inspect the low pressure fuel system for leaks. Are leaks present?
Refer to section "FIS Low Pressure Leak Test" .
19.a Yes; Repair as necessary.
20. Cap the fuel rail at all six fuel injector feed connections using J-48704 injector rail caps and crank the
engine for 10 seconds. Does the ASL001 rail pressure reach AS098 desired rail pressure?
20.b No; Replace high pressure fuel pump.
Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System" .
21. With the fuel injectors still capped after cranking engine for 10 seconds, does the rail pressure bleed down
under 100 bar in less than five minutes?
21.a Yes; replace the high pressure fuel pump.
22. Using DiagnosticLink 8.x, navigate to Service Routines and Fuel System Integrity Check test and select
Manual FSIC. Test drive the truck to see if the code sets. Does the code become active
22.b No; replace the fuel filters and release vehicle to customer.
23. Remove the MCM 120-pin connector. Inspect for damage including fuel, water corrosion or bent terminals.
Is damage found?
24. Install a test MCM using the extension harness and test drive the truck. Does the code come active?
24.a Yes; contact the Detroit Customer Support Center at 800-445-1980. Be prepared to provide the FSIC
log files and completed troubleshooting.
24.b No; replace MCM and verify repair.
6
61.2 SPN 157/FMI 15 - GHG17

Rail Pressure Level For Injection Enabling Not Reached
Bar, while under a load, the MCM sets the code. This fault can occur due to the conditions listed below:
• External Fuel Leakage between the High Pressure Pump and Fuel Injectors
• Pressure Limiting Valve Leakage (Internal)
• Fuel Filter Integrity (Loose Caps, Plugged Filters)
• Fuel Supply Issues (Fuel Level, Fuel Aeration, Leaking Fuel Lines, Fuel Restrictions)
• Intermittent Loss of Engine Speed Signal
• High Pressure Pump Internal Failure
• Fuel Injector (Amplifier or Needle) Leakage
• Rail Pressure Sensor
• Motor Control Module (MCM)

DiagnosticLink 8.x Electronic Diagnostic Tool
Note : It is important to obtain information from the customer about check engine lamp occurrences, performance
concerns, or exhaust smoke.
1. Did SPN 157/FMI 15 or SPN 520268/FMI 18 appear after the fuel system was repaired or fuel filter
maintenance was performed?
data” Fuel Tank Level. Is the fuel tank level below ¼ tank (or 25%)?
3. Check and record fuel level in all fuel tanks. Is fuel level blow ¼ tank (25%)?
If the code becomes active during the road test with over ¼ tank (or 25%) of fuel, Go to step 4.
3.b No; view fuel tank level in extended data (EPA10) or question the driver about the fuel level when the
code was set. If the level was under ¼ tank (or 25%), fuel sloshing in the tank could be the cause of
aerated fuel that could cause this code. If the fuel level was over ¼ tank (or 25%) when the code was
set, Go to step 4.
4. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, kerosene, coolant, etc.
Is contamination found?
4.a Yes; refer to section "Contaminated Fluids" in this manual.
5. Visually inspect for external fuel leaks on the engine and on the chassis. Was a leak found?
6. Using DiagnosticLink , check for multiple codes. Are any of the fault codes below active?
7
6.a Yes; perform the associated diagnostics first:

• SPN 94/FMI 15 Fuel Filter plugged
• SPN 94/FMI 16 Fuel Filter plugged
• SPN 97/FMI 15 Water in the fuel
• SPN 157/FMI 1 Rail Pressure Too High.
• SPN 164/FMI (All) Rail pressure sensor faults
• SPN 174/FMI 0 Fuel Temperature too High
• SPN 636/FMI (all) Crank sensor codes
• SPN 1077/FMI 5, 6 or 14
6.b No; only SPN 1077/FMI 7, SPN 157/FMI 16 or SPN 1077/FMI 31 is present, Go to step 7.
7. Using DiagnosticLink check the value of Pressure Limiting Valve (PLV) openings. With key ON, engine
OFF, select the Actions tab in the top tool bar. Select Fuel System, then Pressure Limiting Valve (PLV)
Change or view (E2P_RPG_CTR_PLV_OPEN) under “Extended Data Record Number 5th” list. View and
record the PLV open counts. Is the counter greater than 50?
7.a Yes; replace the PLV. Verify repairs.
Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
Refer to section "Verify Repairs" .
8. Perform Automatic Fuel System Integrity Check (FSIC) routine using DiagnosticLink. With key ON, engine
OFF, start the Automatic FSIC routine. The software/tool will ask to start the engine when required. Once
the engine is running, the software will have the engine enter and exit several engine operating conditions.
Once the engine shuts down, leave the key on for five minutes. Disconnect DiagnosticLink. and open the
log file. The next part of the troubleshooting will require reviewing the FSIC log file. Go to step 9.
9. Monitor rail pressure bleed-off time. Is bleed-off time less than 35 second?
9.a Yes; perform an HP leak test.
10. From the previous step, is rail pressure bleed-off time greater than 2 minutes 30 seconds?
10.a Yes; with engine warm, Refer to section "Idle Speed Balance Test" .
11. Does Kw/Nw show/stay “ON / Enabled / True” while the engine is running during the Automatic FSIC
routine?
13. At 600 rpm, is ASL003 Fuel Compensation Pressure within range per the fuel pressure chart?

14. Monitor AS124 LPPO sensor (if equipped) or use manual gauge J-48706. Is the pressure in range at 600
and 1800 rpm?
8

14.b No; Repair cause of incorrect fuel pressure.
15. Monitor AS124 LPPO (if equipped) and ASL003 Fuel Compensation Pressure at all engine speeds. Are
pressures stable with no oscillations?
15.b No; pressures are unstable WITH oscillations of more than 1.5 psi at a steady rpm check for aerated
fuel.
Refer to section "Aerated Fuel Test – Two-Filter Fuel System"
16.a Yes; Follow repair procedures in Idle Speed Balance (ISB) test and verify repairs. Refer to section "Verify
Repairs" .

9
10

18. Perform the aerated fuel test. Was fuel aerated?
Refer to section "Aerated Fuel Test – Two-Filter Fuel System"
18.a Yes; repair cause of aerated fuel.

18.b No; replace the Quantity Control Valve.
Refer to section "Removal of the Quantity Control Valve - Two-Filter System"
19. Perform Pressure Limiting Valve (PLV) flow test. Did the PLV flow test pass?
Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System"
11
19.b No; replace the PLV.

Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System"
Note : Prime the fuel system after performing the low pressure fuel system leak test.
20. Inspect the low pressure fuel system for leaks. Are leaks present?
Refer to section "FIS Low Pressure Leak Test"
20.a Yes; Repair as necessary.

21. Cap the rail at all six injector feed connections using J-48704 injector rail caps and crank the engine for 10
seconds. Does the ASL001 rail pressure reach AS098 desired rail pressure?
21.b No; Replace high pressure pump.
22. With the injectors still capped after cranking engine for 10 seconds, does the rail pressure bleed down
22.a Yes; Replace the high pressure fuel pump.
23. Using DiagnosticLink 8.x, navigate to Service Routines and Fuel System Integrity Check test and select
Manual FSIC. Test drive the truck to see if the code sets. Did the code set?
23.b No; replace the fuel filters and release vehicle to customer.
Is damage found?
25. Install a test MCM using the extension harness and test drive the truck. Does the Code come active?
25.a Yes; contact the Detroit™ Customer Support Center at 800-445-1980. Be prepared to provide the FSIC
log files and completed troubleshooting.
12
61.3 SPN 157/FMI 16 - GHG17

Note : It is important to obtain information from the customer on when the check engine lamp occurs and if there
were any performance concerns or exhaust smoke.
Check as follows:
4. Check fuel tank level in extended fault code data. Was fuel tank level over ¼ tank (25%) when the code
logged?
5.a Yes; refer to "Contaminated Fluids" in this manual.
6. Visually inspect for external fuel leaks on the engine and on the chassis. Are any leaks found?
7. Using DL 8.03 or higher, check for other active codes. Are any of the following codes active?
• SPN 157/FMI 1 Rail Pressure too High
• SPN 164/FMI (All) Rail Pressure Sensor Faults
• SPN 1077/FMI 5, 6 or 14
7.b If only SPN 1077/7, 157/16 or 1077/31 is present, Go to step 8.
8. Using DL 8.03 or higher, check the value of Pressure Limiting Valve (PLV) openings. With key ON, engine
Change or view (RPG_CTR_PLV_OPEN) under "Extended Data Record #5" list. View and record the PLV
open counts. Is the counter greater than 50?
8.a Yes; replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" . Verify repairs.
13

Note : Engines not equipped with a Low Pressure Pump Outlet (LPPO) sensor should utilize J-48876 Test Gauge,
Priming Port to monitor LPPO.
9. Perform Automatic Fuel System Integrity Check (FSIC) routine using DL 8.03 or higher. With the ignition
ON (key ON, engine OFF) start the Automatic FSIC. The software/tool will ask to start the engine when
required. Once the engine is running, the software will have the engine enter and exit several engine
operating conditions. Once the engine shuts down, leave the key on for five minutes. Disconnect
DiagnosticLink and open the log file. The next steps of the troubleshooting will require reviewing the FSIC
log file. Go to step 10.
10. Monitor rail pressure bleed-off time. Is bleed off time below 35 seconds?
10.a Yes; Refer to section "High Pressure Fuel System - Leak Test - Two-Filter System " .
11. In the previous step, was bleed off time greater than two minutes and thirty seconds?
11.a Yes; Refer to section "Idle Speed Balance Test" .
12. Does Kw/Nw show/stay "ON / Enabled / True" while the engine is running during the Automatic FSIC
routine?
12.b No; Refer to section "SPN 723/FMI 10 - GHG17" .
13. Was the fuel temperature rise greater than 5.6°C (10°F)?
14. At 600 rpm, is ASL003 Fuel Compensation Pressure between 586 kPa (85 psi) and 6 kPa (100 psi)?
15. Monitor AS124 LPPO sensor (if equipped) or use manual gauge J-48706. Is the pressure between 496 kPa
(72 psi) and 551 kPa (80 psi) at 600 rpm and 689 kPa (100 psi) to 869 kPa (126 psi) at 1800 rpm?
15.b No; repair cause of incorrect fuel pressure.
16. Monitor AS124 LPPO (if equipped) and ASL003 Fuel Compensation Pressure at all engine speeds; are
pressures stable with no oscillations? Unstable pressures will have oscillations greater than 1.5 psi at
stable engine speed.
16.b No; Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
17.a Yes; follow repair procedures in "Idle Speed Balance (ISB) Test" and verify repairs. Refer to section "Verify
Repairs" .

18. Is ASL001 Rail Pressure erratic or does it have a saw tooth pattern?
14
15

19. Perform the Aerated Fuel test. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Was fuel aerated?
19.a Yes; repair cause of aerated fuel. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
19.b No; replace the Quantity Control Valve. Refer to section "Removal of the Quantity Control Valve - Two-Filter System" .
20. Perform Pressure Limiting Valve Flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System" .
Did the PLV flow test pass?
21. Inspect the low pressure fuel system for leaks. Refer to section "FIS Low Pressure Leak Test" . Are leaks present?
16
NOTICE
Prime fuel system prior to going to next step. Refer to section "Priming the Fuel System -
KM63 GEN2 - Two-Filter System"
21.b No; repair as necessary. Refer to section "FIS Low Pressure Leak Test" .
22.b No; replace high pressure pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System" .
System" .

24. Using DL 8.03 or higher, navigate to Service Routines and Fuel System Integrity Check test and select
Manual FSIC. Road test the truck. Does the code set?
24.b No; replace fuel filters and release unit to customer.
Is damage found?
26.a Yes; install original MCM. Go to step 27.
27. Inspect chassis fuel system for restrictions or debris. Refer to OEM procedures. Is there a chassis fuel
system issue?
27.a Yes; identify source of issue and repair as necessary.
27.b No; replace fuel filters and release to customer.
SPN 157/FMI 16
Description Fuel Rail Pressure Too Low
Monitored Parameter Rail Pressure
Typical Enabling Conditions Fuel Rail Pressure desired - Fuel Rail Pressure Actual > 200
bar
Typical Duration Eight Seconds
Dash Lamps MIL, CEL
The fault can occur due to the conditions listed below:

• Pressure limiting valve leakage (internal)
17

• High pressure pump internal failure
• Fuel contamination
• Rail pressure sensor

DiagnosticLink
Note : It is important to obtain information from the customer on when the check engine lamp occurs and if there
Check as follows:
logged?
5.a Yes; refer to "Contaminated Fluids" in this manual.
7. Using DL 8.03 or higher, check for other active codes. Are any of the following codes active?
• SPN 157/FMI 1 Rail Pressure too High
18

• SPN 1077/FMI 5, 6 or 14
7.b If only SPN 1077/7, 157/16 or 1077/31 is present, Go to step 8.
8. Using DL 8.03 or higher, check the value of Pressure Limiting Valve (PLV) openings. With key ON, engine
Change or view (RPG_CTR_PLV_OPEN) under "Extended Data Record #5" list. View and record the PLV
open counts. Is the counter greater than 50?

Note : Engines not equipped with a Low Pressure Pump Outlet (LPPO) sensor should utilize J-48876 Test Gauge,
Priming Port to monitor LPPO.
9. Perform Automatic Fuel System Integrity Check (FSIC) routine using DL 8.03 or higher. With the ignition
ON (key ON, engine OFF) start the Automatic FSIC. The software/tool will ask to start the engine when
operating conditions. Follow the on-screen instructions and key ON and OFF as necessary. Go to step 10.
10. Did the FSIC detect a leak?
10.a Yes; perform the High Pressure Fuel System - Leak Test. Refer to section "High Pressure Fuel System - Leak
Test - Two-Filter System " .

11. Did the rail pressure take longer than two minutes and thirty seconds to bleed down under 10 bar?
11.a Yes; perform the idle speed balance test to attempt to identify a faulty injector. Refer to section "Idle Speed
Balance Test" .

routine?
12.a Yes; Go to step
14. Monitor AS124 LPPO sensor (if equipped) or use manual gauge J-48706. Is the pressure between 496 kPa
(72 psi) and 551 kPa (80 psi) at 600 rpm and 689 kPa (100 psi) to 869 kPa (126 psi) at 1800 rpm?
pressures stable with no oscillations? Unstable pressures will have oscillations greater than 1.5 psi at
stable engine speed.
16.a Yes; follow repair procedures in "Idle Speed Balance (ISB) Test" and verify repairs. Refer to section "Verify
Repairs" .
19
17. Is ASL001 Rail Pressure erratic or does it have a saw tooth pattern?
20

18. Perform the Aerated Fuel test. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Was fuel aerated?
19. Perform Pressure Limiting Valve Flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System" .
Did the PLV flow test pass?
21
NOTICE
KM63 GEN2 - Two-Filter System"
System" .

23. Using DL 8.03 or higher, navigate to Service Routines and Fuel System Integrity Check test and select
Manual FSIC. Road test the truck. Does the code set?
Is damage found?
26. Inspect chassis fuel system for restrictions or debris. Refer to OEM procedures. Is there a chassis fuel
system issue?
22
61.4 SPN 157/FMI 17 - GHG17

SPN 157/FMI 17 - GHG17
Description Minimum Rail Pressure For Injection Not Achieved
Monitored Parameter Fuel Rail Pressure
Execution Frequency MIL
Typical Duration DD13 - 90 Seconds of Cranking
DD15 - 60 Seconds of Cranking
Dash Lamps MIL
Verification Turn the ignition on.
Clear codes using DiagnosticLink®.
Start the engine.
Check for codes.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
The Motor Control Module (MCM) monitors the fuel rail pressure and when fuel rail pressure does not reach a
minimum 150 bar within three cranking cycles, the MCM sets the code. One cranking cycle for the DD13 is 30
seconds. One cranking cycle for the DD15 and DD16 is 20 seconds. This fault can occur due to the conditions
listed below:
23

logged?
3. Did SPN 157/FMI 17 set after the fuel system was repaired, fuel filter maintenance was performed or the
vehicle was run out of fuel?
3.a Yes; the code may have set due to air in the fuel system. Clear the codes and road test the vehicle. If
the code does not reset, release the vehicle to the customer.
4. Check for any external fuel leaks. Are there any external fuel leaks present?
4.a Yes; repair the fuel leaks as necessary. Verify repair.
5. Connect DiagnosticLink and check for other codes. Are there other codes present?
5.a Yes; diagnose the other codes that are present. Verify repair.
6. Does the vehicle exhibit a no start or hard start concern?
6.a Yes;
Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be Done First)" .
7. Clear the code and start the engine. Does the SPN 157/FMI 17 become active?
7.a Yes; Install a test MCM and restart the engine. If the code is no longer present, install a new MCM.
7.b No; inform the customer that the fault was set due to a hard start or no start condition. Return the
vehicle to the customer.
SPN 157/FMI 17 - GHG17

Description Minimum Rail Pressure For Injection Not Achieved
Execution Frequency MIL
Typical Duration DD13 - 90 Seconds of Cranking
Dash Lamps MIL
Verification Turn the ignition on.
Clear codes using DiagnosticLink®.
Start the engine.
Check for codes.
24
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
The Motor Control Module (MCM) monitors the fuel rail pressure and when fuel rail pressure does not reach a
minimum 150 bar within three cranking cycles, the MCM sets the code. One cranking cycle for the DD13 is 30
seconds. One cranking cycle for the DD15 and DD16 is 20 seconds. This fault can occur due to the conditions
listed below:
logged?
3. Did SPN 157/FMI 17 set after the fuel system was repaired, fuel filter maintenance was performed or the
vehicle was run out of fuel?
3.a Yes; the code may have set due to air in the fuel system. Clear the codes and road test the vehicle. If
the code does not reset, release the vehicle to the customer.
4. Check for any external fuel leaks. Are there any external fuel leaks present?
4.a Yes; repair the fuel leaks as necessary. Verify repair.
25
5. Connect DiagnosticLink and check for other codes. Are there other codes present?
5.a Yes; diagnose the other codes that are present. Verify repair.
6. Does the vehicle exhibit a no start or hard start concern?
6.a Yes;
Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be Done First)" .
7. Clear the code and start the engine. Does the SPN 157/FMI 17 become active?
7.a Yes; Install a test MCM and restart the engine. If the code is no longer present, install a new MCM.
7.b No; inform the customer that the fault was set due to a hard start or no start condition. Return the
vehicle to the customer.
26
61.5 SPN 157/FMI 18 - GHG17

Fault of the Fuel Rail Pressure Sensor, Wiring or Quantity Control Valve
The motor control module (MCM) monitors the fuel rail pressure and when fuel rail pressure deviation is greater
than 200 bar higher than requested fuel rail pressure for eight seconds, the MCM sets the code. This fault can
occur due to the conditions listed below:
• Faulty fuel rail pressure sensor
• Faulty Quantity Control Valve (QCV)
• Faulty MCM
• Faulty wiring
SPN 157/FMI 18
Description Fuel Rail Pressure High
Typical Enabling Conditions Closed Loop & Actual RP greater than 200 Bar of Desired RP
Dash Lamps MIL, CEL
Verification Steady Engine rpm 1400 - 1500 (2 minute)

2.a If additional codes (with the exception of DPF codes) are present along with SPN 157/FMI 18, service
the additional codes first.
2.b If only SPN 157/FMI 18 is present, Go to step 3.
3. Check actual fuel rail pressure (key ON, engine OFF).
3.a If actual fuel rail pressure is greater than 5 bar, Go to step 4.
3.b If actual rail pressure is less than 5 bar, Go to step 5.
4. Remove the fuel rail pressure sensor and reconnect the sensor to the harness. Refer to section "Removal of the
Fuel Rail Pressure Sensor" . Is the fuel rail pressure sensor reading greater than 5 bar with sensor removed from
rail?
4.a Yes; replace the fuel rail pressure sensor. Refer to section "Installation of the Fuel Rail Pressure Sensor" .
4.b No; install the removed fuel rail pressure sensor. Refer to section "Installation of the Fuel Rail Pressure Sensor" . Go
to step 5.
5. Perform the Fuel System Integrity Check (FSIC) test using DDDL 7.X.
6. Is the actual fuel rail pressure (ASL001) 200 bar higher than the desired rail pressure (AS098) at any point
during the FSIC test?
6.a Yes; replace the quantity control valve.
6.b No; the deviation is less than 200 bar, Go to step 7.
7. Does the fuel rail pressure bleed down below 5 bar after the test is complete?
7.a Yes; fuel rail pressure is below 5 bar. Check the fuel rail pressure sensor connector and 120-pin
connector for corrosion. If OK, replace the fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail
Pressure Sensor" .
7.b No; fuel rail pressure will not drop below 5 bar. Contact the Customer Support Center (CSC).
Fault of the Fuel Rail Pressure Sensor, Wiring or Quantity Control Valve
27
The motor control module (MCM) monitors the fuel rail pressure and when fuel rail pressure deviation is greater
than 200 bar higher than requested fuel rail pressure for eight seconds, the MCM sets the code. This fault can
occur due to the conditions listed below:
• Faulty fuel rail pressure sensor
• Faulty Quantity Control Valve (QCV)
• Faulty MCM
• Faulty wiring
SPN 157/FMI 18
Typical Enabling Conditions Closed Loop & Actual RP greater than 200 Bar of Desired RP
Dash Lamps MIL, CEL
Verification Steady Engine rpm 1400 - 1500 (2 minute)

2.a If additional codes (with the exception of DPF codes) are present along with SPN 157/FMI 18, service
the additional codes first.
3. Check actual fuel rail pressure (key ON, engine OFF).
3.a If actual fuel rail pressure is greater than 5 bar, Go to step 4.
3.b If actual rail pressure is less than 5 bar, Go to step 5.
4. Remove the fuel rail pressure sensor and reconnect the sensor to the harness. Refer to section "Removal of the
Fuel Rail Pressure Sensor" . Is the fuel rail pressure sensor reading greater than 5 bar with sensor removed from
rail?
4.a Yes; replace the fuel rail pressure sensor. Refer to section "Installation of the Fuel Rail Pressure Sensor" .
4.b No; install the removed fuel rail pressure sensor. Refer to section "Installation of the Fuel Rail Pressure Sensor" . Go
to step 5.
5. Perform the Fuel System Integrity Check (FSIC) test using DDDL 7.X.
6. Is the actual fuel rail pressure (ASL001) 200 bar higher than the desired rail pressure (AS098) at any point
during the FSIC test?
6.a Yes; replace the quantity control valve.
6.b No; the deviation is less than 200 bar, Go to step 7.
7. Does the fuel rail pressure bleed down below 5 bar after the test is complete?
7.a Yes; fuel rail pressure is below 5 bar. Check the fuel rail pressure sensor connector and 120-pin
connector for corrosion. If OK, replace the fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail
Pressure Sensor" .
7.b No; fuel rail pressure will not drop below 5 bar. Contact the Customer Support Center (CSC).
28
62.1 SPN 158/FMI 2 – GHG17

SPN 158/FMI 2
Description Ignition Switch Status of CPC and MCM Do Not Match
Monitored Parameter Ignition Switch
Dash Lamps CEL
Verification Key ON
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2. Clear the fault code, cycle ignition switch and start the engine. Does SPN 158/FMI 2 become active after 10
seconds?
2.b No; release the truck back to service.
5. Measure the voltage between pin 7 of the MCM 21-pin connector and ground. Is the voltage greater than
11.5 volts?
5.b No; repair the cause of the low/no voltage to pin 7 of the MCM 21-pin connector.
1

7. Disconnect the Common Powertrain Controller (CPC) connector #2.
9. Measure the voltage between pin 3 of the CPC connector #2 and ground. Is the voltage greater than 11.5
volts?
9.a Yes; repeat this procedure. If the results are the same, replace the CPC. Refer to Original Equipment
Manufacturer (OEM) procedures.
9.b No; repair the cause of the low/no voltage to pin 3 of the CPC connector #2.
2
63.1 SPN 158/FMI 2 - GHG17

Ignition Switch Not Plausible
1. If SPN 158/FMI 2 is active, Go to step 3.
WARNING
PERSONAL INJURY
2. If SPN 158/FMI 2 is inactive, clear the fault code, cycle ignition switch and start the engine. Does SPN
158/FMI 2 become active after 10 seconds?
2.b No; release the truck back to service.
4. Turn the Ignition ON, (key ON, engine OFF).
5. Measure the voltage between pin 7 of the MCM 21-pin connector and ground. Is the voltage greater than
11.5 volts?
5.b No; repair the cause of the low/no voltage to pin 7.
6. Turn the Ignition OFF.
8. Turn the Ignition ON (key ON, engine OFF).
9. Measure the voltage between pin 3of the CPC connector #2 and ground. Is the voltage greater than 11.5
volts?
9.a Yes; repeat this procedure. If the results are the same, replace the MCM. Refer to section "Removal of the
Motor Control Module" .
9.b No; repair the cause of the low/no voltage to pin 3 of the CPC connector #2.
1
64.1 SPN 164/FMI 2 - GHG17

SPN 164/FMI 2
Description Fuel Rail Pressure Drift High
Dash Lamps MIL, CEL
Check as follows:
1
1. Disconnect the fuel rail pressure sensor.

2. Inspect the fuel rail pressure harness connector and sensor housing for signs of damage: bent, spread,
broken corroded or unseated (pushed out) pins or wire damage near the connector. Is damage present?
4. Measure the voltage between pins 1 and 3 of the fuel rail pressure sensor harness connector. Is the
5. Measure the voltage between pin 3 of the fuel rail pressure sensor harness connector and battery ground.
Is the voltage between 4.5 and 5.5 volts?
5.a Yes; repair the wire between pin 1 of the fuel rail pressure sensor harness connector and pin 120 of the
5.b No; repair the wire between pin 3 of the fuel rail pressure sensor harness connector and pin 58 of the
MCM 120-pin harness connector.
7. Disconnect the MCM 120-pin harness connector.
8. Inspect the MCM 120-pin module connector housing and harness connector for signs of damage, bent,
spread, broken, corroded or unseated (pushed out) pins or wire damage near the connector. Is damage
present?
9. Measure the resistance between pin 2 of the fuel rail pressure sensor harness connector and pin 78 of the
MCM 120-pin harness connector. Is the resistance less than five ohms?
11.b No; repair the wire between pin 3 of the fuel rail pressure sensor and pin 58 of the MCM 120-pin
harness connector.
12. Reconnect the MCM 120-pin connector.
14.a Yes; replace the Fuel Rail Pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
14.b No; repeat this procedure. If the results are the same, replace the MCM. Refer to section "Removal of the
2
64.2 SPN 164/FMI 3 - GHG17

SPN 164/FMI 3
Description Fuel Rail Pressure Sensor Circuit Failed High
Monitored Parameter Fuel Rail Pressure Sensor
Dash Lamps MIL, CEL
Check as follows:
1. Check for multiple codes. Are two or more of the following codes present SPN 2631/FMI 3, SPN 2630/FMI
3, SPN 164/FMI 3, or SPN 94/FMI 3?
3
1.a Yes; repair the open in the common ground wire from pin 102 of the MCM 120-pin harness connector
to the respective sensor ground pin on the sensor connector. See above diagram.
2. Disconnect the fuel rail pressure sensor connector.
3. Inspect the harness connector for signs of damage: bent, spread, corroded, broken or unseated (pushed
out) pins, signs of water or oil intrusion and signs of wire damage near the connector. Is damage present?
9. Inspect the MCM 120-pin module connector housing and harness connector for signs of damage: bent,
spread, corroded, broken or unseated (pushed out) pins, sign of water or oil intrusion and signs of wire
damage near the connector. Is damage present?
11. Reconnect the MCM 120-pin harness connector.
13.a Yes; replace the fuel rail pressure connector. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
4
64.3 SPN 164/FMI 4 - GHG17

Note : Fault may be induced by low battery voltage.
SPN 164/FMI 4
Description Fuel Rail Pressure Sensor Circuit Failed Low
Dash Lamps MIL, CEL
Check as follows:
1. Is battery voltage SPN 168/FMI (any) also present?
5
1.a Yes; repair battery voltage fault code.

2. Disconnect the fuel rail pressure sensor connector.
3. Inspect the harness connector for signs of damage: bent, spread, broken, corroded or unseated (pushed
out) pins and signs of moisture in the connector or wire damage near the connector. Is damage present?
MCM 120- pin harness connector.
spread, corroded, broken or unseated (pushed out) pins, signs of water or oil intrusion and signs of wire
damage near the harness connector. Is damage present?
10. Measure the resistance between pin 2 of the fuel rail pressure sensor and pin 78 of the MCM 120-pin
harness connector. Is the resistance less than five ohms?
harness connector.
11. Measure the resistance between pin 2 of the fuel rail pressure sensor harness connector and battery
ground. Is the resistance less than 10k ohms?
11.a Yes; repair the short to ground in the wire between pin 2 of the fuel rail pressure sensor and pin 78 of
the MCM 120-pin harness connector.
14.a Yes; replace the fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
6
64.4 SPN 164/FMI 5 - GHG17

SPN 164/FMI 5
Description Fuel Rail Pressure Sensor Circuit Failed Open
Dash Lamps MIL, CEL
Check as follows:
2. Inspect the harness connector for signs of damage: bent, spread, broken, corroded, or unseated (pushed
out) pins or wire damage near the connector. Is damage present?
7

spread, broken, corroded or unseated (pushed out) pins, signs of water or oil intrusion and signs of wire
damage near the harness connector. Is damage present?
harness connector.
8
64.5 SPN 164/FMI 15 - GHG17
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
bar, while under a load, the MCM sets the code. This fault can occur due to the conditions listed below:
• Pressure Limiting Valve (PLV) leakage (internal)
• High Pressure (HP) pump internal failure
• Fuel contamination
• Rail pressure sensor

J-48706 Fuel Diagnostic Gauge Set LP, HDE
DiagnosticLink
Note : It is important to obtain information from the customer about the check engine lamp occurrence and any
performance concerns or exhaust smoke occurrence.
Check as follows:
1. Did SPN 157/FMI 16 or 520268/FMI 18 appear after the fuel system was repaired or fuel filter maintenance
was performed?
9
Data” Fuel Tank Level.
3. Review fault code extended data. Was the fuel tank level below 25% when the fault triggered?
3.a Yes; make sure the fuel tank level is now above ¼ tank (25%). If not, add fuel and road test the
vehicle. If code does not become active during road test, release the truck. If the code becomes active
during the road test with over ¼ tank (25%) of fuel. Go to step 4.
3.b No; if the fuel level is over ¼ tank (25%), view fuel tank level in extended data (EPA10) or question the
driver about the fuel level when the code was set. If the level was under ¼ tank (25%), fuel sloshing in
the tank could be the cause of aerated fuel that could cause this code. If the fuel level was over ¼ tank
(25%) when the code was set. Go to step 4.
Is fuel contaminated?
4.a Yes; refer to "Contaminated Fluids."
5. Visually inspect for external fuel leaks on the engine and on the chassis. Are leaks present?
5.a Yes; repair leak and verify repair.
6. Using DiagnosticLink, check for multiple codes. Are any of the below fault codes active?
• SPN 157/FMI 1 Rail Pressure too High.
• SPN 723/FMI (All) Cam Sensor Codes
• SPN 636/FMI (All) Crank Sensor Codes
• SPN 1077/FMI 5, 6 or 14
7. Using DiagnosticLink, check the value of PLV openings. With key ON, engine OFF, select the Actions tab
in the top tool bar. Select Fuel System and then Pressure Limiting Valve (PLV). Change or view
(E2P_RPG_CTR_PLV_OPEN) under "Extended Data Record Number 5th" list. View and record the PLV
open counts. Is the PLV counter greater than 50?
8. Perform the Automatic Fuel System Integrity Check (FSIC) routine using DiagnosticLink. With the ignition
ON (key ON, engine OFF), start the Automatic FSIC. The software/tool will ask to start the engine when
DiagnosticLink and open the log file. The next part of the troubleshooting will require reviewing the FSIC log
file.
9. Monitor rail pressure bleed-off time. Is the bleed-off time below 35 seconds?
10
9.a Yes; Refer to section "High Pressure Fuel System - Leak Test - Two-Filter System " .
10. Was the bleed-off below two minutes and 30 seconds?
10.b No; Refer to section "Idle Speed Balance Test" .
11. Does KW/NW show/stay "ON / Enabled / True" while the engine is running during the Automatic FSIC
routine?
13. At 600 rpm, is ASL003 Fuel Compensation Pressure within range per the fuel pressure chart? Refer to section
"Normal Fuel System Pressures - Two-Filter System" .

14. Monitor AS124 LPPO sensor or use manual gauge J-48876 to measure priming port pressure. Is the
pressure in range at 600 and 1800 rpm? Refer to section "Normal Fuel System Pressures - Two-Filter System" .
14.b No; repair cause of incorrect fuel pressure. Refer to section "Normal Fuel System Pressures - Two-Filter System" .
15. Monitor AS124 LPPO (if equipped) and ASL003 Fuel Compensation Pressure at all engine speeds. Are the
pressures stable with no oscillations greater than 1.5 psi at a steady rpm?
16.a Yes; follow repair procedures in "Idle Speed Balance (ISB) test" and verify repairs.
17. Is ASL001 Rail Pressure erratic or does it have a sawtooth pattern?
11
12

Note : See examples of erratic pressure showing (1) ASL001 rail pressure and (2) AS098 desired rail pressure.
18. Perform the aerated fuel test. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Was fuel aerated?
19. Perform PLV flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel System" . Did the PLV flow
test pass?
20.a Yes; repair as necessary. Refer to section "FIS Low Pressure Leak Test" .
13

Note : Prime fuel system prior to going to next step.System PrimingRefer to section "Priming the Fuel System -
KM63 GEN2 - Two-Filter System"Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"
22.a Yes; replace high pressure pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter System" .
23. Using DiagnosticLink, navigate to Service Routines and Fuel System Integrity Check test and select
Manual FSIC. Test drive the truck to see if the code sets. Does SPN 164/FMI 15 come active?
Is damage found?
25.b No; replace MCM and verify repair. Refer to section "Removal of the Motor Control Module" .
SPN 164/FMI 15
Description Fuel Rail Pressure Deviation Under Load
Typical Enabling Conditions Code Sets When Rail Pressure Deviation is Greater than 200
Bar, While Under a Load
Dash Lamps MIL, CEL
1. Complete the troubleshooting for SPN 157/FMI 16. Refer to section "SPN 157/FMI 16 - GHG17" .
14
64.6 SPN 164/FMI 20 - GHG17

SPN 164/FMI 20
Description Fuel Rail Pressure Sensor - Drift High
Typical Enabling Conditions Key ON, Engine OFF
Execution Frequency Once when enabling conditions met
Dash Lamps MIL, CEL
Check as follows:
2. Inspect the fuel rail pressure sensor connector and harness connector for signs of damage: bent, spread,
broken, unseated (pushed out) or corroded pins, signs of water intrusion or damaged wiring near the
connector. Are signs of damage present?
15

connector.
8. Inspect the MCM 120-pin connector and harness connector for signs of damage: bent, spread, broken,
unseated (pushed out) or corroded pins, signs of water intrusion or damaged wiring near the connector. Is
there damage present?
MCM 120-pin connector. Is the resistance less than five ohms?
11. Measure the resistance between pins 2 and 3 of the fuel rail pressure sensor harness connector. Is the
resistance greater than 10K ohms?
11.b No; repair the short in the wires between pins 2 and 3 of the fuel rail pressure sensor harness
connector.
16
SPN 164/FMI 20
Description Fuel Rail Pressure Sensor - Drift High
Dash Lamps MIL, CEL
Check as follows:
connector. Are signs of damage present?
17

connector.
8. Inspect the MCM 120-pin connector and harness connector for signs of damage: bent, spread, broken,
there damage present?
connector.
18
64.7 SPN 164/FMI 21 - GHG17

SPN 164/FMI 21
Description Fuel Rail Pressure Sensor - Drift Low
Dash Lamps MIL, CEL
Check as follows:
connector. Is damage present?
19

4.a No; Go to step 5.
connector.
8. Inspect the MCM 120-pin connector and harness connector for signs of damage; bent, spread, broken,
damage present?
connector.
14.a Yes; replace fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
20
SPN 164/FMI 21
Description Fuel Rail Pressure Sensor - Drift Low
Dash Lamps MIL, CEL
Check as follows:
21

4.a No; Go to step 5.
connector.
8. Inspect the MCM 120-pin connector and harness connector for signs of damage; bent, spread, broken,
damage present?
connector.
14.a Yes; replace fuel rail pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
22
66.1 SPN 168/FMI 0 - GHG17

SPN 168/FMI 0
Description Battery Voltage is Higher than 16 Volts
Monitored Parameter ACM Battery Voltage
Typical Enabling Conditions Key ON Engine OFF
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
PERSONAL INJURY
Check as follows:
1. Measure battery voltage with the engine running at maximum rpm.
2. If greater than 16 volts, check for proper alternator operation and repair or replace, as required.
1
66.2 SPN 168/FMI 1 - GHG17

SPN 168/FMI 1
Description Battery Voltage Below 10.5 Volts
Monitored Parameter ACM Battery Voltage
Typical Enabling Conditions Key ON Engine OFF
Dash Lamps CEL
2
WARNING
ENGINE EXHAUST
CAUTION
ELECTRICAL SHOCK
WARNING
PERSONAL INJURY
Check as follows:
1. Check for multiple battery voltage faults. Are there other ECU voltage fault codes present?
2. Check the condition of the alternator drive belt and replace, if required. Is fault still active?
2.b No; verify repairs.
3. Check for loose alternator mounting and retighten or repair, as required. Is fault still active?
4. Check for proper alternator operation and repair or replace, as required. Is fault still active?
4.b No; erase fault code memory.
5. Check the condition of the battery; does it hold the charge? Replace if required. Is fault still active?
7. Disconnect the ACM 21-pin connector. Inspect the harness for bent, spread, or corroded pins. Is damage
found?
8. Measure the resistance of the Aftertreatment Control Module (ACM) ground circuits located on pins 3, 5, 6,
8, and 9 of the ACM 21-pin connector to battery ground. Is the resistance less than five ohms?
8.b No; repair the wire(s) with the high resistance reading.
10. Measure the battery voltage of the individual wires in the power circuits at pins 11, 12, 14, 15, and 18 on
the ACM 21-pin connector. Is battery voltage less than 10.5 volts?
3
10.a Yes; repair the circuit(s) in question.

10.b No; reconnect ACM 21-pin connector. Go to step 11.
11. Connect DiagnosticLink . Monitor (chart) the following parameters.
• ASL: Ignition Switch Voltage
• ASL: Main Battery Voltage
• AAS: Battery Voltage
• ASL: Battery Voltage
12. Wiggle test the harness, looking for abnormal voltage spikes. Is a voltage spike detected?
12.a Yes; isolate that section of harness and inspect for wire chaffing, corrosion, improper connections or
physical damage and repair as necessary.
13. Using DiagnosticLink, clear codes. Does fault return?
13.a Yes; install a test ACM and retest.
13.b No; verify repairs and release vehicle.
4
67.1 SPN 168/FMI 0 - GHG17

SPN 168/FMI 0
Description Battery Voltage Above 16 Volts
Monitored Parameter MCM Battery Voltage
Dash Lamps CEL
Verification Engine Running
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Measure battery voltage with the engine running at maximum rpm without exceeding 1700 rpm. Is battery
voltage greater than 16 volts?
1.a Yes; check for proper alternator operation, repair as necessary. Verify repair.
1.b No; refer to Original Equipment Manufacturer (OEM) literature for the vehicle battery schematics.
1
67.2 SPN 168/FMI 1 - GHG17

SPN 168/FMI 1
Typical Enabling Conditions Key On Engine Off
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
2
WARNING
PERSONAL INJURY
Check as follows:
2. Check the condition of the alternator drive belt and replace, if required. Are faults still active?
3. Check for loose alternator mounting and retighten or repair, as required. Are faults still active?
4. Check for proper alternator operation and repair or replace, as required. Are faults still active?
5. Check the condition of the battery; does it hold the charge? Replace if required. Are faults still active?
7. Disconnect the MCM 21-pin connector. Inspect the harness for bent, spread, or corroded pins. Is damage
found?
8. Measure the resistance of the Motor Control Module (MCM) ground circuits located on pins 5, 6, 8, and 9 of
the MCM 21-pin connector to battery ground. Is the resistance less than five ohms?
10. Measure the battery voltage of the individual wires in the power circuits at pins 11, 12, 14, 15 of the MCM
21-pin connector. Is battery voltage less than 10.5 volts?
10.b No; reconnect MCM 21-pin connector. Go to step 11.
12. Wiggle test the harness; look for abnormal voltage spikes. Is a voltage spike detected?
3

13.a Yes; install a test CPC and retest.
4
67.3 SPN 168/FMI 7 - GHG17

SPN 168/FMI 7
Description Battery Voltage Low Failure
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
5
WARNING
PERSONAL INJURY
Check as follows:
1. Inspect the following and Go to step 2.
• Alternator mounting, drive belt and operation
• Battery condition and charge
2. Measure the resistance of the ground circuit pins 5, 6, 8, and 9 of the MCM 21-pin connector and pin 2 of
the Common Powertrain Controller (CPC). Is the resistance greater than 0.5 ohms in any wire?
2.a Yes; repair or replace the wire and connector, verify repairs.
3. Measure the resistance of the power circuit pins 11, 12, 14 and 15 of the MCM 21-pin connector and pin 1
of the CPC with the engine running and battery voltage greater than 12.5 V. Is the resistance greater than
0.5 ohms in any wire?
3.a Yes; repair or replace the power circuit wires and connector.
4. Measure the current drop of the ground circuit pins 5, 6, 8, and 9 of the MCM 21-pin connector and pin 2 of
the CPC. Is the current drop more than 0.2 volts in any wire?
4.a Yes; repair or replace the ground circuit wires and connector.
5. Measure the current drop of the power circuit pins 11, 12, 14, and 15 of the MCM 21-pin connector and pin
1 of the CPC. Is the current drop more than 0.2 volts in any wire?
5.b No; check and verify repairs.
6
67.4 SPN 168/FMI 9 - GHG17

SPN 168/FMI 9
Description Battery Voltage Missing
Monitored Parameter Motor Control Module (MCM) Battery Voltage
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
7
WARNING
PERSONAL INJURY
Check as follows:
2. Measure the resistance of the ground circuit pins 5, 6, 8, and 9 of the MCM 21-pin connector and pin 2 of
the Common Powertrain Controller (CPC). Is the resistance greater than 0.5 ohms in any wire?
3. Measure the resistance of the power circuit pins 11, 12, 14, and 15 of the MCM 21-pin connector and pin 1
8
67.5 SPN 168/FMI 18 - GHG17

SPN 168/FMI 18
Description Battery Voltage Low Failure
Monitored Parameter Motor Control Module (MCM) Battery Voltage
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
9
WARNING
PERSONAL INJURY
Check as follows:
2. Measure the resistance of ground circuit pins 5, 6, 8, and 9 of the MCM 21-pin connector and pin 2 of the
CPC. Is the resistance greater than 0.5 ohms in any wire?
3. Measure the resistance of the power circuit pins 11, 12, 14, and 15 of the MCM 21-pin connector and pin 1
10
68.1 SPN 168/FMI 0 - GHG17

SPN 168/FMI 0
Description Battery Voltage Above 16 Volts
Dash Lamps CEL
Check as follows:
Note : This fault indicates the CPC3 has detected voltage greater than 16 volts on pin 9 of connector #5.
1. Connect DiagnosticLink 8.04 or higher.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

3. Is SPN 168/FMI 0 active?
3.b No; clear fault codes. If fault does not become active, release vehicle. If fault becomes active, Go to step
4.
4. Refer to New Cascadia Electrical Systems and Troubleshooting Manual section 2.06 for battery and
charging system diagnostics.
1
68.2 SPN 168/FMI 1 - GHG17

SPN 168/FMI 1
Dash Lamps CEL
Note : This fault indicates the CPC3 has detected voltage difference while comparing pins 9 and 3 voltages on
connector #5.
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
2
WARNING
ENGINE EXHAUST
2. Start the engine. Is SPN 168/FMI 5 active?

2.b No; clear all faults. If fault remains inactive, release vehicle. If fault becomes active, Go to step 3.
4. Disconnect CPC3 connector #5.
5. Inspect harness connector for bent, spread, or corroded pins. Is pin damage found?
7. Measure the voltage between pin 9 on connector #5 and ground. Is voltage reading equal to battery
voltage?
7.a Yes; replace the CPC3.
7.b b. No; restore battery voltage to pin 9. Refer to New Cascadia Electrical Systems and Troubleshooting
Manual section 2.06 for battery and charging system diagnostics.
3
68.3 SPN 168/FMI 2 - GHG17

Ignition Circuit Voltage Erratic
Note : This fault indicates the CPC3 has detected erratic voltage on pin 3 of the CPC3 connector #5.
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2. Start the engine. Is SPN 168/FMI 2 active?

5. Inspect harness connector for bent, spread or corroded pins. Is pin damage found?
4

7. Measure the voltage between pin 3 of the CPC3 connector #5 and ground. Is voltage reading equal to
battery voltage?
7.a Yes; verify ignition voltage at pin 7 of the MCM 21-pin connector and pin 13 of the ICU4 connector X1.
Refer to Original Equipment Manufacturer (OEM) wiring schematics for harness layout.
7.b No; restore battery voltage to pin 3. Refer to New Cascadia Electrical Systems and Troubleshooting
Manual section 2.06 for battery and charging system diagnostics.
5
68.4 SPN 168/FMI 5 - GHG17

SPN 168/FMI 5
Description Common Powertrain Controller (CPC) Battery Voltage Open,
Connector 5, Pin 9
Monitored Parameter CPC Battery Voltage
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Note : This fault indicates the CPC3evo has detected no/low voltage on pin 9 of the CPC3 connector #5.
2. Turn the ignition ON (key ON, engine OFF). Is SPN 168/FMI 5 active?
4. Disconnect CPC3evo connector #5.
5. Inspect harness connector for bent, spread or corroded pins. Is pin damage found?
6
7. Measure the voltage between pin 9 of the CPC3 connector #5 and ground. Is voltage reading within .25v of
battery voltage?
7.a Yes; replace the CPC3.
7.b No; restore battery voltage to pin 9. Refer to EZ wiring schematics module 149, 285 and 164 for further
information.
7
68.5 SPN 168/FMI 14 - GHG17

Optimized Idle: Charging System or Battery Failure
This is an information fault. The CPC3 has detected a battery/charging system failure while operating in Optimized
Idle Mode. When this fault is detected, the engine will continuously run while optimized idle is activated. Refer to
Original Equipment Manufacturer (OEM) literature for battery and charging system diagnostics.
8
65.1 SPN 168/FMI 0 - GHG17

SPN 168/FMI 0
Description Battery Voltage is higher than 16 Volts
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
PERSONAL INJURY
Check as follows:
1. Measure battery voltage with the engine running at maximum rpm.
2. If greater than 16 volts, check for proper alternator operation and repair or replace, as required.
1
65.2 SPN 168/FMI 1 - GHG17

SPN 168/FMI 1
Dash Lamps CEL
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
2
WARNING
PERSONAL INJURY
Check as follows:
2. Check the condition of the alternator drive belt and replace, if required. Are faults still active?
3. Check for loose alternator mounting and re-tighten or repair, as required. Are faults still active?
4. Check for proper alternator operation and repair or replace, as required. Are faults still active?
5. Check the condition of the battery; does it hold the charge?
5.b No; replace if required. Verify repairs.
7. Disconnect the MCM 21-pin connector. Inspect the harness for bent, spread, or corroded pins. Is damage
found?
8. Measure the resistance of the Motor Control Module (MCM) ground circuits located on pins 5, 6, 8, and 9 of
the MCM 21–pin connector to battery ground. Is the resistance less than five ohms?
10. Measure the battery voltage of the individual wires in the power circuits at pins 11, 12, 14, 15 on the MCM
21-pin connector. Is battery voltage less than 10.5 volts?
10.b No; reconnect MCM 21-pin connector. Go to step 11.
12. Wiggle test the harness; look for abnormal voltage spikes. Is a voltage spike detected?
3

13.a Yes; install a test MCM and retest.
4
71.1 SPN 171/FMI 13 - GHG17

Ambient Air Temperature Signal Not Available via the Controller Area Network
1.a Yes, clear faults codes if they do not become active release vehicle.
2. Turn the ignition OFF and disconnect DiagnosticLink . Wait 5 minutes for all modules to power down.
4. Reconnect DiagnosticLink, are fault codes active?
4.a Yes; Refer to section "SPN 625/FMI 9 – GHG17" . Follow the entire procedure for further PT-CAN
troubleshooting.
1
69.1 SPN 171/FMI 2 - GHG17

Ambient Temperature Sensor Data Erratic
SPN 171/FMI 2
Description Ambient Temperature Sensor Data Signal Error
Monitored Parameter Ambient Temperature
Dash Lamps CEL
Verification Key Cycle - Five Minutes Off - Engine Idle (Two minute)
2. Is the Common Powertrain Controller (CPC) parameter group PRG031 configured correctly?
2.b No; correct as necessary. Verify repairs.
3. Disconnect the ambient air temperature sensor.
1
5. Measure the voltage between pins A and B on the harness side of the ambient air temperature sensor
connector. Is the voltage between 4.5 and 5.2 volts?
5.a Yes; replace the ambient air temperature sensor.
6. Measure the resistance between pin 2 of the CPC connector #3 and ground. Is the resistance less than five
ohms?
6.a Yes; repair the open between pin 15 of the CPC connector #3 and the ambient air Temperature
sensor.
6.b No; repair the open between pin 2 of the CPC connector #3 and the ambient air temperature sensor.
2
69.2 SPN 171/FMI 3 - GHG17

Ambient Temperature Sensor Failed High
SPN 171/FMI 3
Description Ambient air temperature sensor input (AI_01 or AI_07) - Short
to UBATT or Open Circuit
Dash Lamps CEL
Verification Key Cycle - 5 Minutes Off - Engine Idle (2 minute)
Check as follows:
2. Check for multiple fault codes. Are SPN 2630/FMI any (Temperature Sensor) faults present?
3.a Yes; check for proper configuration of the CPC against the server information. To verify repair, Go to step
4.
3

5. Disconnect the CPC #3 21-pin connector.
6. Inspect the CPC #3 harness connector for signs of damaged, bent, spread, corroded or unseated (pushed
out) pins and signs of moisture in the connector or wire damage near the connector. Is any damage found?
8. Measure the voltage between pin 15 of the CPC connector #3 harness side and ground. Is any voltage
present?
8.a Yes; repair the short to power on the ambient air sensor harness. Refer to Original Equipment
Manufacturer (OEM) literature for schematic information Verify repairs.
10. Disconnect the ambient air temperature sensor. Refer to Original Equipment Manufacturer (OEM) literature.
11. Inspect the ambient air temperature sensor harness connector for signs of damaged, bent, spread,
corroded or unseated (pushed out) pins and signs of moisture in the connector or wire damage near the
connector. Is any damage found?
12. Measure the resistance between pin A of the ambient air sensor connector, harness side and pin 15 of the
CPC #3 connector harness side. Is the resistance less than 5 ohms?
12.b No; repair the open wire between pin A of the ambient air sensor connector and pin 15 of the CPC #3
connector.
13. Measure the resistance between pin B of the ambient air sensor connector, harness side and ground. Is the
13.a Yes; replace the ambient air temperature sensor. Refer to Original Equipment Manufacturer (OEM)
literature. Go to step 14. to verify repairs.
13.b No; repair the open wire between pin B of the ambient air sensor connector and ground.
power down. Verify repair. Does fault code return?
14.a Yes; replace CPC. Verify repairs.
4
69.3 SPN 171/FMI 4 - GHG17

Ambient Temperature Sensor Failed Low
SPN 171/FMI 4
Description Ambient air temperature sensor input (AI_01 or AI_07) - Short
to GND
Dash Lamps CEL
Verification Key Cycle - 5 Minutes off - Engine Idle (2 minute)
Check as follows:
1. Disconnect the ambient air temperature sensor. Refer to Original Equipment Manufacturer (OEM) literature.
2. Inspect the ambient air temperature sensor harness connector for signs of damaged, bent, spread,
4. Using DiagnosticLink , monitor fault code SPN 171/ FMI 4 with the ambient air sensor disconnected. Does
the fault code change or go inactive?
5
4.a Yes; replace the ambient air temperature sensor. Refer to Original Equipment Manufacturer (OEM)
6. Disconnect the CPC #3 21-pin connector. Refer to Original Equipment Manufacturer (OEM) literature for
schematic information.
7. Inspect the CPC #3 harness connector for signs of damaged, bent, spread, corroded or unseated (pushed
out) pins and signs of moisture in the connector or wire damage near the connector. Is any damage found?
8. Measure the resistance between pins A and B of the ambient air sensor connector, harness side. Is the
8.b No; repair the short between pin A and pin B of the ambient air sensor harness. Verify repairs.
9. Measure the resistance between pin A of the ambient air sensor connector, harness side and ground. Is the
9.a Yes; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature. Verify repairs.
9.b No; repair the wire shorted to ground between pin A of the ambient air sensor connector and pin 15 of
the CPC #3 connector.
6
69.4 SPN 171/FMI 9 - GHG17

SPN 171/FMI 9
Description Ambient Air Temperature Sensor Input Loss CAN
Dash Lamps CEL
Verification Key Cycle - Five Minutes Off - Engine Idle (Two minutes)
Check as follows:
1.a Yes; clear faults codes if they do not become active and release vehicle.
troubleshooting.
7
69.5 SPN 171/FMI 14 - GHG17

SPN 171/FMI 9
Description Ambient Air Temperature Sensor Input Loss CAN
Dash Lamps CEL
Verification Key Cycle - Five Minutes Off - Engine Idle (Two minutes)
Check as follows:
1.a Yes; clear faults codes if they do not become active and release vehicle.
troubleshooting.
8
70.1 SPN 171/FMI 3 - GHG17

SPN 171/FMI 3
Description Ambient Air Temperature Sensor Input Open Circuit
Dash Lamps CEL
Verification Key Cycle - Five Minutes Off - Engine Idle (Two Minute)
Check as follows:
1. Disconnect the ambient temperature sensor.
2. Inspect the ambient temperature sensor harness connector for bent, spread, or corroded terminals. Is pin
damage found?
4. Measure the voltage between pins 1 and 2 of the ambient temperature sensor harness connector. Is the
4.a Yes; replace the ambient temperature sensor.
5. Measure the voltage between pin 1 of the ambient temperature sensor harness connector and ground. Is
the voltage between 4.5 and 5.0 volts?
5.a Yes; repair wire between pin 2 of the ambient temperature sensor harness connector and pin 16 of the
CPC3 connector #2.
5.b No; repair wire between pin 1 of the ambient temperature sensor harness connector and pin 2 of the
CPC3 connector #3.
1
70.2 SPN 171/FMI 4 - GHG17

SPN 171/FMI 4
Description Ambient Air Temperature Sensor Input - Short to GND
Dash Lamps CEL
Verification Key Cycle - Five Minutes Off - Engine Idle (Two Minute)
Check as follows:
damage found?
5.a Yes, repair wire between pin 2 of the ambient temperature sensor harness connector and pin 16 of the
CPC3 connector #2.
5.b No, repair wire between pin 1 of the ambient temperature sensor harness connector and pin 2 of the
CPC3 connector #3.
2
72.1 SPN 171/FMI 20 - GHG17

Ambient Temperature Sensor Signal Not Plausible
SPN 171/FMI 20
Description This fault code sets when the Motor Control Module (MCM)
detects that the ambient air temperature is greater than 20°C
(36°F) degrees from the expected temperature after the
engine has been turned off for 8 hours.
Monitored Parameter
Ambient air temperature
Typical Enabling Conditions Key ON, engine OFF, battery voltage greater than 11 volts,
engine rpm at zero, ambient temperature less than 40°C
(104°F), engine OFF for no less than 8 hours.
Execution Frequency Once per cool down cycle
Typical Duration 5 seconds
Dash Lamps MIL
Verification Road test the vehicle for 30 minutes until the coolant reaches
operating temperature. Then verify that the ambient
temperature is within 10°C (18°F) of the compressor inlet
temperature.
1. Has the Common Powertrain Controller (CPC) recently been reprogrammed or has the internal clock time
been changed?
1.a Yes; this fault may have been caused by the change in the CPC time.
4. Check for multiple fault codes. Are fault codes SPN 171//FMI 3 or 4 present?
5. Disconnect and inspect the ambient temperature sensor electrical connector. Refer to Original Equipment
Manufacturer literature for location information. Is there damage or corrosion present?
5.b No; replace the intake ambient temperature sensor. Refer to OEM literature for remove and installation
procedures. Verify repair.
1
73.1 SPN 174/FMI 0 - GHG17

Supply Fuel Temperature Sensor Too High
1. Are any cooling system fault codes present?

2. Is SPN 174/FMI 3 or 4 also present?
3. For further diagnosis, Refer to section "Low Pressure Fuel System – Measuring Fuel Pressure Using Fuel System Integrity
Check – Two-Filter Fuel System" .
1
73.2 SPN 174/FMI 3 - GHG17

SPN 174/FMI 3
Description Fuel Temperature Circuit Failed High
Monitored Parameter Fuel Temperature Sensor
Dash Lamps MIL, CEL
Engine Reaction
1. Check for multiple codes. Are the following codes active at the same time?
• SPN 174/FMI 3
• SPN 175/FMI 3
• SPN 4076/FMI 3
1.a Yes; repair the open circuit between pin 55 of the Motor Control Module (MCM) 120-pin connector and
pin 1 of the supply fuel temperature sensor, (or) pin 1 of the engine oil temperature sensor, (or) pin1 of
the engine coolant inlet temperature sensor, (or) pin 1 of the engine coolant outlet temperature sensor.
2. Disconnect the supply fuel temperature sensor.
3. Measure the resistance across pins 1 and 2 of the supply fuel temperature sensor. Is the resistance greater
than 2.2K ohms?
2
3.a Yes; replace the supply fuel temperature sensor. Refer to section "Removal of the Supply Fuel Temperature Sensor"
.
5. Measure the voltage between pins 1 and 2 of the supply fuel temperature sensor harness connector. Is the
6. Measure the voltage between pin 2 of the supply fuel temperature sensor harness connector and ground.
6.a Yes; repair the open circuit between pin 1 of the supply fuel temperature sensor harness connector and
pin 55 of the MCM 120-pin connector.
6.b No; repair the open circuit between pin 2 of the supply fuel temperature sensor harness connector and
pin 77 of the 120-pin MCM connector.
7. Disconnect the 120-pin MCM connector and measure the resistance between pins 1 and 2 of the supply
fuel temperature sensor harness connector. Is the resistance greater than 10k ohms?
7.a Yes; replace supply fuel temperature sensor. Refer to section "Removal of the Supply Fuel Temperature Sensor" .
7.b No; repair the short between pins 55 and 77 of the MCM 120-pin connector.
3
73.3 SPN 174/FMI 4 - GHG17

SPN 174/FMI 4
Detects a Short to Ground on the Supply Fuel Temperature
Circuit.
Dash Lamps MIL, CEL
Engine Reaction
WARNING
ENGINE EXHAUST
Check as follows:
4
2. Disconnect and inspect the fuel temperature sensor electrical connector (2) harness side. Is there any
corrosion present?
2.a Yes; replace the fuel temperature sensor and the electrical connector. Refer to section "Removal of the Supply
Fuel Temperature Sensor" . Verify repair.

4. Inspect the fuel temperature sensor electrical connector components side. Are any of the pins or the
connector damaged?
4.a Yes; replace the fuel temperature sensor and the electrical connector. Refer to section "Removal of the Supply
Fuel Temperature Sensor" . Verify repair.
4.b No; replace the fuel temperature sensor electrical connector. Verify repair.
5. Use the appropriate flex probe to check the pins in the fuel temperature sensor electrical connector harness
side. Are the pins spread?
5.a Yes; replace the fuel temperature sensor electrical connector. Verify repair.
8. Check the fault codes. Is fault code SPN 174/FMI 3 inactive and SPN 174/FMI 4 active?
8.a Yes; replace the fuel temperature sensor. Refer to section "Removal of the Supply Fuel Temperature Sensor" .
Verify repair.
8.b No; repair the circuit between pin 2 of the of the fuel temperature sensor electrical connector harness
side and pin 77 of the MCM 120-pin electrical connector harness side.
5
73.4 SPN 174/FMI 17 - GHG17

Fuel Temperature Sensor, Minimum Temperature Plausibility
SPN 174/FMI 17
Description Fuel Temperature Sensor Plausibility Error when Compared
to Other Group 3 Sensors
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Note : During cold ambient temperatures, this fault can be induced if vehicle is equipped with auxiliary oil or
coolant heaters. If unit is equipped with an auxiliary heater, clear fault code and release. Advise driver of this
issue. This is a Malfunction Indication Light (MIL) - only fault.
1. Are any cooling system fault codes present?
3. Disconnect the supply fuel temperature sensor.
4. Inspect the supply fuel temperature harness connector for bent, spread or corroded pins. Is pin damage
found?
6
4.a Yes; repair or replace the electrical connector as necessary.

4.b No; replace the supply fuel temperature sensor. Refer to section "Removal of the Supply Fuel Temperature Sensor"
.
7
74.1 SPN 175/FMI 0 - GHG17

Oil Temperature High Warning
SPN 175/FMI 0
Description This Code Sets When the Motor Control Module (MCM)
Detects High Oil Temperature.
Monitored Parameter Engine Oil Temperature Sensor
Dash Lamps MIL, CEL
Verification Run the Engine at 1200 rpm Until Coolant Temperature
Reaches 49°C (120°F)
WARNING
ENGINE EXHAUST
1. Check engine oil level. Is the oil level low?

1.a Yes; add appropriate oil to bring level to full mark.
2. Are Fault codes SPN 110/FMI Any or SPN 100/FMI Any present?
2.a Yes; repair those first.
3. Are SPN 175/FMI 3 or 4 also present?
3.b No; replace the engine oil temperature sensor. Refer to section "Removal of the Engine Oil Temperature Sensor" .
1
74.2 SPN 175/FMI 3 - GHG17

SPN 175/FMI 3
Description Short to Voltage or Open on Engine Oil Temperature Sensor
Circuit
Dash Lamps MIL, CEL
Engine Reaction
1. Turn the ignition the ON (key ON, engine OFF).

2. Check for multiple codes. Are there any additional circuit failed high codes (FMI 3) present for the supply
fuel temperature sensor, engine oil temperature sensor, and coolant inlet temperature sensor?
2.a Yes; repair a short to power or open between pin 55 of the MCM 120-pin harness connector and pin 1
of the supply fuel temperature sensor, pin 1 of the engine oil temperature sensor, pin 1 of the coolant
inlet temperature sensor, and pin 1 of the coolant outlet temperature sensor.
3. Disconnect the engine oil temperature sensor.
4. Inspect the sensor harness for bent, spread, or corroded pins. Is damage present?
2

5. Measure the voltage between pin 2 of the engine oil temperature sensor and ground. Is the voltage less
than 2.75 volts?
5.a Yes; repair the open circuit between pin 2 of the engine oil temperature sensor harness connector and
6. Measure the voltage between pin 1 of the engine oil temperature sensor harness connector and ground. Is
the voltage less than 2.75 volts?
6.b No; repair the short to power between pin 1 of the engine oil temperature sensor harness connector
and pin 55 of the 120-pin MCM connector.
7. Measure the resistance between pin 1 of the engine oil temperature sensor harness connector and ground.
Is the resistance less than 5 ohms?
7.b No; repair the open circuit between pin 1 of the engine oil temperature sensor harness connector and
8. Disconnect the 120-pin MCM connector and measure the resistance between pins 1 and 2 of the engine oil
temperature sensor harness connector. Is the resistance less than 5 ohms?
8.a Yes; repair the short between pins 55 and 108 of the MCM 120-pin connector.
8.b No; replace engine oil temperature sensor. Refer to section "Removal of the Engine Oil Temperature Sensor" .
3
74.3 SPN 175/FMI 4 - GHG17

Engine Oil Temperature Circuit Failed Low
SPN 175/FMI 4
Description This Fault Code Sets when the Motor Control Module Detects
a Short to Ground on the Engine Oil Temperature Circuit.
Dash Lamps MIL, CEL
Engine Reaction
WARNING
ENGINE EXHAUST
Check as follows:
1. Disconnect and inspect the Engine Oil Temperature sensor electrical connector harness side. Is there
corrosion present in the connector?
4
1.a Yes; replace the Engine Oil Temperature sensor and the electrical connector. Refer to section "Removal of
the Engine Oil Temperature Sensor" and Technical Service letter 13 TS-16 . Verify repair.

2. Inspect the Engine Oil Temperature sensor electrical connector harness side. Are the pins or the connector
damaged?
3. Inspect the Engine Oil Temperature sensor electrical connector component side. Are the pins or the
connector damaged?
3.a Yes; replace the Engine Oil Temperature sensor and the electrical connector. Refer to section "Removal of
the Engine Oil Temperature Sensor" and Technical Service letter 13 TS-16 . Verify repair.
3.b No; replace the Engine Oil Temperature electrical connector. Refer to Technical Service letter 13 TS-16 .
Verify repair.
4. With the Engine Oil Temperature sensor disconnected, turn the ignition ON (Key On, engine OFF).
5.b No; replace the Engine Oil Temperature sensor. Refer to section "Removal of the Engine Oil Temperature Sensor" .
Verify repair.
7. Disconnect and inspect the MCM 120-pin electrical connector harness side. Are the pins or the connector
damaged?
8. Inspect the MCM 120-pin electrical connector component side. Are the pins or the connector damaged?
repair.
9. Measure the resistance between pin 2 of the engine oil temperature sensor electrical connector harness
side and pin 108 of the MCM 120-pin electrical connector harness side. Is the resistance less than 10k
ohms?
9.a Yes; repair the short to ground between pin 2 of the Engine Oil Temperature sensor electrical
connector harness side and pin 108 of the MCM 120-pin electrical connector harness side. Verify
repair.
9.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" .Verify repair.
5
74.4 SPN 175/FMI 15 - GHG17

Engine Oil Temperature High Pre Warning
SPN 175/FMI 15
Detects Engine Oil Temperature Above Normal Range.
Dash Lamps CEL
Verification Run the Engine at 1200 rpm Until Coolant Temperature
Reaches 49°C (120°F)
WARNING
ENGINE EXHAUST
Check as follows:
1.a Yes; add appropriate oil to bring level to full mark.
2. Are Fault codes SPN 110/FMI Any or SPN 100/FMI Any present?
6
74.5 SPN 175/FMI 18 - GHG17

SPN 175/FMI 18
Description This Fault Code Sets When the Engine Oil Temperature Rises
Too Slowly.
Monitored Parameter Oil Temperature
Typical Enabling Conditions Coolant Outlet and Oil Temperature Sensors
Dash Lamps MIL
Verification Run the Engine at 1200 RPM Until Coolant Temperature
Reaches (49°C) 120°F
WARNING
ENGINE EXHAUST
Check as follows:
1.a Yes; bring the oil level to full mark.
2. Disconnect the engine oil temperature sensor.
3. Inspect the engine oil temperature sensor connector and engine oil temperature sensor harness connector
for damage, bent, spread or unseated (pushed out) pins, corrosion or wire damage. Is damage present?
7
74.6 SPN 175/FMI 20 - GHG17

Engine Oil Temperature Signal Not Plausible
SPN 175/FMI 20
detects that the engine oil temperature is greater than 20°C
(36°F) degrees from the expected temperature after the
Monitored Parameter
Engine Oil Temperature
(104°F), ignition OFF for no less than 8 hours.
Execution Frequency Once per cold soak cycle
Dash Lamps MIL
operating temperature. Then verify that the engine oil
temperature is within 20°C (36°F) of the engine coolant outlet
temperature.
Possible causes:
Note : The use of an external heating unit while the engine has been shut down for a minimum of 8 hours can
cause this fault code to set erroneously.
been changed?
1.a Yes; this fault may have been caused by the change in the CPC time. Go to step 8.
4. Check for multiple fault codes. Are fault codes SPN 175/FMI 3 or 4 present?
5. Monitor and record the engine oil temperature.
WARNING
PERSONAL INJURY
8
WARNING
ENGINE EXHAUST

7. Road test the vehicle for 30 minutes until the coolant reaches operating temperature.
8. Monitor engine oil temperature. Has the temperature increased from the previously recorded value?
9. Compare the engine oil temperature to the engine coolant outlet temperature. Is the difference greater than
20°C (36°F)?
9.b No; the fault may have been caused by an external heating unit.
10. Disconnect and inspect the engine oil temperature electrical connector. Is there damage or corrosion
present?
10.b No; replace the engine oil temperature sensor. Verify repair.
9
75.1 SPN 188/FMI 31 - GHG17

Idle Speed is Higher than Targeted Idle Speed
SPN 188/FMI 31
Description Idle Speed Out of range
Monitored Parameter Engine RPM
Typical Enabling Conditions Engine RPM = idle
Dash Lamps MIL
Engine Reaction

2. Are there any camshaft or crankshaft sensor faults present?
3. Are there any throttle pedal or idle validation switch faults present?
4. Perform idle speed balance test. Are any faulty fuel injectors identified?
4.a Yes; replace suspect fuel injector.
1
76.1 SPN 190/FMI 9 - GHG17

Engine Speed Signal not Available via Controller Area Network (CAN)
1. Has the Aftertreatment Control Module (ACM), Motor Control Module (MCM), or Common Powertrain
Controller (CPC) been recently reprogrammed?
4.a Yes; follow entire CPC SPN 625/FMI 9 procedure for further PT CAN troubleshooting.
1
77.1 SPN 190/FMI 0 - GHG17

SPN 190/FMI 0 is an information code which indicates the Motor Control Module (MCM) detected an engine
speed greater than 2500 rpm for a specific amount of time.
Note : If the unit is a crank no-start, Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must
Be Done First)"Refer to section "Hard Start/No Start - Two-Filter Fuel System (This Test Must Be Done First).
1. Inspect the Exhaust Gas Recirculation (EGR) hot pipe for fuel. Is fuel present in the EGR hot pipe?
1.a Yes, fuel is present. Refer to section "Test-E - Two-Filter Fuel System" Refer to section "Test-E - Two-Filter Fuel
System.
2. Connect using DiagnosticLink . Go to step 3.
4. Review the extended fault data for SPN 190/FMI 0 Engine Speed High in DiagnosticLink. Is the engine
speed 3000 rpm or higher?
4.a Yes; replace both camshafts. Inspect engine brake rocker arms for loose actuator piston retainers and
loose or missing return springs. Repair as necessary; Go to step 6.
5. Check the maximum engine speed on DDEC reports. Is the maximum engine speed 3000 rpm or higher?
5.a Yes; replace both camshafts. Inspect engine brake rocker arms for loose actuator piston retainers and
loose or missing return springs. Repair as necessary; Go to step 6.
5.b No; no repair is necessary. If no other issues are present, release the vehicle.
6. Perform a cylinder leak-down test. Refer to section "Cylinder Leak-Down Test" Refer to section "Cylinder Leak
Down Test . Did all cylinders pass the leak-down test?
6.a Yes; reassemble the engine and road test to verify repairs.
6.b No; remove the head and inspect for damage. Repair as necessary.
1
77.2 SPN 190/FMI 9 - GHG17

Engine Speed Signal not Available via Controller Area Network (CAN)
4.a Yes; follow entire CPC SPN 625/FMI 9 procedure for further PT CAN troubleshooting.
2
77.3 SPN 190/FMI 14 - GHG17

Engine Overspeed while Driving
Check as follows:
SPN 190/FMI 14 is an information code only. It is used to provide the operator a message on the instrument
cluster. The function is to warn the operator that the engine speed is getting high and the service brakes should
be applied to avoid engine/transmission damage, typically on a steep grade deceleration. The code will self-delete
with each ignition cycle. Driver should be questioned about vehicle driving conditions. Obtain a copy of DDEC
reports and review the data with the customer.
3
77.4 SPN 190/FMI 15 - GHG17

Engine Over Speed Pre-Warning
SPN 190/FMI 15
Description This Fault Code Sets When the Engine Speed is Above 2300
rpm.
Monitored Parameter Engine Speed
Typical Enabling Conditions Engine Speed Greater than 2300 rpm
Dash Lamps None
Engine Reaction Engine Brakes are Activated
Verification Start and Run the Engine
Check as follows:
This fault is an information code only. It is used to provide the operator a message on the instrument cluster. The
function is to warn the operator that the engine speed is getting high and the service brakes should be applied to
avoid engine/transmission damage, typically on a steep grade deceleration. The code will self-delete with each
ignition cycle. Once the engine rpm is within normal operating range the message in the IC and the CEL will no
longer be present.
2. Check for multiple fault codes. Is fault code SPN 190/FMI Any also present?
2.a Yes; diagnose the other fault code first.
2.b No; SPN 190/FMI 15 is an information code only. It is used to provide a warning to the instrument
cluster. Question the driver about driving conditions and driving habits.
4
77.5 SPN 190/FMI 16 - GHG17

Engine Overspeed while Stationary
Check as follows:
SPN 190/FMI 16 is an information code only. It is used to provide the operator a message on the instrument
cluster. The function is to warn the operator that the engine speed is getting high and the service brakes should
be applied to avoid engine/transmission damage, typically on a steep grade deceleration. The code will self-delete
with each ignition cycle. Driver should be questioned about vehicle driving conditions. Obtain a copy of DDEC
reports and review the data with the customer.
5
78.1 SPN 191/FMI 9 - GHG17

SPN 191/FMI 13
Description J1939 Transmission Message is Missing
Monitored Parameter CAN Communication
Dash Lamps MIL
Engine Reaction
Check as follows:
Note : Fault will set during Eaton transmission module reprogramming. If fault occurs while programming, clear
code and release vehicle.
1. Check for multiple codes. Are CPC SPN 168/FMI 0/14/18 (battery voltage) codes present?
2. Is MCM SPN 625/FMI 9 code present?
module.
1
78.2 SPN 191/FMI 13 - GHG17

SPN 191/FMI 13
Description J1939 Transmission Output Shaft Speed Signal is Missing
Dash Lamps MIL
Engine Reaction
Check as follows:
3.b No; determine which modules are configured for the vehicle and their communication status. Then
follow the appropriate module communication troubleshooting procedures for the affected module.
2
78.3 SPN 191/FMI 19 - GHG17

Transmission Output Speed Shaft Signal is Erratic
SPN 191/FMI 19
Description J1939 Transmission Output Shaft Speed Signal is Erratic
Monitored Parameter Controller Area Network (CAN) Communication
Dash Lamps MIL
Engine Reaction
Check as follows:
3
79.1 SPN 247/FMI 0 - GHG17

Module (MCM) faults. DDDL 7.X makes the distinction between the MCM and CPC when diagnosing a fault.
This diagnostic is typically MCM engine hours data higher than expected. This fault usually occurs after
reprogramming the CPC or MCM. The internal clocks of the CPC or MCM do not match. After reprogramming
either module, all fault codes must be cleared.
1
79.2 SPN 247/FMI 1 - GHG17

This diagnostic is typically MCM engine hours data lower than expected. This fault usually occurs after
2
79.3 SPN 247/FMI 9 - GHG17

This diagnostic is typically MCM engine hours data not received or stopped arriving. This fault usually occurs after
3
79.4 SPN 247/FMI 10 – GHG17

Module (MCM) faults. DDDL 7.08 SP2 makes the distinction between the MCM and CPC when diagnosing a fault.
This diagnostic is typically MCM Engine Hours Data Increasing at an Implausible Rate. This fault usually occurs
after reprogramming the CPC or MCM. The internal clocks of the CPC or MCM do not match. After
reprogramming either module, all fault codes must be cleared.
4
79.5 SPN 247/FMI 14 - GHG17

Aftertreatment Control Module Reported Ash Mileage is Lower than the Common Powertrain Controller Stored
Value
3. Select Diesel Particulate Filter (DPF) ash accumulator from the actions drop-down menu.
4. Choose Aftertreatment Control Module (ACM) replacement option, then select set ash volume button.
5. Verify that the ACM value has changed in the DPF ash accumulator window and that the 247/14 CPC fault
is no longer active. ACM will change to a value that should be within 5% of the CPC displayed volume
within 5-10 seconds of executing the routine. Clear all faults and release vehicle.
5
80.1 SPN 411/FMI 2 - GHG17

Exhaust Gas Recirculation Delta P Sensor Out Of Calibration
SPN 411/FMI 2
Description EGR delta Pressure Sensor Out Of Calibration
Monitored Parameter EGR delta Pressure
Typical Enabling Conditions Coolant Temperature greater than 176F
Dash Lamps MIL, CEL
Verification Coolant Temperature greater than 176F, then engine off for
15 seconds, then Key ON
1

2. Using DiagnosticLink , monitor EGR delta P voltage (pin 109).
3. Is the EGR delta P voltage between 0.55 and 0.83 volts?
4. Remove the EGR delta P sensor from the mounting pad, leave electrical harness connected. Refer to section
"Removal of the Delta P Sensor" .

6. Inspect the EGR Delivery pipe delta P pressure ports for blockage.
2
6.a If excessive build up or blockage is found, clean the venturi pipe and reinstall the sensor. Refer to section
"Cleaning of the Exhaust Gas Recirculation Venturi Pipe Delta P Sensor Ports" .

7. Disconnect the EGR delta P sensor harness connector.
8. Inspect the EGR delta P sensor harness connector for loose, bent, spread or corroded pins.
8.a If pin damage is found, repair as necessary.
9. Disconnect the Motor Control Module (MCM) 120–pin connector.
10. Measure the resistance between pins 1 and 2 of the EGR delta P sensor.
10.a If the resistance is greater than 5 ohms, Go to step 11.
10.b If the resistance is less than 5 ohms, repair the short between pins 103 and 117 of the MCM 120–pin
connector.
connector.
12. Measure the resistance between pin 1 of the EGR delta P sensor and ground.
12.b If the resistance is less than 3 ohms, repair the short circuit between pin 1 of the EGR delta P sensor
harness connector and ground.
13.a If the resistance is greater than 3 ohms, repeat the previous steps. If the results are the same, call the
Detroit™ Customer Support Center (800-445-1980).
16. Disconnect the MCM 120–pin connector.
connector.
connector.
20.a If the resistance is greater than 3 ohms, repeat the previous steps. If the results are the same, replace
the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" . After sensor replacement, perform
EGR delta P sensor re-calibration service routine.
3
4
80.2 SPN 411/FMI 3 - GHG17

EGR Delta Pressure Sensor Circuit Failed High
SPN 411/FMI 3
Description This fault code sets when there is short to ground on the
signal return circuit.
Monitored Parameter EGR Delta Pressure Sensor return signal
Dash Lamps MIL, CEL
5
WARNING
ELECTRICAL SHOCK
usage.
WARNING
ELECTRICAL SHOCK
To avoid injury from electrical shock, do not touch battery terminals, alternator terminals,
or wiring cables while the engine is operating.
3. Check for multiple fault codes. Is fault code SPN 3509/FMI 3 also present?
3.a Yes; Diagnose fault code SPN 3509/FMI 3.
4. Disconnect and inspect the EGR Delta P sensor electrical connector. Is there any damage or corrosion
present?
6. Recheck for the fault code. Did SPN 411/FMI 3 become inactive and fault code SPN 411/FMI 4 become
active?
6.a Yes; replace the EGR Delta P sensor. Refer to section "Removal of the Delta P Sensor" .
8. Disconnect and inspect the MCM 120-pin electrical connector. Is the MCM connector damaged?
10. Recheck for the fault code. Is SPN 411/FMI 3 still present?
10.b No; repair the short to ground on the circuit between pin 3 of the EGR Delta P sensor electrical
connector harness side, and pin 109 of the 120- pin MCM electrical connector, harness side.
6
80.3 SPN 411/FMI 4 - GHG17

SPN 411/FMI 4
Description This Fault Code Sets when there is an Open in the Voltage
Supply Circuit, an Open or Short to Ground on the Signal
Return Circuit
Monitored Parameter EGR Delta Pressure Sensor Return Signal
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7
Check as follows:
8
5. Disconnect and inspect the EGR Delta P sensor electrical connector harness side. Is there any corrosion
present?
5.a Yes; replace the EGR Delta P sensor and the electrical connector. Refer to section "Removal of the Delta P
Sensor" . Verify repair.

6. Is the connector or any of the pins damaged?
7. Inspect the EGR Delta P sensor electrical connector component side, is the connector or are any of the
pins damaged?
7.a Yes; replace the EGR Delta P sensor and the electrical connector. Refer to section "Removal of the Delta P
7.b No; replace the EGR Delta P sensor electrical connector.

9. Measure the voltage between pin 1 and pin 2 of the EGR Delta P sensor electrical connector harness side.
9.a Yes. Go to step 11.
10. Measure the voltage between pin 1 and ground. Is the voltage between 4.5 and 5.5 volts?
10.a Yes; repair the circuit between pin 1 of the EGR Delta P sensor electrical connector harness side and
the splice. Verify repair.
10.b No; repair the circuit between pin 2 of the EGR Delta P sensor electrical connector harness side and
the splice. Verify repair.
11. Use the appropriate flex probes to jump pin 1 and pin 3 of the EGR Delta P sensor electrical connector
harness side together.
9
12. Check the fault codes, does fault code SPN 411 FMI 4 become inactive and fault code SPN 411/FMI 3
become active?
12.a Yes; replace the EGR Delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
12.b No; repair the circuit between pin 3 of the EGR Delta P sensor electrical connector harness side and
pin 109 of the 120-pin MCM electrical connector harness side.
10
80.4 SPN 411/FMI 13 - GHG17

EGR Delta Pressure Sensor Out Of Calibration
SPN 411/FMI 13
Description EGR delta Pressure Sensor Out Of Calibration
Monitored Parameter EGR delta Pressure
Typical Enabling Conditions Coolant Temperature greater than 176F
Dash Lamps MIL, CEL
Verification Coolant Temperature greater than 176F, then engine off for
15 seconds, then Key ON
11

2. Using DiagnosticLink , monitor EGR delta P voltage (pin 109).
4. Remove the EGR delta P sensor from the mounting pad; leave electrical harness connected.
6. Inspect the EGR delivery pipe delta P pressure ports for blockage.
6.a If excessive build up or blockage is found, clean the venturi pipe and reinstall the sensor.
12

10. Measure the resistance between pins 1 and 2 of the EGR delta P sensor connector on the engine sensor
harness.
connector.
harness.
connector.
12. Measure the resistance between pin 1 of the EGR delta P sensor connector on the engine sensor harness
and ground.
and ground.
13.a If the resistance is greater than 3 ohms, repeat the previous steps (Go back to Step 1). If the results
are the same, call the Detroit™ Customer Support Center (800-445-1980).
harness.
connector.
harness.
18.b If the resistance is less than 5 ohms, repair the short circuit between pin 103 and 109 of the MCM 120-
pin connector.
and ground.
19.b If the resistance is less than 3 ohms, repair the short between pin 1 of the EGR delta P sensor harness
connector and ground.
and ground.
13
20.a If the resistance is greater than 3 ohms, repeat the previous steps; Go to step 1. If the results are the
same, replace the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" Refer to section
"Removal of the Delta P Sensor". After sensor replacement, perform EGR delta P sensor re-calibration
service routine.
14
81.1 SPN 513/FMI 9 - GHG17

Actual Torque Signal Not Available via CAN.
1.a Yes; clear faults codes. If they do not become active, release the vehicle.
2. Turn the ignition OFF and disconnect DiagnosticLink ; then wait 5 minutes for all modules to power-down.
4.a Yes; Refer to section "SPN 625/FMI 9 - GHG17" troubleshooting procedure for further PT Controller
Area Network (CAN) troubleshooting.
1
82.1 SPN 520/FMI 1 - GHG17

SPN 520/FMI 1
Description This Fault Code Sets When the engine brake power has been
limited to prevent engine damage due to a fault in the Exhaust
Gas Recirculation (EGR), intake or aftertreatment system.
Monitored Parameter Engine brake
Typical Enabling Conditions Engine brake request active.
Dash Lamps MIL, CEL
Engine Reaction Based on other fault codes present
Verification Road test vehicle using engine brakes.
Check as follows:
Note : This fault code is an information fault code that sets when there is a fault with the EGR, intake or
aftertreatment system.
2. Turn the ignition ON( key ON, engine OFF).
3. Check for multiple fault codes. Are there any EGR, intake system or aftertreatment fault codes present?
4. Clear the fault codes.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5. Start and run the engine until the coolant temperature reaches 85°C (185°F).
6. Road test the vehicle and use the engine brakes. Does fault code SPN 520/FMI 1 become active?
6.a Yes; replace the MCM., Refer to section "Removal of the Motor Control Module" . Verify repair.
1
82.2 SPN 520/FMI 18 - GHG17

SPN 520/FMI 18
Description This Fault Code Sets When the Engine Brake Power has
Been Limited to Prevent Engine Damage Due to a Fault in the
Exhaust Gas Recirculation (EGR), Intake or Aftertreatment
System
Monitored Parameter Engine Brake
Typical Enabling Conditions Engine Brake Request Active
Dash Lamps MIL, CEL
Engine Reaction Based on Other Fault Codes Present
Verification Road Test Vehicle Using Engine Brakes
Note : This fault code is an information only code that sets when there is a system fault that results in derated
engine brake performance. Troubleshoot the other active faults.
2
83.1 SPN 523/FMI 13 - GHG17

SPN 523/FMI 13
Description Transmission Gear Signal Not Available
Monitored Parameter Gear Signal
Dash Lamps CEL
Verification Key On Engine On
WARNING
PERSONAL INJURY
Check as follows:
3.a Yes; diagnose SPN 625/FMI 9 fault code first. Verify repair.
module. For wiring schematic information, refer to Original Equipment Manufacturer (OEM) literature.
1
83.2 SPN 523/FMI 19 - GHG17

SPN 523/FMI 19
Description Transmission Gear Signal Erratic
Monitored Parameter Gear Signal
Dash Lamps CEL
WARNING
PERSONAL INJURY
Check as follows:
2
84.1 SPN 523/FMI 13 - GHG17

Check as follows:
1. Check for multiple codes: Is (CPC) SPN 168/FMI 0/14/18 (Battery Voltage) present?
1
84.2 SPN 523/FMI 19 - GHG17

Check as follows:
2
85.1 SPN 524/FMI 9 - GHG17

J1939 ETC2 Message Missing
Check as follows:
1. Check for multiple codes: Is (CPC) SPN 168/FMI 0/14/18 (Battery Voltage) code present?
module.
1
86.1 SPN 525/FMI 7 - GHG17

Internal Error with the DT12 Shift Stalk Lever
Shift Lever Pin Number Signal Description CPC Connector Pin

1 12V Ignition 2/3 Ignition
2 LIN 2/4 LIN COM
3 GND 2/2 Main Battery Ground
4 No Connection No Connection
Check as follows:
1. Disconnect shift stalk lever.
3. Measure voltage between pin 1 of the shift stalk harness connector and ground. Is the voltage between
11.5 and 12 volts?
6. Inspect CPC connector #2 for bent, spread or corroded pins . Was any damage found?
7. Measure the resistance between pin 4 of the CPC connector #2 and pin 2 of the shift stalk lever harness
connector. Is the resistance less than 5 ohms?
7.b No; repair wire between pin 4 of the CPC connector #2 and pin 2 of the shift stalk lever harness
connector.
8.a Yes; replace the shift stalk lever.
connector.
11.a Yes; refer to Original Equipment Manufacturer literature for chassis side harness information on
Ignition supply voltage to pin 3 of the CPC connector #2.
connector.
1
86.2 SPN 525/FMI 9 – GHG17

J1939 Powertrain Message (Transfer Case/PTO) is Missing
Check as follows:
Note : This fault code may be set by two or more source inputs configured with the same address. Verify proper
parameter settings.
configuration?
4.a Yes; replace CPC. Refer to Original Equipment Manufacturer (OEM) literature.
4.b No; reprogram the CPC with the correct information as necessary. To verify repair, Go to step 5.
2
87.1 SPN 527/FMI 9 - GHG17

J1939 Cruise Control Vehicle Speed (CCVS) Message From Source #1, #2, or #3 Missing
SPN 527/FMI 9
Description Missing Message form J1939 Source Address
Monitored Parameter J1939 Source Address
Dash Lamps CEL
Verification Key ON engine ON
WARNING
ENGINE EXHAUST
Check as follows:

module.
1
88.1 SPN 556/FMI 9 - GHG17

SPN 556/FMI 9
Description J1939 Message is Missing
Dash Lamps None
1
89.1 SPN 558/FMI 2 - GHG17

Idle Validation Switch Inputs Reversed
Check as follows:
1. Verify correct wiring of idle validation switch 1 and 2 from switch to Common Powertrain Controller (CPC)
connector #1 and #2. If wired correctly, replace the throttle position sensor.
1
89.2 SPN 558/FMI 3 - GHG17

SPN 558/FMI 3
Description IVS Short to Voltage or Open Circuit
Monitored Parameter Idle Validation Switch
Dash Lamps CEL
Verification Key ON, Engine ON
Check as follows:
1. Disconnect the Idle Validation Switch (IVS).
3. Measure the voltage between the IVS pins 4 and 6. Is the voltage greater than 11.5 volts?
4. Measure the voltage between the IVS pin 4 and ground. Is the voltage greater than 11.5 volts?
4.b No; repair the open wire between pin 6 of the Common Powertrain Controller (CPC) #1 connector and
pin 4 of the IVS.
2

6. Measure the resistance between pin 2 of the CPC #2 connector and pin 6 of the IVS. Is the resistance
6.a Yes; repair the open the wire between pin 2 of the CPC #2 connector and pin 6 of the IVS.
6.b No; replace the IVS. Refer to OEM procedures.
7.a Yes; replace the IVS. Refer to Original Equipment Manufacturer (OEM) procedures.
7.b No; repair the open the wire between pin 3 of the CPC #1 connector and pin 5 of the IVS.
3
89.3 SPN 558/FMI 4 - GHG17

SPN 558/FMI 4
Description IVS Short to Ground
Dash Lamps CEL
Check as follows:
2. Disconnect the Common Powertrain Controller (CPC) #1 connector.
3. Measure the resistance between pin 4 of the IVS connector and ground. Is the resistance less than five
ohms?
3.a Yes; repair the short to ground between pin 6 of the CPC #1 connector and pin 4 of the IVS connector.
4. Measure the resistance between pin 5 of the IVS connector and ground. Is the resistance less than five
ohms?
4.a Yes; repair the short to ground between pin 3 of the CPC #1 connector and pin 5 of the Idle Validation
Switch connector.
4
4.b No; replace the IVS. Refer to Original Equipment Manufacturer (OEM) procedures.
5
89.4 SPN 558/FMI 5 - GHG17

SPN 558/FMI 5
Description IVS Short to Voltage or Open Circuit
Dash Lamps CEL
Check as follows:
2. Disconnect the Common Powertrain Controller (CPC) #1 connector.
3. Measure the resistance between pin 4 of the IVS connector and ground. Is the resistance less than 10K
ohms?
3.a Yes; repair the short to ground between pin 6 of the CPC #1 connector and pin 4 of the IVS connector.
4. Measure the resistance between pin 5 of the IVS connector and ground. Is the resistance less than 10K
ohms?
4.a Yes; repair the short to ground between pin 3 of the CPC #1 connector and pin 5 of the Idle Validation
Switch connector.
6
7
89.5 SPN 558/FMI 6 - GHG17

SPN 558/FMI 6
Description IVS Circuit Short to Voltage or Open Circuit
Dash Lamps CEL
Check as follows:
4. Measure the voltage between the IVS pin 4 and ground. Is the voltage greater than 11.5 volts?
4.b No; repair the open wire between pin 6 of the Common Powertrain Controller (CPC) #1 connector and
pin 4 of the IVS.
8

6. Measure the resistance between pin 2 of the CPC #2 connector and pin 6 of the IVS. Is the resistance
6.a Yes; repair the open wire between pin 2 of the CPC #2 connector and pin 6 of the IVS.
7.a Yes; replace the IVS. Refer to OEM procedures.
7.b No; repair the open wire between pin 3 of the CPC #1 connector and pin 5 of the IVS.
9
90.1 SPN 558/FMI 7 - GHG17

Check as follows:
3. Are CPC2 SPN 91/FMI 8/13 or CPC3 SPN 2623/FMI 8 also present?
4. Physically inspect the accelerator pedal for any obstructions, binding, loose mounting bracket, and that
pedal has full travel. Is damage found?
4.b No; replace accelerator pedal.
1
91.1 SPN 569/ FMI 9 - GHG17

J1939 EAC1 Message (Electronic Axle Controller 1) is missing
SPN 569/FMI 9
Description J1939 EAC1 message has not been received within expected
time
Monitored Parameter
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps CEL
Engine Reaction Default values for the J1939 Message are used
Verification
Check as follows:
parameter settings.
configuration?
1
92.1 SPN 571/FMI 4 - GHG17

SPN 571/FMI 4
Description Input 4/18 Short To Ground
Monitored Parameter 4 18 DI Selection
Dash Lamps CEL
1. Check for multiple codes. Is Common Powertrain Controller (CPC) SPN 168/FMI 0/14/18 (battery voltage)
code present?
2. Is Motor Control Module (MCM) SPN 625/FMI 9 code present?
3.b No; clear fault and retest. Go to step 4.
5. Does active fault return?
5.b No; testing is completed. Release vehicle.
7. Measure the resistance between pin 18 of the CPC connector #4 and ground. Is the resistance more than
10k ohms?
7.a Yes; replace the engine brake disable push-button (switch).
7.b No; repair the short to ground on the wire between pin 18 of the CPC connector #4 and the engine
brake disable push-button.
1
93.1 SPN 596/FMI 13 - GHG17

SPN 596/FMI 13
Description J1939 Cruise Control Enable Has Not Been Received Within
Expected Time
Monitored Parameter Cruise Control Enable
Dash Lamps CEL
Verification Cruise Control Operation
Check as follows:
1. Check for multiple codes:
module.
1
93.2 SPN 596/FMI 19 - GHG17

SPN 596/FMI 19
Description J1939 Cruise Control Enable Has Not Been Received Within
Expected Time
Monitored Parameter Cruise Control Enable
Dash Lamps CEL
Check as follows:
module.
2
94.1 SPN 597/FMI 2 - GHG17

SPN 597/FMI 2
Description Engine Service Brake Not Plausible
Monitored Parameter Service Brake Status
Dash Lamps CEL
Verification Service Brake Operation
Check as follows:
1. Check for multiple codes: is Common Powertrain Controller (CPC) SPN 168/FMI 0/14/18 (Battery Voltage)
present?
2. Is Motor Control Module (MCM) SPN 625/FMI 9 present?
module.
1
94.2 SPN 597/FMI 13 - GHG17

SPN 597/FMI 13
Description J1939 Service Brake Signal has not been Received Within
Expected Time
Monitored Parameter Service Brake
Dash Lamps CEL
Check as follows:
present?
module.
2
94.3 SPN 597/FMI 19 - GHG17

SPN 597/FMI 19
Description J1939 Service Brake Signal Has Not Been Received Within
Expected Time
Monitored Parameter Service Brake Status
Dash Lamps CEL
Check as follows:
present?
module.
3
95.1 SPN 598/FMI 2 - GHG17

Clutch Switch Not Plausible.
SPN 598/FMI 2
Description Clutch Switch not Plausible
Monitored Parameter Clutch Switch Status
Dash Lamps CEL
Verification Clutch Switch Operation
Check as follows:
module.
1
96.1 SPN 599/FMI 4 - GHG17

Both Cruise Control switches, Set and Resume, are shorted to ground.
SPN 599/FMI 4
Description Set and Resume short to ground
Monitored Parameter Set switch and Resume switch
Dash Lamps CEL
Check as follows:
1. Turn the ignition ON (key ON, engine OFF) and place the cruise control switch in the OFF position. DO
NOT start the engine.
2. Check the driver console display. Is cruise control switch resume status displayed?
3. Unplug the cruise control resume switch. Is resume status no longer displayed?
3.a Yes; replace the cruise control resume switch.
3.b No; repair the short to ground in the wire from the resume switch to pin 16 of the CPC #1 connector.
4. Unplug the cruise control set switch. Is set status no longer displayed?
4.a Yes; replace the cruise control set switch.
4.b No; repair the short to ground in the wire from the set switch to pin 12 of the CPC #1 connector.
1
97.1 SPN 600/FMI 13 - GHG17

J1939 Cruise Control Coast Switch Signal from Source #1, #2, or #3 is Missing or Not Available
SPN 600/FMI 13
Description Cruise Control Coast Switch Signal from Source #1, #2, or #3
is Missing
Monitored Parameter Cruise Control Signal
Dash Lamps CEL
WARNING
PERSONAL INJURY
Check as follows:
1
97.2 SPN 600/FMI 19 - GHG17

J1939 Cruise Control Coast Switch Signal from Source #1, #2, or #3 is Erratic
SPN 600/FMI 19
Description Cruise Control Coast Switch Signal from Source #1, #2, or #3
is Erratic
Dash Lamps CEL
WARNING
PERSONAL INJURY
Check as follows:
2
98.1 SPN 602/FMI 13 - GHG17

SPN 602/FMI 13
Description Cruise Control Signal Not Available
Dash Lamps CEL
Verification Key ON Engine ON
WARNING
ENGINE EXHAUST
Check as follows:
1
98.2 SPN 602/FMI 19 - GHG17

SPN 602/FMI 19
Description Cruise Control Signal Erratic
Dash Lamps CEL
Verification Key ON Engine ON
WARNING
ENGINE EXHAUST
Check as follows:
2. Check for multiµple codes. Are there any SPN 168 (battery voltage) fault codes present?
2
99.1 SPN 609/FMI 12 - GHG17

SPN 609/FMI 12
Description Common Powertrain Controller (CPC) Failure
Monitored Parameter CPC Hardware
Dash Lamps CEL
Verification Idle
Check as follows:
3. Turn on the ignition (key ON, engine OFF).
1
99.2 SPN 609/FMI 13 - GHG17

CPC Software Diagnostics
SPN 609/FMI 13
Description This fault sets when the CPC software is corrupt or when two
or more source inputs are configured with the same address
Monitored Parameter CPC source address inputs
Dash Lamps CEL
Verification Idle
Check as follows:
1.a If any other fault codes are present, troubleshoot these first.
1.b If only SPN 609/FMI 13 fault is present, reprogram CPC with the proper configuration for the vehicle.
Note: The tables below shows a set of commonly miss configured source inputs that will set the code.
Parameter Name Cascadia Chassis Parameter M2 Chassis Parameter Value
Value
CM1 DPF Source Addr SAE J1939 49 33
CM1 Fan Source Addr 1 SAE J1939 25 49
CM1 Fan Source Addr 2 SAE J1939 49 33
2
99.3 SPN 609/FMI 16 - GHG17

SPN 609/FMI 16
Description Common Powertrain Controller (CPC) Failure
Monitored Parameter CPC Hardware
Dash Lamps CEL
Verification Idle
Check as follows:
3. Turn on the ignition (key ON, engine OFF).
3
102.1 SPN 625/FMI 2 - GHG17

SPN 625/FMI 2
Description CPC Message Not Received Or Has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
1. Are there any battery voltage faults (SPN 168/FMI any)?
1.a Yes; troubleshoot battery voltage faults first.
Control Module (CPC) been recently programmed?
2.a Yes; clear the fault codes. If faults do not become active, release the vehicle. If faults become active,
Go to step 3.

Note : Main battery power must be left ON.
Note : The five minute timeframe allows the ACM to go completely offline.
3. Disconnect the ACM 21-pin connector.
4. Check ACM internal terminating resistor by measuring and recording the resistance across pins 10 and 20
of the ACM 21-pin connector. Is the resistance between 120 plus or minus 10 ohms?
1

4.b No; replace the ACM.
5. Disconnect the CPC electrical harness connector #3.
6. Check CPC internal terminating resistor by measuring and recording the resistance across pins 19 and 21
of the CPC electrical harness connector cavity #3. Is the resistance between 120 plus or minus 10 ohms?
2

6.b No; replace the CPC.
7. Check for continuity between pin 19 of the CPC connector #3 and pin 20 of the ACM 21-pin connector. Is
there continuity?
7.b No; repair the wire between CPC connector #3 pin 19 and the ACM 21-pin connector pin 20.
8. Measure and record the resistance between pin 21 of the CPC connector #3 and pin 10 of the ACM 21-pin
connector. Is there continuity?
8.b No; repair the wire between pin 21 of the CPC connector #3 and pin 10 of the ACM 21-pin connector.
9. Measure and record the resistance between pin 19 of the CPC connector #3 and pin 19 of the MCM 21-pin
3

9.b No; repair the wire between pin 19 of the CPC connector #3 and pin 19 of the MCM 21-pin connector.
11. Measure and record the resistance between pin 19 of the MCM 21-pin connector and pin 20 of the ACM
21-pin connector. Is there continuity?
11.b No; repair the wire between pin 19 of the MCM 21-pin connector and pin 20 of the ACM 21-pin
connector.
12.a No; replace the ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .
connector.
15. Measure the voltage between pins 11, 12, 14, 15 and 18 (battery voltage), pin 16 (ignition voltage) of the
ACM 21-pin connector and ground. Is the voltage less than 11.5 volts?
4
15.a Yes; restore voltage to pins 11, 12, 14, 15 and 18 of the ACM 21-pin connector.
15.b No; restore ground connection to pins 3, 5, 6 and 9 of the ACM 21-pin connector.
5
102.2 SPN 625/FMI 9 – GHG17

PT-CAN Heartbeat Missing
SPN 625/FMI 9
Description PT-CAN Heartbeat Missing
Dash Lamps MIL, CEL
Verification Ignition Cycle
1. Are there any battery voltage faults (any SPN 168 FMI faults)?
Controller (CPC) been recently programmed?
Go to step 3.

Note : ACM, MCM, and CPC all communicate on the same CAN line. If water penetrates any connector, it can
short the CAN line and may prevent communications with other ECUs.
6

Note : The five minute time-frame allows the ACM to go completely offline.
3. Turn ignition OFF and wait five minutes before proceeding.
4. Disconnect ACM 21-pin connector.
5. Inspect the 21–pin ACM connector for corroded, unseated (pushed out) or damaged pins, bent or spread
pins; inspect the connector seal for damage (signs of water or oil intrusion).
5.a If contamination or damage is found, repair as necessary. Go to step 21.
5.b If no contamination or damage is found, Go to step 6.
of the ACM 21-pin connector, component side.
6.a If the resistance is between 110 to 130 ohms, Go to step 7.
7
6.b If the resistance is not between 110 to 130 ohms, replace the ACM. Go to step 21.
7. Measure the resistance between pin 10 of the ACM 21-pin harness connector and battery ground.
7.a If the resistance is greater than 10K ohms, Go to step 8.
7.b If the resistance is less than 10K ohms, repair the short to ground on pin 10 of the ACM 21-pin harness
connector. Refer to Original Equipment Manufacturer (OEM) literature for wiring schematic information.
Go to step 21.
8. Measure the resistance between pin 20 of the ACM 21-pin harness connector and battery ground.
8.b If the resistance is less than 10K ohms, repair the short to ground on pin 20 of the ACM 21-pin harness
connector. Refer to Original Equipment Manufacturer (OEM) literature for wiring schematic information.
Go to step 21.
9. Disconnect the CPC electrical harness connector #3.

10. Inspect the CPC connector for corroded, unseated (pushed out) or damaged pins, bent or spread pins;
inspect the connector seal for damage (signs of water or oil intrusion).
11. Check CPC internal terminating resistor by measuring the resistance across pins 19 and 21 of the CPC
electrical connector #3 component side.
8
11.a If the resistance is between 110 to 130 ohms, Go to step 12.

11.b If the resistance is not between 110 to 130 ohms, replace the CPC. Go to step 21.
12. Check the resistance between pin 19 of the CPC harness connector #3 and pin 20 of the ACM 21-pin
harness connector.
12.a If the resistance is less than 5 ohms, Go to step 13.
12.b If the resistance is greater than 5 ohms, repair the wire between pin 19 of the CPC harness connector
#3 and pin 20 of the ACM 21-pin harness connector. Go to step 21.
13. Measure the resistance between pin 21 of the CPC harness connector #3 and pin 10 of the ACM 21-pin
harness connector.
#3 and pin 10 of the ACM 21-pin harness connector. Go to step 21.
14. Disconnect MCM 21-pin connector.
9
15. Inspect the 21–pin MCM connector for corroded, unseated (pushed out) or damaged pins, bent or spread
16. Measure the resistance between pin 19 of the CPC harness connector #3 and pin 19 of the MCM 21-pin
harness connector.
#3 and pin 19 of the MCM 21-pin harness connector. Go to step 21.
harness connector.
#3 and pin 13 of the MCM 21-pin harness connector. Go to step 21.
Note : Ensure ACM and MCM connectors are disconnected during this step.
18. Measure the resistance between pins 19 and 21 of the CPC harness connector #3.
18.b If the resistance is less than 10K ohms, repair the harness shorted wires between pin 19 and pin 21 of
the CPC harness connector #3. Refer to Original Equipment Manufacturer (OEM) literature for
schematic information. Go to step 21.
19. Measure the resistance between pin 19 of the MCM 21-pin harness connector and pin 20 of the ACM 21-
pin harness connector.
19.b If the resistance is greater than 5 ohms, repair the wire between pin 19 of the MCM 21-pin harness
connector and pin 20 of the ACM 21-pin harness connector. Go to step 21.
20. Measure the resistance between pin 13 of the MCM 21-pin harness connector and pin 10 of the ACM 21-
pin harness connector.
20.a If the resistance is less than 5 ohms, install a test ACM and retest. If code does not return, replace
ACM. Refer to OEM procedures. Go to step 21.
20.b If the resistance is greater than 5 ohms, repair the wire between pin 13 of the MCM 21-pin harness
connector and pin 10 of the ACM 21-pin harness connector. Go to step 21.
21. Verify repairs. Restore all connections. Cycle the ignition key. Is fault code still active?
21.a Yes; replace the ACM. Refer to OEM procedures.
21.b No; If fault does not become active, clear the fault codes and release the vehicle.
10
101.1 SPN 625/FMI 2 - GHG17

PTCAN Incorrect MCM System ID Received
SPN 625/FMI 2
Description Invalid Data on Engine Controller Area Network (CAN) Link
Dash Lamps MIL, CEL
Engine Reaction
1
Check as follows:
1. Have the Motor Control Module (MCM) and/or the Common Powertrain Controller (CPC) recently been
changed or reprogrammed?
1.a Yes; verify that the correct MCM calibration and/or the correct CPC parameter list has been installed. If
the correct calibration and correct parameter list have been installed, then Go to step 2.
Note : Poor battery grounds can be a possible cause of low battery voltage.
4. Measure the battery voltage at pin 7 on the MCM 21-pin connector. Is the battery voltage less than 10.5
volts?
4.a Yes; restore the battery voltage at pins 7, 11, 12, 14, and 15 on the MCM 21-pin connector.
5. Turn ignition OFF. Leave the MCM 21-pin connector disconnected.
6. Disconnect the CPC connector #3.
five ohms?
7.b No; repair the short circuit in the wires between pins 21 and 19 of the CPC connector #3 and pins 13
and 19 of the MCM 21-pin connector.
8. Measure the resistance between pin 21 of the CPC connector #3 and ground. Is the resistance greater than
five ohms?
8.b No; repair the short circuit to ground between pin 21 of the CPC connector #3 and ground.
9. Check the resistance between pin 19 of the CPC connector #3 and ground. Is the resistance greater than
five ohms?
10. Measure the resistance between pin 19 of the CPC connector #3 and pin 19 of the MCM 21-pin connector.
10.a Yes; repair the open circuit between pin 19 of the CPC connector #3 and pin 19 of the MCM 21-pin
connector.
connector.
11.b No; replace the CPC. Refer to OEM procedures.
2
101.2 SPN 625/FMI 4 - GHG17

ECAN Link Circuit Failure
SPN 625/FMI 4
Description Erratic Data on Engine Controller Area Network (CAN) Link
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
Note : This diagnostic is typically erratic data or the CAN propriety data link has failed between the MCM and the
3
CPC.
1. Have the Motor Control Module (MCM) and/or the Common Powertrain Controller (CPC) recently been
changed or reprogrammed?
1.a Yes; verify that the correct MCM calibration and/or the correct CPC parameter list has been installed. If
the correct calibration and correct parameter list have been installed, then Go to step 2.
Note : Poor battery grounds can be a possible cause of low battery voltage.
4. Measure the battery voltage at pin 7 on the MCM 21-pin connector. Is the battery voltage less than 10.5
volts?
4.a Yes; restore the battery voltage at pins 7, 11, 12, 14, and 15 on the MCM 21-pin connector.
5. Turn ignition OFF; leave the MCM 21-pin connector disconnected.
five ohms?
7.b No; repair the short circuit in the wires between pins 19 and 21 of the CPC connector #3 and pins 13
and 19 of the MCM 21-pin connector.
8. Measure the resistance between pin 19 of the CPC connector #3 and ground. Is the resistance greater than
five ohms?
9. Check the resistance between pin 21 of the CPC connector #3 and ground. Is the resistance greater than
five ohms?
connector.
connector.
11.b No; replace the CPC. Refer to OEM procedures.
4
101.3 SPN 625/FMI 8 - GHG17

MCM PT-CAN DM1 Message Not Received or has Stopped Arriving
SPN 625/FMI 8
Description Powertrain Controller Area Network DM1 Message Not
Received Or Has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
1. Are there any battery voltage faults present (SPN 168/FMI any)?
2. Have the Aftertreatment Control Module (ACM), Motor Control Module (MCM) or Common Powertrain
2.a Yes; verify that the correct MCM, CPC and/or ACM parameter list has been installed, then clear the
fault codes. If faults do not become active, release the vehicle. If faults become active, Go to step 3.
5
3. Turn ignition OFF and wait five minutes before proceeding. Main battery power must be left ON (the five-
minute time frame allows the ACM to go completely offline).
5. Inspect the MCM 21-pin connector for corroded, unseated (pushed out) or damaged pins, bent or spread
pins; inspect the connector seal for damage (signs of water or oil intrusion). Is damage present?
6. Measure and record the resistance across pins 13 and 19 of the MCM 21-pin connector. Is the resistance
greater than 80 ohms?
6
7. Is the resistance reading from step 6 less than five ohms?

7.a Yes; replace the PT-CAN harness.
8. Is the resistance from step 6 between 40 and 80 ohms?
10. Inspect the ACM 21–pin connector for corroded, unseated (pushed out) or damaged pins, bent or spread
of the ACM 21-pin connector. Is the resistance between 110 and 130 ohms?
7

inspect the connector seal for damage (signs of water or oil intrusion). Is damage present?
electrical connector #3, component side. Is the resistance between 110 and 130 ohms?
8

15. Measure and record the resistance between pin 19 of CPC connector #3, and pin 20 of the ACM 21-pin
connector. Is resistance less than five ohms?
15.b No; repair the wire between pin 19 of the CPC connector #3, and pin 20 of the ACM 21-pin connector.
16. Measure and record the resistance between pin 21 of the CPC connector #3, and pin 10 of the ACM 21-pin
16.b No; repair the wire between pin 21 of the CPC connector #3, and pin 10 of the ACM 21-pin connector.
17. Measure and record the resistance between pin 19 of the CPC connector #3, and pin 19 of the MCM 21-pin
9

17.b No; repair the wire between pin 19 of the CPC connector #3, and pin 19 of the MCM 21-pin connector.
18. Measure and record the resistance between pin 21 of the CPC connector #3, and pin 13 of the MCM 21-pin
18.b No; repair the wire between pin 21 of the CPC connector #3, and pin 13 of the MCM 21-pin connector.
21-pin connector. Is resistance less than five ohms?
connector.
20. Measure and record the resistance between the pin 13 of the MCM 21-pin connector and pin 10 of the
ACM 21-pin connector. Is resistance less than five ohms?
connector
10
11
22. Measure the voltage between pins 7, 11, 12, 14, and 15 of the MCM 21-pin connector (ignition/battery
voltage) and ground. Is the voltage less than 11.5 volts?
22.a Yes; restore voltage to pins 7, 11, 12, 14, and 15 of the MCM 21-pin connector.
24. Measure the resistance between pins 5, 6, 8 and 9 of the MCM 21-pin connector and the negative battery
post. Is resistance greater than five ohms?
24.a Yes; restore the battery ground to pins 5, 6, 8 and 9 of the 21-pin connector.
25. Disconnect MCM 120-pin connector and inspect connector for corrosion, or oil, fuel or water intrusion. Is
25.b No; install a test MCM. If communication is restored (fault inactive), replace the MCM. Refer to section
"Removal of the Motor Control Module" .
12
101.4 SPN 625/FMI 9 – GHG17

SPN 625/FMI 9
Description This Fault Code Sets when the Common Powertrain
Controller (CPC) Stops Receiving Messages from the
Aftertreatment Control Module (ACM)
Monitored Parameter ACM Controller Area Network (CAN) Communication
Dash Lamps MIL is Solid, CEL and AWL Flash
Engine Reaction 30 Seconds Shutdown
Verification Turn the Ignition OFF, Wait Five Minutes, then Turn the
Ignition ON
13
Possible causes:
• Over/under voltage supply to the module
• Fault set during a reprogram event
• Loss of ground to the ACM
• Loss of power to the ACM
• Loss of ignition switch power to the ACM
• Open in the CAN communication circuits
Check as follows:
2. Check for multiple fault codes. Are fault codes SPN 168/FMI any present in any of the modules?
2.a Yes; diagnose the other fault codes.
3.a Yes; clear the fault codes and Go to step 4.
4. Turn the ignition OFF, wait 5 minutes and turn the ignition back ON. Does fault code SPN 625/FMI 9
return?
14

4.b No; the fault code was set during the reprogramming event. No further diagnostics or repairs are
needed.
5. Check for MCM communication fault codes; is fault code SPN 625/FMI 9 also present in the MCM?
7. Disconnect and inspect the ACM 21-pin electrical connector, harness side. Is there any corrosion present?
7.a Yes; replace the ACM and the 21-pin electrical connector, harness side.
8. Is the connector or are any of the pins damaged?
9. Inspect the 21-pin ACM electrical connector, component side. Is the connector or are any of the pins
damaged?
9.a Yes; replace the ACM and repair the 21-pin electrical connector, harness side.
9.b No; repair the ACM 21-pin electrical connector.
10. Using the appropriate flex probe check pins 3, 5, 6, 8, 9, 10, 11, 12, 14, 15, 16, 18, and 20 in the ACM 21-
pin electrical connector, harness side. Are any of the pins spread?
10.a Yes; replace the spread pins.
11. Measure the resistance between 3, 5, 6, 8, and 9 of the 21-pin ACM connector, harness side and ground.
Are the resistances less than five ohms for each pin?
15

11.b No; repair the circuit between pins 3, 5, 6, 8, 9 and the circuit splice.
12. Measure the battery voltage directly at the batteries. Record the results.
14. Measure the voltage on pins 7, 8, 9, 10, and 11 of the ACM 21-pin connector, harness side and ground. Is
the voltage measurement on pins 7, 8, 9, 10, and 11 within one volt of the battery voltage?

14.b No; repair the circuits in question.
15. Measure the voltage between pin 18 of the ACM 21-pin electrical connector, harness side and ground. Is
the voltage within one volt of the battery voltage?
16

15.b No; repair the ignition power circuit between pin 18 of the ACM 21-pin electrical connector, harness
side, and fuse A in the Powernet Distribution Box (PNDB).
17. Measure resistance between pin 10 and pin 20 on the ACM connector, component side. Is the resistance
between 115 and 125 ohms?
17

Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module"
Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module"
18. Measure resistance between pin 10 and pin 20 on the ACM connector, harness side. Is the resistance
18


19. Disconnect and inspect the 18-pin star point electrical connector, harness side. Is there any corrosion
present?
19
19.a Yes; replace the star point assembly and repair the 18-pin electrical connector, harness side.
20. Is the connector or are pins 7 and/or 9 damaged?
20.a Yes; replace the pins.
21. Using the appropriate flex probe, check pins 3, 5, 6, 8, 10, 11, 12, 14, 15, 16, 18, and 20. Are any of the
pins spread?
21.a Yes; replace the spread pin(s).
22. Measure the resistance between pin 10 of the ACM 21-pin electrical connector, harness side, and pin 9 of
the 18-pin star point electrical connector, harness side. Is the resistance greater than five ohms?
20
22.a Yes; repair the circuit between pin 10 of the ACM 21-pin electrical connector, harness side, and pin 9
of the 18-pin star point electrical connector, harness side.
22.b No; repair the circuit between pin 20 of the ACM 21-pin electrical connector, harness side, and pin 7 of
the 18-pin star point electrical connector, harness side.
23. Disconnect and inspect the CPC #3 electrical connector, harness side. Is there any corrosion present?
21
23.a Yes; replace the CPC and the electrical connector.

22
BROWN FRONT
Looking into Pins on the Harness

25. Inspect the CPC #3 electrical connector, component side. Is the connector or are any of the pins damaged?
25.a Yes; replace the CPC and repair the electrical connector, harness side.
25.b No; repair the CPC electrical connector, harness side.
26. Using the correct flex probe check pins 19 and 21. Are the pins spread?
27. Measure the resistance between pin 19 and pin 21. Is the resistance between 115 and 125 ohms?
28. Disconnect and inspect the 18-pin star point electrical connector, harness side. Is there any corrosion
present?
23
28.a Yes; replace the star point assembly and repair the 18-pin electrical connector, harness side.
30. Using the appropriate flex probe check pins 10 and 12. Are either of the pins spread?
30.a Yes; replace the spread pin(s).
31. Measure the resistance between CPC #3 electrical connector pin 19, harness side and pin 10 of the 18-pin
star point electrical connector, harness side. Is the resistance greater than five ohms?
24
25
BROWN FRONT
Looking into Pins on the Harness
31.a Yes; repair the circuit between CPC #3 electrical connector pin 19, harness side, and pin 10 of the 18-
pin star point electrical connector, harness side.
31.b No; repair the circuit between CPC #3 electrical connector pin 21, harness side, and pin 12 of the 18-
pin star point electrical connector, harness side.
26
101.5 SPN 625/FMI 13 – GHG17

SPN 625/FMI 13
Description ECAN ID_1629 Message Not Received Or Has Stopped
Arriving
Monitored Parameter Controller Area Network (CAN) Communication
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
27
Check as follows:
1. Are there any battery voltage faults (SPN 168/FMI any faults)?
2. Are there any other SPN 625/FMI codes present?
2.a Yes; repair the other CAN communication codes first.
4. Disconnect the Common Powertrain Controller (CPC) connector #3 and inspect connector for corroded,
unseated (pushed out ), damaged, bent or spread pins; inspect the connector seal for damage (signs of
water or oil intrusion). Is contamination found?
electrical connector #3, component side. Is the resistance between 110 and 130 ohms?
28

6.b No; repair the wire short to ground between pin 19 of the CPC connector #3, harness side and pin 20
of the Aftertreatment Control Module (ACM) 21-pin connector, harness side.
7.b No; repair the wire short to ground between pin 21 of the CPC connector #3, harness side and pin 10
of the ACM 21-pin connector, harness side.
8. Disconnect Transmission Control Module (TCM) X1 21-pin connector and inspect connector for corroded,
unseated (pushed out) or damaged pins, bent or spread pins; inspect the connector seal for damage (signs
29
of water or oil intrusion). Is contamination found?

9. Measure the resistance between pin 19 of the CPC connector #3, harness side and pin 10 of the TCM X1
21-pin connector. Is the resistance less than five ohms?
9.b No; repair the wire between pin 19 of the CPC connector #3 and pin 10 of the TCM X1 21-pin
connector.
10.b No; repair the wire between pin 21 of the CPC connector #3 and pin 11 of the TCM X1 21-pin
connector.
11.b No, repair the wire between pin 20 of the CPC connector #3 and pin 7 of the TCM X1 21-pin connector.
12.a Yes, install a test CPC and retest. Go to step 13.
12.b No, repair the wire between pin 20 of the CPC connector #3 and pin 8 of the TCM X1 21-pin connector.
13. Does the code return with the test CPC?
WARNING
ENGINE EXHAUST
14. Verify repairs. Restore all connections. Idle the engine for one minute. Is fault code still active?
14.a Yes; replace the TCM. Refer to OEM procedures.
14.b No; if fault does not become active, clear the fault codes and release the vehicle.
30
101.6 SPN 625/FMI 14 - GHG17

PTCAN: MCM System ID/MCM_C01 Not Received or Stopped Arriving
SPN 625/FMI 14
Description MCM Message Not Received Or Has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
2.a Yes; verify that the correct MCM, CPC and/or ACM parameter list has been installed, then clear the
fault codes. If faults do not become active, release the vehicle; if faults become active, Go to step 3.
3. Turn ignition OFF and wait five minutes before proceeding. Main battery power must be left ON (the five-
minute time frame allows the ACM to go completely offline).
31

5. Inspect the MCM 21–pin connector for corroded, unseated (pushed out) or damaged pins, bent or spread
7. Is the resistance reading from step 6 less than five ohms?
32

8. Is the resistance from step 6 between 40 and 80 ohms?
10. Inspect the ACM 21-pin connector for corroded, unseated (pushed out) or damaged pins, bent or spread
of the ACM 21-pin connector. Is the resistance between 110 and 130 ohms?
33

inspect the connector seal for damage (signs of water or oil intrusion). Is damage present?
14. Check the CPC internal terminating resistor by measuring and recording the resistance across pins 19 and
21 of the CPC connector #3. Is the resistance between 110 and 130 ohms?

34
21-pin connector. Is resistance less than five ohms?
connector.
20. Measure and record the resistance between the pin 13 of the MCM 21-pin connector and pin 10 of the
ACM 21-pin connector. Is resistance less than five ohms?
connector
35
36
22. Measure the voltage between pins 7, 11, 12, 14, and 15 of the MCM 21-pin connector (ignition/battery
voltage) and ground. Is the voltage less than 11.5 volts?
22.a Yes; restore voltage to pins 7, 11, 12, 14, and 15 of the MCM 21-pin connector.
24. Measure the resistance between pins 5, 6, 8 and 9 of the MCM 21-pin connector and the negative battery
post. Is resistance greater than five ohms?
24.a Yes; restore the battery ground to pins, 5, 6, 8 and 9 of the MCM 21-pin connector.
25.b No; install a test MCM. If communication is restored (fault inactive), replace the MCM. Refer to section
37
100.1 SPN 625/FMI 8 - GHG17

SPN 625/FMI 8
Description DM1 Message Not Received or Has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
Go to step 3.

3. Turn ignition OFF and wait five minutes before proceeding. Main battery power must be left ON (The five-
minute timeframe allows the ACM to go completely offline).
1
6. Is the resistance reading from step 5 less than 6 ohms?
7. Is the resistance between 60 plus or minus 20 ohms?
2
of the ACM 21-pin connector. Is the resistance between 120 plus or minus 10 ohms?

21 of the CPC connector cavity #3. Is the resistance between 120 plus or minus 10 ohms?
3

12. Check for continuity between pin 19 of the CPC connector #3 and pin 20 of the ACM 21-pin connector. Is
there continuity?
4

connector.
connector.
5
6
19. Measure the voltage between pins 7, 11, 12, 14, and 15 (ignition/battery voltage) of the MCM 21-pin
connector and ground. Is the voltage less than 11.5 volts?
19.a Yes; restore voltage to MCM 21-pin connector pins 7, 11, 12, 14, and 15.
21. Measure the resistance between pins, 5, 6, 8 and 9 of the negative battery post of the MCM 21-pin
connector . Is resistance greater than three ohms?
21.a Yes; restore the battery ground to pins, 5, 6, 8 and 9 of the MCM 21-pin connector.
22.b o; install a test MCM. If communication is restored (fault inactive), replace the MCM. Refer to section
7
100.2 SPN 625/FMI 9 - GHG17

Aftertreatment Control Module PT-CAN DM1 Message Not Received or has Stopped Arriving
SPN 625/FMI 9
Description Aftertreatment Control Module (ACM) Message Not Received
or has Stopped Arriving.
Dash Lamps MIL, CEL
2. Check for multiple fault codes. Are fault codes SPN 168/ FMI present in any of the modules?
3. Has the Aftertreament Control Module (ACM), Motor Control Module (MCM) or Common Powertrain
3.a Yes; clear the fault codes and cycle the ignition. If the fault code returns, Go to step 4.
8

5. Disconnect and inspect the ACM 21-pin electrical harness connector. Are there any damaged pins or
corrosion present in the connector?
5.a Yes; repair the connector as necessary.
6. Measure the battery voltage at the batteries and record the voltage.
CAUTION
ELECTRICAL SHOCK
8. Measure the voltage between pins 11, 12, 14, 15, 18 and ground of the 21-pin ACM connector, harness
side. Is the voltage measurement on pins 11, 12, 14, 15, and 18 within one volt of the battery voltage?
FRONT LOOKING INTO PINS ON THE HARNESS

8.b No; repair the power circuits to pins 11, 12, 14, 15, and 18 of the 21-pin ACM connector.
9. Measure resistance between pins 3, 5, 6, 8, and 9 of the 21-pin ACM connector, harness side and ground.
Are the resistances less than five ohms for each pin?
9

9.b No; repair the circuit in question.
11. Measure resistance between pin 10 and pin 20 on the ACM connector, components side. Is the resistance
10

12. Measure resistance between pin 10 and pin 20 on the ACM connector, harness side. Is the resistance
11

12.b No; repair the CAN circuits to pins 10 and 20 of the ACM 21-pin connector, harness side.
12
100.3 SPN 625/FMI 17 - GHG17

This fault indicates an interruption in ACM/MCM communication.
SPN 625/FMI 17
Description Motor Control Module (MCM) Message Not Received or has
Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
2. Has the ACM, the Motor Control Module (MCM), or Common Powertrain Controller (CPC) been recently
programmed?
2.a Yes; clear the fault codes. Go to step 3.
13
Note : The five-minute timeframe allows the ACM to go completely offline.

4. Wait five minutes before proceeding.
6. After 30 seconds, is SPN 1231/FMI 9 active?
10. Inspect the MCM 21-pin harness and module connectors for signs of damage; bent, spread, broken,
corroded or unseated (pushed out) pins, signs of water, oil or fuel intrusion or damaged seals. Is damage
present?
11. Measure the resistance between pin 13 of the MCM 21-pin harness connector and battery ground. Is the
11.b No; repair the short to ground in the wire between pin 13 of the MCM 21-pin harness connector and pin
10 of the ACM 21-pin harness connector.
13. Disconnect the ACM 21-pin harness connector.
14. Inspect the ACM 21-pin harness and module connectors for signs of damage; bent, spread, moist, broken,
present?
15. Check ACM internal terminating resistor by measuring the resistance across pins 10 and 20 of the ACM 21-
pin module connector. Is the resistance between 110 and 120 ohms?
14

15.b No; replace the ACM. Refer to Original Equipment Manufacturer (OEM) procedures.
16. Disconnect the CPC harness connector #3.
17. Inspect the CPC harness and module connectors for signs of damage; bent, spread, broken, corroded or
unseated (pushed out) pins, signs of water, oil or fuel intrusion or damaged seals. Is damage present?
module connector cavity #3. Is the resistance between 110 and 130 ohms?
15

18.b No; replace the CPC. Refer to Original Equipment Manufacturer (OEM) procedures.
connector. Is the resistance less than five ohms?
19.b No; repair the wire between pin 19 of the CPC harness connector #3 and pin 20 of the ACM 21-pin
harness connector.
harness connector.
16

21.b No; repair the wire between pin 19 of the CPC harness connector #3 and pin 19 of the MCM 21-pin
harness connector.
harness connector.
24. After 30 seconds, check for an active SPN 1231/FMI 9 fault code. Is the code active?
24.b No; clear codes and release the vehicle.
17
100.4 SPN 625/FMI 18 - GHG17

SPN 625/FMI 18
Dash Lamps Derate 25%
Check as follows:
programmed?
Note : The five-minute timeframe allows the ACM to go completely offline.
18

present?
present?
19

20

harness connector.
harness connector.
21

harness connector.
harness connector.
22
103.1 SPN 628/FMI 2 - GHG17

EEPROM Checksum Failure. Replace the Common Powertrain Controller (CPC) and reprogram with the latest
software release
1
103.2 SPN 628/FMI 14 - GHG17

XFLASH Failure
Replace the Common Powertrain Controller (CPC) and reprogram with the latest software release.
2
103.3 SPN 628/FMI 17 - GHG17

Replace the Common Powertrain Controller (CPC) and reprogram with the latest software release.
3
104.1 SPN 629/FMI 2 - GHG17

SPN 629/FMI 2
Description This Code Logs when the CPC Hardware Does Not Match the
CPC Software.
Monitored Parameter CPC software
Dash Lamps CEL
Verification Key On
Check as follows:
1. Was the Common Powertrain Controller (CPC) recently replaced?
1.a Yes; the CPC hardware is not the correct one for the engine serial number and/or software
programmed onto the CPC. Replace the CPC hardware with the correct hardware. Verify repair.
2. Was the CPC recently reprogrammed?
2.a Yes; reprogram the CPC with the correct engine serial number and/or software. Verify repair.
4. Under the identification screen, make sure the CPC is programmed to the correct engine serial number
and/or software. Is the correct engine serial number and/or software programmed?
4.a Yes; replace the CPC and program with the latest software release. Verify repair.
4.b No; reprogram the CPC with the correct software. Verify repair.
1
104.2 SPN 629/FMI 12 - GHG17

SPN 629/FMI 12
Description This Code Indicates A Flash Error.
Monitored Parameter CPC Data Write Error
Dash Lamps CEL
Verification Key On
Replace the Common Powertrain Controller (CPC) and program with the latest software release. Verify repair.
2
105.1 SPN 630/FMI 13 – GHG17

SPN 630/FMI 13
Description Selective Catalytic Reduction Number Out of Range
Monitored Parameter EPROM Values
Dash Lamps CEL
Verification Key On
Note : A fault may set during Common Powertrain Controller (CPC) module reprogramming. If a fault occurs while
programming, clear the code and release the vehicle.
2. Check for multiple codes. Is CPC SPN 168/FMI 0/14/18 (battery voltage) present?
2.a Yes; troubleshoot SPN 168/FMI 0/14/18 first.
3.a Yes; troubleshoot and repair the CAN line.
4.a Yes; check the proper configuration of the CPC. Go to step 5.
5. Clear fault code SPN 630/FMI 13 and cycle the ignition. Does SPN 630/FMI 13 return?
5.a Yes; reprogram the CPC with the latest software available.
1
106.1 SPN 630/FMI 2 - GHG17

Check as follows:
1. This fault indicates there is an internal EEPROM failure in the CPC3. Replace the CPC3. After
replacement, reprogram module to latest server configuration.
1
107.1 SPN 636/FMI 1 - GHG17

Crankshaft Position Sensor Signal Voltage Too Low
SPN 636/FMI 1
Description Crankshaft Position (CKP) Sensor Signal Voltage Too Low
Monitored Parameter Crankshaft Position Sensor Signal
Typical Enabling Conditions Engine Idle
Dash Lamps MIL, CEL
Engine Reaction
Note : If the sensor is removed, be sure to check the sensor tip for metal debris and clutch material and clean it if
necessary.
1. If fault occurs only when cranking the engine (and engine will not start), check that the Crankshaft Position
(CKP) sensor and Camshaft Position (CMP) sensors are correctly wired to the Motor Control Module
(MCM).
1.a If wires are not correctly wired, repair or replace wires as required.
1.b If wires are correctly wired, Go to step 2.
2. If fault occurs at other times then when cranking the engine, check that the CKP sensor position is correct
(the sensor is seated in all the way and the tip of the sensor is clean).
2.a If fault is not active after checking CKP sensor position, repair the CKP sensor clamping sleeve.
2.b If fault is still active after checking the CKP sensor position, Go to step 3.
3. Check the flywheel position through the inspection window of the timing case using turning tool. Look for
timing marks and damage.
3.a If the flywheel is out of position, repair or replace, as required.
3.b If the flywheel is not out of position, Go to step 4.
4. Check crankshaft axial play.
4.a If axial play is not within specifications, repair or replace crankshaft thrust bearings, as required.
4.b If axial play is within specifications, replace the MCM.
1
107.2 SPN 636/FMI 2 - GHG17

SPN 636/FMI 2
Description This Code Will Set When There is a Camshaft and a
Crankshaft Mismatch Signal
Monitored Parameter Camshaft/Crankshaft Sensors
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
1. Are there any other camshaft (SPN 723/FMI Any) or crankshaft (SPN 636/FMI 3, 8, 10, or 11) faults active?
1.a Yes, repair circuit failure first. If the problem is still present after circuit repair, Go to step 2.
2. Has the engine been recently overhauled or had valve train maintenance?
2.a Yes, verify proper camshaft timing and gear lash adjustment.
Refer to section "Camshaft Timing Verification" .
Refer to section "Checking and Adjusting Gear Lash with Camshaft Housing Removed" .
3. Remove the Camshaft Position (CMP) sensor and inspect for damage. Refer to section "Removal of the Camshaft
Position Sensor" . Is there damage to the sensor?

3.b No; replace the camshaft position sensor. Refer to section "Removal of the Camshaft Position Sensor" . After
replacing the CMP sensor, verify the repair. Go to step 5.
2
4. Inspect the tone wheel on the intake camshaft for damage. Check gear train for excessive lash or damage.
Is damage present?
4.a Yes; repair as necessary, and replace the camshaft position sensor. After replacing the CMP sensor,
verify the repair and Go to step 5.
5. Connect to DiagnosticLink® and check for codes. Is SPN 636/FMI 2 active?
5.a Yes; replace the camshaft. Refer to section "Removal of the Camshafts" .
3
107.3 SPN 636/FMI 3 - GHG17

SPN 636/FMI 3
Description Crankshaft Position Sensor Open Circuit
Monitored Parameter Crankshaft Position Sensor
Dash Lamps MIL, CEL
Engine Reaction
necessary.
4
Check as follows:
1. Disconnect the Crankshaft Position (CKP) sensor.
2. Measure the resistance across pins 1 and 2 of the CKP sensor. Is the resistance between 774 ohms and
946 ohms?
2.b No; replace the CKP sensor. Refer to section "Removal of the Crankshaft Position Sensor" .
4. Measure the resistance across pins 1 and 2 of the CKP sensor harness connector. Is the resistance greater
than 10k ohms?
4.b No; repair the short between pins 1 and 2 of the CKP sensor harness connector and pins 73 and 43 of
5
5. Measure the resistance between pin 1 of the CKP sensor harness connector and pin 73 of the MCM 120-
pin connector. Is the resistance less than five ohms?
5.b No; repair the open between pin 1 of the CKP sensor harness connector and pin 73 of the 120–pin
MCM connector.
6.a Yes; replace the CKP sensor. Refer to section "Removal of the Crankshaft Position Sensor" .
6.b No; repair the open between pin 2 of the CKP sensor harness connector and pin 43 of the MCM120-
pin connector.
6
107.4 SPN 636/FMI 8 - GHG17

SPN 636/FMI 8
Description Crankshaft Position Sensor Time Out
Dash Lamps MIL, CEL
Engine Reaction
necessary.
7
Check as follows:
946 ohms?
than 10k ohms?
8
5.b No; repair the open between pin 1 of the CKP sensor harness connector and pin 73 of the MCM 120-
pin connector.
pin connector.
7. Remove the CKP sensor and ensure the sensor and tone wheel are clean and ensure the sensor is not
damaged. Is damage present?
7.a Yes; inspect debris and identify source (clutch material, flywheel material). Clean and repair as
necessary.
9
107.5 SPN 636/FMI 10 - GHG17

SPN 636/FMI 10
Description Crankshaft Position (CKP) Sensor Signal Erratic
Monitored Parameter Crankshaft Position Sensor Signal
Dash Lamps MIL
Engine Reaction
Verification Engine Idle
10
Check as follows:
946 ohms?
than 10k ohms?
pin connector.
pin connector.
7. Remove the CKP sensor and ensure the sensor and tone wheel are clean and ensure the sensor is not
damaged. Is damage present?
7.a Yes; inspect debris and identify source (clutch material, flywheel material). Clean and repair as
necessary.
11
107.6 SPN 636/FMI 11 - GHG17

Crankshaft Position Sensor - Sensor Failure
SPN 636/FMI 11
Description Crankshaft Position (CKP) Sensor Failure
Dash Lamps MIL
12
Check as follows:
1. Disconnect the CKP sensor.
2. Inspect the CKP sensor and harness side connector for signs of damage; bent, spread, broken, unseated
(pushed out) or corroded pins, signs of moisture indicating seal damage and signs of wire damage near the
946 ohms?
13
5. Inspect the 120-pin MCM and harness connectors for signs of damage; bent, spread, broken, unseated
6. Measure the resistance across pins 1 and 2 of the CKP sensor harness side connector. Is the reistance
6.b No; repair the short between pins 1 and 2 of the CKP sensor harness side connector and pins 73 and
43 of the 120-pin MCM connector. Verify repair.
7. Measure the resistance between pin 1 of the CKP sensor harness connector and pin 73 of the 120-pin
MCM connector. Is the resistance less than five ohms?
7.b No; repair the wire between pin 1 of the CKP sensor harness connector and pin 73 of the 120-pin MCM
8. Measure the resistance between pin 2 of the CKP sensor harness connector and pin 43 of the 120-pin
MCM connector. Is the resistance less than five ohms?
8.b No; repair the wire between pin 2 of the CKP sensor harness connector and pin 43 of the 120-pin MCM
9. Remove the CKP sensor and inspect tip for debris build-up or damage. Is any damage found?
9.a Yes; replace the CKP sensor. Verify repair.
10. Inspect crankshaft flywheel ring gear for wear. Is any damage found?
10.a Yes; repair as needed. Refer to section "Removal of the Ring Gear" .
10.b No; replace the CKP sensor. Verify repair.
14
107.7 SPN 636/FMI 15 - GHG17

SPN 636/FMI 15
Description This Code Will Set When a Mismatch Signal Between the
Camshaft and the Crankshaft is Detected
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
1. Are there any other camshaft (SPN 723/FMI Any) or crankshaft (SPN 636/FMI 3, 8, 10, or 11) faults active?
1.a Yes; repair circuit failure first. If the problem is still present after circuit repair, Go to step 2.
2. Has the engine been recently overhauled or had valve train maintenance?
2.a Yes; verify proper camshaft timing and gear lash adjustment.
Refer to section "Camshaft Timing Verification" .
Refer to section "Checking and Adjusting Gear Lash with Camshaft Housing Removed" .
3. Remove the Camshaft Position (CMP) sensor and inspect for damage. Refer to section "Removal of the Camshaft
Position Sensor" . Is there damage to the sensor?

15
Is damage present?
verify the repair. Go to step 5.
16
108.1 SPN 639/FMI 9 - GHG17

SPN 639/FMI 9
Description J1939 Message Missing
Monitored Parameter
Dash Lamps CEL
Verification Key ON
Check as follows:
1. Check for multiple codes. Are other communication codes present?
1.a Yes; troubleshoot those faults first. This could be an indication to which communication line is missing.
2. Determine which modules are configured for the vehicle and their communication status. Once this is done,
follow the appropriate module communication troubleshooting procedure for the affected module.
1
108.2 SPN 639/FMI 13 - GHG17

SPN 639/FMI 13
Description J1939 Fan Message Missing
Monitored Parameter
Dash Lamps CEL
Verification Key ON
Check as follows:
2. Check the CPC parameters to ensure they are correct for the vehicle configuration. Are the parameters
correct?
2.a a. Yes; replace and set parameters on the new CPC.
2.b No; reset parameters on the CPC.
2
108.3 SPN 639/FMI 14 - GHG17

SPN 639/FMI 14
Description J1939 Data Link Message Missing
Monitored Parameter
Dash Lamps CEL
Verification Key ON
Check as follows:
2. Determine which modules are configured for the vehicle and their communication status. Once this is done,
follow the appropriate module communication troubleshooting procedure for the affected module.
3
109.1 SPN 647/FMI 3 - GHG17

Fan Circuit Short to Power
SPN 647/FMI 3
Description Fan Stage 1 Circuit Failed High
Monitored Parameter Fan Control Solenoid
Dash Lamps CEL
Verification Engine Idle (one minute)
1

2. Disconnect the Original Equipment Manufacturer (OEM)10-pin harness connector.
3. Inspect the OEM 10-pin harness connector for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are signs of
damage present?
5. Connect DiagnosticLink . Clear fault codes. Does SPN 647/FMI 3 fault code become active?
6. Reconnect the vehicle OEM 10-pin harness connector.
7. Disconnect the fan control solenoid connector.
8. Inspect the fan control solenoid connector for corroded, unseated (pushed out) or damaged pins, bent or
spread pins; inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage
present?
9. Cycle ignition and clear fault codes. Does SPN 647/FMI 3 fault code become active?
9.a Yes; repair short to power between pin 2 of OEM 10-pin chassis harness side connector and pin 1 of
the fan control solenoid. Refer to OEM for wiring information. Go to step 11.
9.b No; replace the fan control solenoid. Refer to OEM procedures. Go to step 11.
10. Measure the voltage between pin 2 of the 10-pin Engine Sensor Harness side and ground. Is the voltage
greater than two volts?
10.a Yes; repair short to power on fan control circuit pin 98 of the 120-pin connector. Go to step 11.
10.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs.
11. Restore all connections. Cycle ignition and clear fault codes. Does SPN 647/FMI 3 fault code become
active?
11.a Yes; replace the MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs.
2
109.2 SPN 647/FMI 4 - GHG17

Fan Circuit Short to Ground
SPN 647/FMI 4
Description Fan Stage 1 Circuit Failed Low
Dash Lamps MIL, CEL

2. Disconnect the Original Equipment Manufacturer (OEM) 10-pin harness connector.
3
3. Inspect the harness OEM 10-pin harness connector for signs of damaged, bent, spread, corroded or
unseated (pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are
signs of damage present?
5. Connect DiagnosticLink . Clear fault codes. Does SPN 647/FMI 4 fault code become active?
7. Reconnect the vehicle OEM 10-pin harness connector.
9. Inspect the fan control solenoid connector for corroded, unseated (pushed out), damaged, bent or spread
pins; inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage present?
10. Cycle ignition and clear fault codes. Does SPN 647/FMI 4 fault code become active?
10.a Yes; repair a failed low circuit on pin 2 of the OEM 10-pin chassis harness side connector. Refer to
OEM for wiring information. Go to step 16.
10.b No; replace the fan control solenoid. Refer to OEM procedures. Go to step 16.
13. Inspect the MCM 120–pin connector for corroded, unseated (pushed out), damaged, bent or spread pins;
inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage present?
15. Connect DiagnosticLink®. Clear fault codes. Does SPN 647/FMI 4 fault code become active?
15.b No; repair a failed low circuit between pin 98 of the 120-pin connector and the 10-pin connector. Go to
step 16.
16. Restore all connections. Cycle ignition. Clear fault codes. Does SPN 647/FMI 3 fault code become active?
4
109.3 SPN 647/FMI 5 - GHG17

Fan Open Circuit
SPN 647/FMI 5
Description Fan Stage 1 Circuit Failed Open
Dash Lamps CEL
Check as follows:
5
2. Disconnect the vehicle OEM 10-pin harness connector.

3. Inspect the vehicle OEM 10-pin harness connector for corroded, unseated (pushed out), damaged, bent or
spread pins; inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage
present?
5. Inspect the MCM 120–pin connector for corroded, unseated (pushed out), damaged, bent or spread pins;
inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage present?
6. Measure the resistance between pin 98 of the MCM 120-pin engine harness side connector and the pin 2
of the OEM 10-pin engine harness side interface connector. Is the resistance less than five ohms?
6.b No; repair the open circuit on fan circuit pin 98 of the MCM 120–pin engine harness side connector to
pin 2 of the OEM 10-pin engine harness side interface connector. Go to step 12.
8. Inspect the fan control solenoid connector for corroded, unseated (pushed out), damaged, bent or spread
pins; inspect the connector seal for damage (signs of water or oil intrusion). Are signs of damage present?
9. Measure the resistance between pin 2 of the OEM 10-pin chassis harness side interface connector and the
fan control solenoid connector pin 1. Is the resistance greater than five ohms?
9.a Yes; repair the open circuit between the fan control solenoid connector and pin 2 of the OEM 10-pin
chassis harness side interface connector. Refer to Original Equipment Manufacturer (OEM)
procedures. Go to step 12.
10. Measure the resistance between pin 91 of the MCM 120-pin engine harness side connector and pin 1 of
the OEM 10-pin engine harness side interface connector. Is the resistance less than five ohms?
10.b No; repair the open circuit on fan circuit pin 91 of the MCM 120–pin engine harness side connector to
pin 1 of the OEM 10-pin engine harness side interface connector. Go to step 12.
11. Measure the resistance between pin 1 of the OEM 10-pin chassis harness side interface connector and the
fan control solenoid connector pin 2. Is the resistance greater than five ohms?
11.a Yes; repair the open circuit between the fan control solenoid connector pin 2 and pin 1 of the OEM 10-
pin chassis harness side interface connector. Refer to Original Equipment Manufacturer (OEM)
procedures. Go to step 12.
11.b No; install a new fan control solenoid. Go to step 12.
12. Restore all connections. Cycle ignition. Clear fault codes. Does SPN 647/FMI 3 fault code become active?
6
Fig 110.1, Fuel Injector Electronic Diagram
1
110.2 SPN 651/FMI 3 - GHG17

SPN 651/FMI 3
Description Injector Cylinder #1 Needle Control Valve Abnormal Operation
(MAX)
Monitored Parameter Injector Cylinder #1 Needle Control Valve
Dash Lamps MIL, CEL
Check as follows:
Note : Submit completed diagnostics with warranty claim.
Note : Injector chart PDF available on DDCSN/SUPPORT/SPECIALIZED SERVICE.
1. Check for multiple codes. Using DiagnosticLink , retain log file of active fault and clear codes (code active
for one key cycle). Is SPN 168 or 723/FMI any present?
1.a Yes; service those faults first.
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
4. Disconnect the front fuel injector harness 14-pin injector connector.
5. Inspect the front fuel injector harness 14-pin injector connectors for bent or spread pins; inspect the
connector seal for damage (signs of water or oil intrusion). Is damage present?
Note : DO NOT touch the metal ohmmeter leads with your hands when the measurements are made.
6. Using the appropriate chart below, measure and record the resistance values between the corresponding
pins on the valve cover side of the front fuel injector harness listed below. Are the resistances within range?
Front Fuel Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 1 and 2 Pins 1 and 8 Pin 2 and ground Pin 8 and ground
Injector #1 Needle 1.3 to 2.5* Greater than 100k* Greater than 100k* Greater than 100k*
* = acceptable resistance
Front Fuel Injector Harness 14-Pin Connector Resistance Chart (Using J-48671-10 Injector Breakout Box)
Note: Ensure J-48671-10 ground strap is connected to cylinder head.
3

8. Remove the front fuel injector harness from the engine.
9. Using the chart below, measure and record the resistance values between the injector pins listed below.
Are the resistances within range?
Injector Needle Resistance Chart (Injector Harness must be removed from engine)
Injector #1 Needle 2.0 or less* Greater than 100k* Greater than 100k* Greater than 100k*
9.a Yes; replace the front fuel injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness -
Two-Filter System" .
9.b No; replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector Cup - Two-
Filter System" .

11. Inspect the MCM 120-pin connector and 120-pin harness connector for signs of corrosion, spread,
unseated (pushed out) or damaged pins, connector seal for damage (signs of water or oil intrusion) or signs
of wire damage. Is damage present?
11.a Yes; verify repairs.
4
12. Using the chart below, measure and record the resistance values between the engine side of the front
valve cover 14-pin connector and the MCM 120-pin connector. Are the resistances within range?
Engine Harness Injector Circuit Resistance Table

Front Engine Side Front Engine Side Acceptable
MCM 120-Pin Acceptable
Valve Cover 14-pin Harness Connector Resistance 1 or less Valve Cover 14 pin Resistance 1K or
connector # connector # greater
1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
12.a Yes; review this procedure. Refer to section "Removal of the Motor Control Module" .
12.b No; repair the engine side harness. Verify repairs.
5
110.3 SPN 651/FMI 4 - GHG17

SPN 651/FMI 4
(MIN)
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
connector seal for damage (signs of water or oil intrusion). is damage present?
7

9.b No; replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector - Two-Filter
System" .

8

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
12.a Yes; review this procedure. If the results are accurate and consistent, replace the MCM. Refer to section
9
110.4 SPN 651/FMI 5 – GHG17

SPN 651/FMI 5
Description Injector Cylinder #1 Needle Control Valve Circuit Open
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Front Fuel Injector Harness 14-Pin Connector (Valve Cover Side) Resistance Chart
11

8. Remove the front fuel injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness - Two-Filter System" .
Are the resistance values within range?
System" .

12

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
13
110.5 SPN 651/FMI 6 - GHG17

SPN 651/FMI 6
Description Injector Cylinder #1 Needle Control Valve Shorted Circuit
Dash Lamps MIL, CEL
Check as follows:
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the front fuel injector harness 14-pin connector.
15

System" .

16

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
12.a Yes; retain log file of active fault. Replace the MCM. Refer to section "Removal of the Motor Control Module" .
17
1
111.2 SPN 652/FMI 3 - GHG17

SPN 652/FMI 3
(MAX)
Dash Lamps MIL, CEL
Check as follows:
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : Do NOT touch the metal ohmmeter leads with your hands when the measurements are made.
3

System" .

4

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
5
111.3 SPN 652/FMI 4 - GHG17

SPN 652/FMI 4
(MIN)
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Injector #1 Needle 1.3 to 2.5* Greater than100k* Greater than100k* Greater than100k*
Injector #3 Needle 1.3 to 2.5* Greater than 100k* Greater than100k* Greater than100k*
7

Injector #1 Needle 2.0 or less* Greater than 100k* Greater than100k* Greater than100k*
System" .

8
Note : DO NOT touch the metal ohmmeter leads with your hands whilen the measurements are being taken.

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
9
111.4 SPN 652/FMI 5 - GHG17

SPN 652/FMI 5
(MAX)
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5. Inspect the front fuel injector harness 14-pin injector connector for bent or spread pins; inspect the
Front Fuel Injector Harness 14-Pin Connector (Valve Cover Side) Resistance Chart
Injector #1 Needle 1.3 - 2.5* greater than100k* greater than100k* greater than100k*
11

Injector #1 Needle 2.0 or less* greater than100k* greater than100k* greater than100k*
System" .

12

Front Engine Side Front Engine Side
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Valve Cover 14-pin Valve Cover 14 pin
Connector 1 or less 1K or greater
connector # connector #
1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
13
111.5 SPN 652/FMI 6 - GHG17

SPN 652/FMI 6
Description Injector Cylinder #2 Needle Control Valve, Valve Shorted
Circuit
Dash Lamps MIL, CEL
Check as follows:
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the front rocker cover 14–pin injector harness connector.
5. Inspect the front injector harness 14–pin injector connectors for bent or spread pins. Inspect the connector
seal for damage (signs of water or oil intrusion). Is damage present?
pins on the valve cover side of the front injector harness listed below. Are the resistances within range?
Injector #3 Needle 1.3 to 2.5* Greater than 100k* Greater than100k* Greater than100k*
15

System" .

16
Note : DO NOT touch the metal ohmmeter leads with your hands whilen the measurements are being taken.
12. Using the chart below, measure and record the resistance values between the engine harness side of the
front valve cover 14-pin connector and the MCM 120-pin harness connector. Are the resistances within
range?

Front Engine Side MCM 120-Pin Acceptable Front Engine Side Acceptable
1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
17
1
112.2 SPN 653/FMI 3 -GHG17

SPN 653/FMI 3
(MAX)
Dash Lamps MIL, CEL
Check as follows:
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Injector #1 Needle 1.3 to 2.5* Greater Than 100k* Greater Than 100k* Greater Than 100k*
3

Injector #1 Needle 2.0 or less* Greater Than 100k* Greater Than 100k* Greater Than 100k*
System" .

4

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
5
112.3 SPN 653/FMI 4 - GHG17

SPN 653/FMI 4
(MIN)
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
7

System" .

8

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
9
112.4 SPN 653/FMI 5 - GHG17

SPN 653/FMI 5
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11

System" .

12

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
13
112.5 SPN 653/FMI 6 - GHG17

SPN 653/FMI 6
Dash Lamps MIL, CEL
Check as follows:
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5. Inspect the front injector harness 14–pin injector connector for bent or spread pins. Inspect the connector
seal for damage (signs of water or oil intrusion). Is damage present?
15

System" .

16

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground
17
1
113.2 SPN 654/FMI 3 - GHG17

SPN 654/FMI 3
(MAX)
Dash Lamps MIL, CEL
Check as follows:
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the rear fuel injector harness 14-pin injector connector.
5. Inspect the rear fuel injector harness 14-pin injector connector for bent or spread pins; inspect the
pins on the valve cover side of the rear fuel injector harness listed below. Are the resistances within range?
Rear Fuel Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Rear Fuel Injector Harness 14-Pin Connector Resistance Chart (Using J-48671-10 Injector Breakout Box)
3

8. Remove the rear fuel injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
9.a Yes; replace the rear fuel injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness -
System" .

4
12. Using the chart below, measure and record the resistance values between the engine side of the rear valve
cover 14-pin connector and the MCM 120-pin connector. Are the resistances within range?

Rear Engine Side Rear Engine Side Acceptable
1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
12.b No; repair the engine side harness.
5
113.3 SPN 654/FMI 4 - GHG17

SPN 654/FMI 4
(MIN)
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : DO NOT touch the metal ohmmeter leads with your hands when the measurements are taken.
7

System" .

of wire damage.
11.a If signs of damage are found, repair as necessary. Verify repairs.
11.b If no signs of damage, Go to step 12.
8
Note : DO NOT touch the metal ohmmeter leads with your hands when the measurements are taken

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
9
113.4 SPN 654/FMI 5 - GHG17

Injector Cylinder #4 Needle Control Valve Circuit Open
SPN 654/FMI 5
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11

System" .

12

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
13
113.5 SPN 654/FMI 6 - GHG17

SPN 654/FMI 6
Dash Lamps MIL, CEL
Check as follows:
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the rear rocker cover 14–pin injector harness connector.
15

8. Remove the rear fuel injector harness from the engine. Refer to section "Removal of the Fuel Injector - Two-Filter
System" .
System" .

16

Rear Engine Side MCM 120-Pin Acceptable Rear Engine Side Acceptable
1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
17
1
114.2 SPN 655/FMI 3 - GHG17

SPN 655/FMI 3
(MAX)
Dash Lamps MIL, CEL
Check as follows:
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3

System" .

4

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
5
114.3 SPN 655/FMI 4 - GHG17

SPN 655/FMI 4
(MIN)
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : DO NOT touch the metal ohmmeter leads with your hands when the measurements are taken
7

System" .

8

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
9
114.4 SPN 655/FMI 5 - GHG17

SPN 655/FMI 5
Monitored Parameter Injector Cylinder #5 Needle Control
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11

System" .

12


Rear Engine Side MCM 120-Pin Acceptable Rear Engine Side Acceptable
1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
13
114.5 SPN 655/FMI 6 - GHG17

SPN 655/FMI 6
Dash Lamps MIL, CEL
Check as follows:
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the rear rocker cover 14-pin injector harness connector.
15

System" .

16

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
17
1
115.2 SPN 656/FMI 3 - GHG17

SPN 656/FMI 3
(MAX)
Dash Lamps MIL, CEL
Check as follows:
2
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the rear fuel injector harness 14-pin connector.
5. Inspect the rear fuel injector harness 14-pin injector connectors for bent or spread pins; inspect the
3

System" .

4

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
5
115.3 SPN 656/FMI 4 - GHG17

SPN 656/FMI 4
(MIN)
Typical Enabling Conditions Engine RPM = idle or higher
Dash Lamps MIL, CEL
Check as follows:
6
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
7

System" .

of wire damage.
8

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
9
115.4 SPN 656/FMI 5 - GHG17

SPN 656/FMI 5
Dash Lamps MIL, CEL
Check as follows:
10
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11

System" .

12

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
13
115.5 SPN 656/FMI 6 - GHG17

SPN 656/FMI 6
Dash Lamps MIL, CEL
Check as follows:
1.b No; If SPN fault code 168 or 723/FMI any is NOT present, Go to step 2.
14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
15

System" .

16

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground
17
116.1 SPN 667/FMI 3 - GHG17

SPN 667/FMI 3
Description Short to Power on Pin 18 of the CPC Connector #1
Monitored Parameter Run Start
Dash Lamps None
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2.b No; repair a short to Power on pin 18 of the CPC Connector #1 circuit. For wiring schematic
information, refer to Original Equipment Manufacturer (OEM) literature.
1
117.1 SPN 677/FMI 2 - GHG17

Starter Switch Inconsistent
SPN 677/FMI 2
Description This Fault Code Sets When the Motor Control Module (MCM)
Sees that the Starter Ignition Status from the Common
Powertrain Controller (CPC) and MCM Do Not Match.
Monitored Parameter Starter Voltage Signal
Typical Enabling Conditions Engine Start
Dash Lamps CEL
Verification Engine Start
2. Erase fault code SPN 677/FMI 2.
1
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Check the fault codes. Does SPN 677/FMI 2 become active?
4.b No; the fault may have been caused by a previous low voltage concern. No further diagnostics or
repairs are needed.
6. Turn the ignition ON (key ON, engine OFF) and reconnect DiagnosticLink.
7. In the left side menu, select Instrumentations and select chart view in the top menu. Load the following
monitors:
• DSL: Starter Signal CPC
• ADS: MCM (wired) Starter Signal Status
• ASL: Actual Engine Speed
• B4B Output Starter Relay Status
2
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Monitor the DSL: Starter Signal CPC and the B4B Output Starter Relay status, then start the engine. Does
the DSL: Starter Signal CPC status change from "Value: off (Open)" to "Value: on (shorted to battery)"
when the B4B Output Starter Relay status changes from "Value: OFF" to "Value: ON"?
Note : It is normal for the ADS: MCM (wired) Starter Signal Status to remain on longer than the DSL: Starter
Signal CPC and B4B Output Starter Relay status.
3
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
11. Monitor the ADS: MCM (wired) Starter Signal Status and the B4B Output Starter Relay status, then start
the engine. Does the ADS: MCM (wired) Starter Signal Status change from "Value: off/disabled/false" to
"Value: on/enabled/true when the B4B Output Starter Relay status changes from "Value: OFF" to "Value:
ON"?
13. Program and install a test CPC.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

16. Does fault code SPN 677/FMI 2 become active?
16.a Yes; replace the MCM.
17. Disconnect and inspect the CPC #1 electrical connector harness side. Is there corrosion present?
17.a Yes; replace the CPC and the electrical connector.
18. Is the connector or pin 18 damaged?
19. Inspect the CPC #1 electrical connector component side. Is the connector or pin 18 damaged?
19.a Yes; replace the CPC and repair the electrical connector.
4
19.b No; repair/replace the CPC electrical connector and/or pin 18.
20. Using the appropriate probe tool, check pin 18 of the CPC #1 electrical connector. Is pin 18 spread?
20.a Yes; replace pin 18 in the CPC #1 electrical connector.
21. Measure the voltage on pin 18 when the ignition is turned ON (key ON, engine OFF). Is the voltage on pin
18 greater than 10.5 volts?
21.b No; repair the circuit between pin 18 of the #1 CPC electrical connector and the circuit splice.
22. Disconnect and inspect the MCM 21-pin electrical connector. Is there any corrosion present?
22.a Yes; replace the MCM and repair the 21-pin electrical connector.
damaged?
24.a Yes; replace the MCM and the 21-pin electrical connector.
24.b No; repair the MCM 21-pin electrical connector.
25. Use the appropriate flex probe to check pin 20 in the MCM 21-pin electrical connector. Is pin 20 spread?
25.a Yes; replace pin 20 in the MCM 21-pin electrical connector harness side. Verify repair.
26. Measure the voltage on pin 20 of the MCM 21-pin electrical connector harness side when the ignition is
turned ON (key ON, engine OFF). Is the voltage on pin 20 greater than 10.5 volts?
26.b No; repair the circuit between pin 20 of the MCM 21-pin electrical connector and the circuit splice.
5
117.2 SPN 677/FMI 3 - GHG17

Engine Starter Relay Shorted to High Source
NOTICE
Ignition must be off for at least 30 seconds before performing this test.
1. Turn ignition OFF for 30 seconds.

4. Measure the voltage between pin 12 of the MCM 21-pin connector and ground.
4.a If voltage is present, repair short to power on pin 12 of the MCM 21-pin connector; refer to Original
Equipment Manufacturer (OEM) manual for wiring diagram.
4.b If no voltage is present, replace the starter relay.
6
117.3 SPN 677/FMI 4 - GHG17

Engine Starter Relay Circuit Failed Low
2. Remove the engine starter relay.
Note : Refer to Original Equipment Manufacturer (OEM) wiring schematic for correct pin location for the engine
starter relay.
3. Measure the resistance between pin 21 of the MCM 21–pin connector and the engine starter relay.
3.a If the resistance is greater than 3 ohms, repair open between pin 21 of the MCM 21–pin connector and
the engine starter relay.
3.b If the resistance is less than 3 ohms, replace the engine starter relay. Refer to OEM procedures.
7
117.4 SPN 677/FMI 7 - GHG17

Engine Starter Relay Jammed
Note : Ignition must be off for at least 30 seconds before performing this test.
1. Turn ignition OFF for 30 seconds.
4.a If voltage is present, repair short to power on pin 21 of the MCM 21-pin connector (refer to OEM
manual for wiring diagram).
4.b If no voltage is present, replace the starter relay. Refer to OEM procedures.
8
118.1 SPN 701/FMI 3 - GHG17

SPN 701/FMI 3
Description Output 3/07 Circuit Short to Power
Monitored Parameter Pin 7 of the CPC #3 Connector
Dash Lamps CEL
1. Turn the ignition ON (Key ON, engine OFF).
3. Verify parameters - go to the parameters work window.
4. Verify that the parameters in PGR035 digital outputs are set to the specific component to which this is
configured (example: grid heater).
5. Are the parameters configured correctly?
5.b No; configure the parameters properly.
6. Fix the short to power on pin 7 circuit of the CPC #3 connector. For wiring schematic information, refer to
Original Equipment Manufacturer (OEM) literature.
1
118.2 SPN 701/FMI 4 - GHG17

Digital Output 3/07 Circuit Failed Low
SPN 701/FMI 4
Description Output 3/07 Circuit Short to Ground
Dash Lamps CEL
3. Verify parameters – go to the parameters work window.
6. Fix the short to ground on pin 7 circuit of the CPC #3 connector. For wiring schematic information, refer to
2
118.3 SPN 701/FMI 5 - GHG17

SPN 701/FMI 5
Description Output 3/07 Open Circuit
Dash Lamps CEL
6. Fix the open circuit on pin 7 circuit of the CPC #3 connector. For wiring schematic information, refer to
3
119.1 SPN 702/FMI 3 - GHG17

SPN 702/FMI 3
Description CPC Output 3 08 Short to Voltage
Monitored Parameter CPC Output 3/8
Dash Lamps CEL
Verification Engine On With Output Activation
Check as follows:
1. Has the Common Powertrain Controller (CPC) recently been changed or reprogrammed?
1.a Yes; verify that the correct CPC parameter list has been installed. If the correct calibration and correct
parameter list have been installed, then Go to step 2.
3. Under parameter, identify the parameter set to 3 08 DO Selection. Based on the parameter selected repair
the short to power between pin 8 of the CPC connector #3 and the OEM component. Refer to Original
Equipment Manufacturer (OEM) literature for wiring schematic information.
1
119.2 SPN 702/FMI 4 - GHG17

SPN 702/FMI 4
Description CPC Output 3 08 Short to Ground
Dash Lamps CEL
the short to ground between pin 8 of the CPC connector #3 and the OEM component. Refer to Original
2
119.3 SPN 702/FMI 5 - GHG17

SPN 702/FMI 5
Description CPC Output 3 08 Open Circuit
Dash Lamps CEL
the open circuit between pin 8 of the CPC connector #3 and the OEM component. Refer to Original
3
120.1 SPN 703/FMI 3 - GHG17

Digital Output 3 09 - Short to Power/open Circuit on Pin 9 of the Common Powertrain Controller #3 Connector
2. Connect to DiagnosticLink.
configured (example: optimized idle active lamp).
6. Fix the short to power / open on pin 9 circuit of the CPC #3 connector. For wiring schematic information,
refer to Original Equipment Manufacturer (OEM) literature.
1
120.2 SPN 703/FMI 4 - GHG17

Digital Output 3 09 – Short to Ground on Pin 9 Circuit of the Common Powertrain Controller #3 Connector
Note : The CPC digital outputs have the same SPN as some Motor Control Module (MCM) faults. DiagnosticLink®
makes the distinction between the MCM and CPC when diagnosing a fault.
configured (example: optimized idle active lamp).
6. Fix the short to ground on pin 9 circuit of the CPC #3 connector. For wiring schematic information, refer to
2
120.3 SPN 703/FMI 5 - GHG17

Water-in-Fuel (WIF) Sensor Indicates an Open Circuit in the Wiring to Pin 09 of the CPC #3 Connector
For wiring schematic information refer to Original Equipment Manufacturer (OEM) literature.
NOTICE
The Common Powertrain Controller (CPC) digital outputs have the same SPN as some
Motor Control Module (MCM) faults. DiagnosticLink® Standard makes the distinction
between the MCM and CPC when diagnosing a fault.
3
121.1 SPN 704/FMI 3 - GHG17

SPN 704/FMI 3
Dash Lamps CEL
Verification Engine On with Output Activation
WARNING
ENGINE EXHAUST
1
3. Verify parameters by going to the parameters work window.

4. Verify that the parameter set to 4 07 DO Selection is set to the specific component to which this is
configured. Are the parameters configured correctly?
4.a Yes; repair the short to power between pin 7 of the CPC connector #4 and the wired component. For
wiring schematic information, refer to Original Equipment Manufacturer (OEM) literature.
4.b No; configure the parameters correctly.
2
121.2 SPN 704/FMI 4 - GHG17

SPN 704/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4.a Yes; repair the short to ground between pin 7 of the CPC connector #4 and the wired component. For
4
121.3 SPN 704/FMI 5 - GHG17

SPN 704/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5

4.a Yes; repair the open circuit between pin 7 of the CPC connector #4 and the wired component. For
6
122.1 SPN 705/FMI 3 - GHG17

SPN 705/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
122.2 SPN 705/FMI 4 - GHG17

SPN 705/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
122.3 SPN 705/FMI 5 - GHG17

SPN 705/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5

6
123.1 SPN 705/FMI 3 - GHG17

Malfunction Indicator Lamp Indicates a Short to Power/open Circuit on Pin 13 of the Common Powertrain
Controller #1 Connector
For wiring schematic information, refer to Original Equipment Manufacturer (OEM) literature.
Module (MCM) faults. DiagnosticLink® Standard makes the distinction between the MCM and CPC when
diagnosing a fault.
1
124.1 SPN 706/FMI 3 - GHG17

SPN 706/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
124.2 SPN 706/FMI 4 - GHG17

SPN 706/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
124.3 SPN 706/FMI 5 - GHG17

SPN 706/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5

6
125.1 SPN 707/FMI 3 - GHG17

SPN 707/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
125.2 SPN 707/FMI 4 - GHG17

SPN 707/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
125.3 SPN 707/FMI 5 - GHG17

SPN 707/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5

6
126.1 SPN 708/FMI 3 - GHG17

SPN 708/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
126.2 SPN 708/FMI 4 - GHG17

SPN 708/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
126.3 SPN 708/FMI 5 - GHG17

SPN 708/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5

6
127.1 SPN 709/FMI 3 - GHG17

SPN 709/FMI 3
Dash Lamps CEL
Check as follows:
1.a a. Yes; verify that the correct CPC parameter list has been installed. If the correct calibration and
correct parameter list have been installed, then Go to step 2.

1
4.a Yes; Repair the short to power between pin 16 of the CPC connector #3 and the wired component. For
2
127.2 SPN 709/FMI 4 - GHG17

SPN 709/FMI 4
Dash Lamps CEL
Check as follows:

4.a Yes; Repair the short to ground between pin 16 of the CPC connector #3 and the wired component.
3
4
127.3 SPN 709/FMI 5 - GHG17

SPN 709/FMI 5
Dash Lamps CEL
Check as follows:

4.a Yes; Repair the open circuit between pin 16 of the CPC connector #3 and the wired component. For
5
6
128.1 SPN 710/FMI 3 - GHG17

Digital Output 4 06 Circuit Failed High
SPN 710/FMI 3
Dash Lamps CEL
Check as follows:
1
2
128.2 SPN 710/FMI 4 - GHG17

Digital Output 4 06 Circuit Failed Low
SPN 710/FMI 4
Dash Lamps CEL
Check as follows:

3
4.a Yes; Repair the short to ground between pin 6 of the CPC connector #4 and the wired component. For
4
128.3 SPN 710/FMI 5 - GHG17

SPN 710/FMI 5
Dash Lamps CEL
Check as follows:

5
6
129.1 SPN 710/FMI 3 - GHG17

diagnosing a fault.
Wait to Start (WTS) Lamp - indicates a short to power/open circuit on pin 6 of the CPC #4 connector. For wiring
schematic information refer to Original Equipment Manufacturer (OEM) literature.
1
129.2 SPN 710/FMI 4 - GHG17

diagnosing a fault.
Wait to Start (WTS) Lamp - indicates a short to power/open circuit on pin 6 of the CPC #4 connector. For wiring
schematic information refer to Original Equipment Manufacturer (OEM) literature.
2
130.1 SPN 711/FMI 3 - GHG17

SPN 711/FMI 3
Dash Lamps CEL
Check as follows:
WARNING
ENGINE EXHAUST
1

2
130.2 SPN 711/FMI 4 - GHG17

SPN 711/FMI 4
Dash Lamps CEL
Check as follows:
WARNING
ENGINE EXHAUST
3

4
130.3 SPN 711/FMI 5 - GHG17

SPN 711/FMI 5
Dash Lamps CEL
Check as follows:
WARNING
ENGINE EXHAUST
5

6
131.1 SPN 712/FMI 3 - GHG17

SPN 712/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1.a Yes; program the CPC to the correct settings.
1.b No; repair the short to power between pin 4 of the CPC connector #1 and the idle validation
switch/analog accelerator pedal. For wiring schematic information, refer to Original Equipment
Manufacturer (OEM) literature.
1
131.2 SPN 712/FMI 4 - GHG17

SPN 712/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1.b No; repair the short to ground between pin 4 of the CPC connector #1 and the idle validation
2
131.3 SPN 712/FMI 5 - GHG17

SPN 712/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1.b No; repair the short to power between pin 4 of the CPC connector #1 and the idle validation
3
132.1 SPN 713/FMI 7 - GHG17

SPN 713/FMI 7
Description This Code is Used for Top2 Output Failure. If the Vehicle is
Not Equipped With a Top2 Transmission, This Code Should
Not Be Turned On
Dash Lamps CEL
Verification Key On, Engine OFF with Output Activation

3. Check for multiple codes. Are SPN 701/FMI any also present?
4. Verify that the parameters in PGR035 digital outputs are set to the specific component to which this vehicle
is configured. Are the parameters configured correctly?
1
4.a Yes; replace the Common Powertrain Controller (CPC) and reprogram with the latest software release.
2
133.1 SPN 714/FMI 3 – GHG17

SPN 714/FMI 3
Dash Lamps CEL
Check as follows:

1
2
133.2 SPN 714/FMI 4 - GHG17

SPN 714/FMI 4
Dash Lamps CEL
Check as follows:

3
4
133.3 SPN 714/FMI 5 - GHG17

SPN 714/FMI 5
Dash Lamps CEL
Check as follows:

5
6
134.1 SPN 715/FMI 3 - GHG17

SPN 715/FMI 3
Monitored Parameter Vehicle Speed Output
Dash Lamps CEL
This fault indicates a short to power on the pin 12 circuit of the Common Powertrain Controller (CPC) #4
connector.
Repair the short to power between pin 12 of the CPC connector #4 and the wired component. For wiring
schematic information, refer to Original Equipment Manufacturer (OEM) literature.
1
134.2 SPN 715/FMI 4 - GHG17

SPN 715/FMI 4
Dash Lamps CEL
This fault indicates a short to ground on the pin 12 circuit of the Common Powertrain Controller (CPC) #4
connector.
Repair the short to ground between pin 12 of the CPC connector #4 and the wired component. For wiring
2
134.3 SPN 715/FMI 5 - GHG17

SPN 715/FMI 5
Dash Lamps CEL
This fault indicates an open circuit on the pin 12 circuit of the Common Powertrain Controller #4 connector.
Repair the open circuit between pin 12 of the CPC connector #4 and the wired component. For wiring schematic
3
135.1 SPN 716/FMI 3 - GHG17

SPN 716/FMI 3
Monitored Parameter Tachometer
Dash Lamps CEL
Verification Engine On
WARNING
ENGINE EXHAUST
This fault indicates a short to power on Pin 9 circuit of the Common Powertrain Controller #1 Connector.
Repair the short to power between pin 9 of the CPC connector #1 and the wired component. For wiring schematic
1
135.2 SPN 716/FMI 4 - GHG17

SPN 716/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
This fault indicates a short to ground on Pin 9 circuit of the Common Powertrain Controller #1 Connector.
2
135.3 SPN 716/FMI 5 - GHG17

Digital Output 1 09 Circuit Open
SPN 716/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
This fault indicates an open circuit on Pin 9 circuit of the Common Powertrain Controller #1 Connector.
3
136.1 SPN 723/FMI 8 - GHG17

SPN 723/FMI 8
Does Not Receive a Signal from the Camshaft Position
Sensor
Monitored Parameter Camshaft Position
Typical Enabling Conditions Engine Running
Monitor Sequence Always
Dash Lamps MIL, CEL, SEL
Engine Reaction 25% Derate and Engine Shutdown after 20 Seconds
Verification Engine Running for One Minute
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1
Check as follows:
1. Use DiagnosticLink Standard to insure that cranking speed is over 150 rpm. Is cranking speed over 150
rpm?
1.b No; determine the cause of low crank speed.
3. Disconnect the Camshaft Position (CMP) sensor electrical harness connector.
4. Inspect the CMP sensor and harness connector for signs of damage: bent, spread, broken, unseated
(pushed out) or corroded pins, signs of moisture indicating seal damage, and signs of wire damage near
the connector. Is damage present?
6. Measure the voltage between pins 1 and 3 on the harness side of the CMP sensor. Is the voltage between
4.5 and 5.5 volts?
7. Measure the voltage between pin 1 of the CMP sensor harness connector and battery ground. Is the
7.a Yes; repair the wire between pin 3 of the CMP harness connector and pin 48 of the Motor Control
Module (MCM) 120-pin connector.
7.b No; repair the wire between pin 1 of the CMP harness connector and pin 82 of the MCM 120-pin
connector.
10. Inspect the MCM 120-pin module and harness connector for signs of damage: bent, spread, broken,
unseated (pushed out) or corroded pins, signs of moisture indicating seal damage and signs of wire
2

11. Measure the resistance between pin 2 of the CMP harness connector and pin 45 of the MCM 120-pin
connector.
12. Measure the resistance between pin 2 of the CMP harness connector and battery ground. Is resistance
12.b No; repair the shorted wire between pin 2 of the CMP harness connector and pin 45 of the MCM 120-
pin connector.
13. Measure the resistance between pins 1 and 2 of the CMP harness connector. Is resistance greater than
10K ohms?
13.b No; repair the shorted wire between pins 1 and 2 of the CMP harness connector and pins 82 and 45 of
10K ohms?
15. Has the engine had any gear train, camshaft, or flywheel repairs made?
15.a Yes; verify proper gear train timing and proper flywheel installation. Refer to section "Camshaft Timing
Verification" .

16. Remove the CMP sensor and inspect for damage. Refer to section "Removal of the Camshaft Position Sensor" . Is
there damage to the sensor?
replacing the CMP sensor, verify the repair and Go to step 18.
Is damage present?
verify the repair and Go to step 18.
WARNING
PERSONAL INJURY
3
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
18. Connect to DiagnosticLink, start the engine and check for codes. Is SPN 723/FMI 8 active?
4
136.2 SPN 723/FMI 10 - GHG17

SPN 723/FMI 10
Description This Code Sets when the Camshaft Position (CMP) Sensor
Signal is Erratic
Monitored Parameter Camshaft Position Sensor Signal
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
1. Use DiagnosticLink to insure that cranking speed is over 150 rpm. Is cranking speed over 150 rpm?
2. Disconnect the CMP sensor harness connector.
5. Measure the voltage between pins 1 and 3 on the harness side of the camshaft position sensor. Is the
voltage greater than 4.5 volts?
5
6. Measure the voltage between pins 2 and 3 on the harness side of the CMP sensor. Is the voltage less than
4.5 volts?
6.a Yes; repair the wire between pin 2 of the harness side of the CMP sensor and pin 45 of the MCM 120-
pin connector.
7. Measure the voltage between pin 1 on the harness side of the CMP sensor and engine ground. Is the
voltage less than 4.5 volts?
7.a Yes; repair the wire between pin 1 of the harness side of the CMP sensor and pin 82 of the MCM 120-
pin connector.
7.b No; repair the wire between pin 2 of the harness side of the CMP sensor and pin 45 of the MCM 120-
pin connector.
Verification" .

Is damage present?
6
136.3 SPN 723/FMI 11 - GHG17

SPN 723/FMI 11
Description This Code Sets When the Camshaft Position (CMP) Sensor
Signal is Disrupted
Monitored Parameter Camshaft Position Sensor
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7
Check as follows:
3. Disconnect the CMP sensor harness connector.
4. Inspect the CMP sensor and harness connectors for signs of damage: bent, spread, broken, unseated
6. Measure the voltage between pins 1 and 3 on the harness side of the CMP sensor. Is the voltage between
4.5 and 5.5 volts?
7. Measure the voltage between pin 1 of the CMP sensor harness connector and battery ground. Is the
7.a Yes; repair the wire between pin 3 of the CMP harness connector and pin 48 of the Motor Control
connector.
10. Inspect the MCM 120-pin module and harness connectors for signs of damage: bent, spread, broken,
unseated (pushed out) or corroded pins, signs of moisture indicating seal damage and signs of wire
8

11. Measure the resistance between pin 2 of the CMP harness connector and pin 45 of the MCM 120-pin
connector. Is resistance less thanfiveohms?
connector.
12. Measure the resistance between pin 2 of the CMP harness connector and battery ground. Is resistance
12.b No; repair the shorted wire between pin 2 of the CMP harness connector and pin 45 of the MCM 120-
pin connector.
10K ohms?
10K ohms?
Verification" .

Is damage present?
18. Connect to DiagnosticLink and check for codes. Is SPN 723/FMI 11 active?
9
136.4 SPN 723/FMI 31 - GHG17

This may be due to an engine temporarily running in a reverse direction. Symptoms include smoke exiting from
intake manifold and a low idle speed, possibly due to a leaky injector.
SPN 723/FMI 31
Description This Code Sets When There is No Match of Camshaft and
Crankshaft Signals
Monitored Parameter Camshaft Reverse Direction Rising Edge Signal
Typical Enabling Conditions Engine State and Low Idle and Camshaft Reverse Direction
Error
Dash Lamps MIL, CEL
Engine Reaction Derate 25%, Shutdown Priority
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
NOTICE
A reverse rotation of the engine will temporarily affect oil pump output. Oil pressure must
be checked after engine starts. Possible bearing damage may exist.
1. Connect to DiagnosticLink . Check for other fault codes. Are there any SPN 723/FMI 8, 10, or 11 present?
2. Inspect the Exhaust Gas Recirculation (EGR) hot pipe for fuel, coolant, or oil.
10
3. Is fuel present in the EGR hot pipe?
(OEM) specifications. Repair as necessary.

7. Are there any Camshaft Position (CMP) sensor SPN 723/FMI Any, Crankshaft Position (CKP) sensor SPN
636/FMI Any, or oil pressure SPN 100/FMI Any faults present?
8. Are there any throttle pedal or idle validation switch faults present?
9. Perform an Idle Speed Balance (ISB) test. Are any faulty fuel injectors identified?
9.a Yes; replace suspect fuel injector(s).
Verification" .

Is damage present?
15. Connect to DiagnosticLink and check for codes. Is SPN 723/FMI 31 active?
11
137.1 SPN 748/FMI 12 - GHG17

Check as follows:
1. This fault indicates the Central Gateway is configured incorrectly. Reprogram Central Gateway to Original
Equipment Manufacturer (OEM) configuration. Retarder Control Module (RCM) is not available in the
NAFTA market. The CGW04T Monitor parameter ECU05 needs to be set to "RCM Not Installed".
1
138.1 SPN 904/FMI 9 - GHG17

J1939 Engine Brake Controller (EBC2) Message from the Anti-Lock Brake System (ABS) is Missing
This fault code indicates a missing message from the ABS module. Refer to Original Equipment Manufacturer
(OEM) material for J1939 troubleshooting for the ABS module.
1
138.2 SPN 904/FMI 13 - GHG17

Front Axle Speed Signal is Missing
1.a If Common Powertrain Controller (CPC) SPN 168/FMI 0/14/18 (battery voltage) are present
troubleshoot these first.
1.b If Motor Control Module (MCM) SPN 625/FMI 9 is present, troubleshoot and repair the Controller Area
Network (CAN) line.
1.c If only a J1939 Error fault is present, Go to step 2.
2.a If yes, check the proper configuration of the CPC.
2.b If no, connect ServiceLink to determine which modules are configured for the vehicle and their
2
138.3 SPN 904/FMI 19 - GHG17

Front Axle Speed Signal is Erratic
Network (CAN) line.
3
139.1 SPN 924/FMI 3 - GHG17

SPN 924/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1

2
139.2 SPN 924/FMI 4 - GHG17

SPN 924/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
3

4
139.3 SPN 924/FMI 5 - GHG17

Digital Output 4 09 Circuit Open
SPN 924/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
5

6
140.1 SPN 925/FMI 3 – GHG17

SPN 925/FMI 3
Monitored Parameter CPC output 3/17
Dash Lamps CEL
Verification Engine On with output activation
WARNING
ENGINE EXHAUST
Check as follows:
1

2
140.2 SPN 925/FMI 4 – GHG17

SPN 925/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
3

4.a Yes; Repair the short to ground between pin 17 of the CPC connector #3 and the wired component.
4
140.3 SPN 925/FMI 5 – GHG17

SPN 925/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
5

6
141.1 SPN 926/FMI 3 – GHG17

SPN 926/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
141.2 SPN 926/FMI 4 – GHG17

SPN 926/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4.a Yes; repair the short to ground between CPC connector #4 pin 01 and the wired component. For wiring
4
141.3 SPN 926/FMI 5 – GHG17

SPN 926/FMI 5
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5

6
142.1 SPN 961/ FMI 2 - GHG17

SPN 961/FMI 2
Description Clock Data Invalid
Monitored Parameter CPC Real-time Clock
Dash Lamps CEL
Verification Ignition ON
Check as follows:
2. Clear code SPN 961/FMI 2 and power down for 30 seconds.
3. Reconnect to DiagnosticLink.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Start and run the engine for 20 seconds.

5. Check for codes. Is SPN 961/FMI 2 active?
1
143.1 SPN 970/FMI 3 - GHG17

Engine Aux. Shutdown Input Failed High
SPN 970/FMI 3
Description Aux Shutdown Switch Short to Voltage or Open
Monitored Parameter Pin 3/1 Status Bit
Dash Lamps CEL
Check as follows:
2. Disconnect the Aux Shutdown switch. For wiring schematic information, refer to Original Equipment
3. Inspect the Aux Shutdown switch harness connector for signs of damaged, bent, spread, corroded or
any signs of damage present?
1

5. Measure the voltage between pin C of the Aux Shutdown switch harness connector and ground. For wiring
schematic information , refer to Original Equipment Manufacturer (OEM) literature. Is the voltage less than
0.5 volts?
5.b No; repair the short to voltage between pin C of the Aux Shutdown switch harness connector and pin 2
of the CPC connector #3. Verify repairs.
6. Measure the voltage between pin A of the Aux Shutdown switch harness connector and ground. For wiring
schematic information, refer to Original Equipment Manufacturer (OEM) literature. Is the voltage less than
0.5 volts?
6.a Yes; repair the open between pin A of the Aux Shutdown switch harness connector and pin 3 of the
CPC connector #3 .Verify repairs.
7. Measure the voltage between pin B of the Aux Shutdown switch harness connector and ground. For wiring
schematic information,refer to Original Equipment Manufacturer (OEM) literature. Is the voltage less than
0.5 volts?
7.b No; repair the short to voltage between pin B of the Aux Shutdown switch harness connector and pin 1
of the CPC connector #3 . Verify repairs.
2
8. Disconnect the 21-pin CPC connector #3.

9. Inspect the CPC harness connector for signs of damaged, bent, spread, corroded or unseated (pushed out)
pins and signs of moisture in the connector or wire damage near the connector. Are any signs of damage
present?
10. Measure the resistance between pin C of the Aux Shutdown switch harness connector and pin 2 of the
CPC harness connector #3 . For wiring schematic information, refer to Original Equipment Manufacturer
(OEM) literature. Is the resistance less than five ohms?
10.b No; repair the open in the wiring harness between pin C of the Aux Shutdown switch harness side
connector and pin 2 of the CPC connector #3. Verify repairs.
11. Measure the resistance between pin B of the Aux Shutdown switch harness connector and pin 1 of the
CPC harness connector #3. For wiring schematic information, refer to Original Equipment Manufacturer
(OEM) literature. Is the resistance less than five ohms?
3
11.a Yes; replace the Aux Shutdown switch. Refer to Original Equipment Manufacturer (OEM) literature.
11.b No; repair the open in the wiring harness between pin B of the Aux Shutdown switch harness side
connector and pin 1 of the CPC connector #3. Verify repairs.
4
143.2 SPN 970/FMI 4 - GHG17

SPN 970/FMI 4
Description Aux Shutdown Switch Short Ground
Monitored Parameter Pin 3/1 Status Bit
Dash Lamps CEL
Check as follows:
2. Disconnect the Aux Shutdown switch. Refer to Original Equipment Manufacturer (OEM) literature for wiring
3. Inspect the Aux Shutdown switch harness connector for signs of damaged, bent, spread, corroded or
any signs of damage present?
4. Measure the resistance between pin B of the Aux Shutdown switch connector harness side and ground.
For wiring schematic information, refer to Original Equipment Manufacturer (OEM) literature. Is the
5

4.b No; repair the short to ground between pin B of the Aux Shutdown switch connector harness side and
pin 1 of the CPC connector #3 harness side. Verify repairs.
5. Measure the resistance between pin A of the Aux Shutdown switch connector harness side and ground.
For wiring schematic information, refer to Original Equipment Manufacturer (OEM) literature. Is the
5.b No; repair the short to ground between pin A of the Aux Shutdown switch connector harness side and
pin 3 of the CPC connector #3 harness side. Verify repairs .
6. With the Aux Shutdown switch still disconnected , clear code SPN 970/FMI 4. Turn the ignition OFF, wait
five minutes , and turn the ignition back ON. Does fault code SPN 970/FMI 4 return?
6.a Yes; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature. Verify repairs.
6.b No; replace the Aux Shutdown switch. Refer to Original Equipment Manufacturer (OEM) literature.
6
144.1 SPN 972/FMI 2 - GHG17

SPN 972/FMI 2
Description Throttle Inhibit Switch Signal Not Plausible
Monitored Parameter Throttle Inhibit
Dash Lamps CEL
Verification Key On
present?
1.a Yes; troubleshoot SPN 168/FMI 0/14/18 first.
4. Turn the ignition on (key ON, engine OFF).
5. Does SPN 972/FMI 2 return?
6. Disconnect and inspect the throttle inhibit switch harness connector for bent, spread or corroded pins.
6.b If no pin damage is found, clear fault and retest with switch disconnected. Go to step 7.
7. Does SPN 972/FMI 2 remain active?
7.a Yes; repair short circuit on pin 17 of the CPC connector #1.
7.b No; replace the throttle inhibit switch. Verify repairs.
1
145.1 SPN 973/FMI 2 - GHG17

Evobus 5-stage Retarder Level Position Not Plausible - Short to Power/Open Circuit on Pin 13 of the Common
Powertrain Controller #2 Connector
For wiring schematic information refer to Original Equipment Manufacturer (OEM) literature.
diagnosing a fault.
1
145.2 SPN 973/FMI 9 - GHG17

J1939 Electronic Brake Controller (EBC1) (Engine Brake Switches) is Missing
Network (CAN) line.
1.c If only SPN 973/FMI 9 is present, Go to step 2.
2.a If yes, ensure the CPC Group PGR001 parameter EBC1 Source Address SAE J1939 is configured
properly: 33 = non multiplex switches, 49 = multiplex switches.
2
145.3 SPN 973/FMI 13 - GHG17

Engine Retarder Selection Signal is Missing
Network (CAN) line.
3
145.4 SPN 973/FMI 19 - GHG17

Engine Retarder Selection Signal is Erratic
Network (CAN) line.
4
146.1 SPN 974/FMI 2 - GHG17

SPN 974/FMI 2
Description This Fault May Occur if Remote Accelerator Pedal is
Programmed ON and Remote Pedal Circuit is Shorted to
Power or Ground
Monitored Parameter Remote Throttle Sensor
Dash Lamps CEL
Check as follows:
1. Is the unit equipped with a remote accelerator pedal?
1.b No; refer to the A & I manual for proper Common Powertrain Controller (CPC) configuration.
2. Disconnect the remote throttle switch.
1
4. Measure the voltage between remote throttle switch connector (from pin 4 of the CPC connector #3) and
ground. Refer to Original Equipment Manufacturer (OEM) literature for schematic information. Is voltage
present?
4.a Yes; repair the short to power between pin 4 of the CPC connector #3 and the remote throttle switch.
4.b No; repair the short to ground between pin 4 of the CPC connector #3 and the remote throttle switch.
2
146.2 SPN 974/FMI 3 - GHG17

SPN 974/FMI 3
Power While Pin 8 of the Common Powertrain Controller
(CPC) Connector #2 is Grounded
Dash Lamps CEL
Verification Key On Engine On with Remote Pedal Activated
Check as follows:
1.b No; refer to the Application and Installation manual for proper Common Powertrain Controller (CPC)
configuration.
4. Measure the voltage between remote throttle switch connector (from pin 4 of the CPC connector #3) and
present?
3
4.a Yes; repair the short to power between pin 4 of the CPC connector #3 and the remote throttle switch.
4.b No; replace the remote throttle switch.
4
146.3 SPN 974/FMI 4 - GHG17

SPN 974/FMI 4
Ground While Pin 8 of the Common Powertrain Controller
(CPC) Connector #2 is Grounded
Dash Lamps CEL
Verification Key On Engine On with Remote Pedal Activated
Check as follows:
configuration.
4. Measure the resistance between remote throttle switch connector (from pin 4 of the CPC connector #3) and
ground. Refer to Original Equipment Manufacturer (OEM) literature for schematic information. Is the
5
4.a Yes; repair the short to ground between pin 4 of the CPC connector #3 and the remote throttle switch.
4.b No; replace the remote throttle switch.
6
147.1 SPN 979/FMI 9 - GHG17

SPN 979/FMI 9
Description PTO Message Missing or Not Received
Monitored Parameter PGR001/052 PTO Source Address SAE J1939
Dash Lamps CEL
Verification Key On
4.a Yes; ensure the CPC Group PGR001 parameter PTO Source Address SAE J1939 is configured
properly:
23 = non multiplex switches
49 = multiplex switches
1
148.1 SPN 986/FMI 9 - GHG17

SPN 986/FMI 9
Description J1939 Message not received by Common Powertrain
Controller (CPC)
Monitored Parameter J1939 CM1 Message
Dash Lamps None
Check as follows:
1. Check for multiple codes. Are there multiple J1939 communication codes present?
1.a Yes; troubleshoot those fault codes first.
2.a Yes; check the proper configuration of the CPC. Ensure CPC and MCM cooling fan type parameters
match.
module.
1
148.2 SPN 986/FMI 13 - GHG17
NOTICE
This fault does not indicate a Common Powertrain Controller (CPC) issue; do not replace
the CPC.
J1939 CM1 SPN 986 Signal from Source #1 or #2 is Missing
SPN 986/FMI 13
Description J1939 Message Missing
Dash Lamps None
This fault indicates that the CPC has received a J1939 CM1 message; however, the "SPN 986 requested fan
percent speed" data signal is not available.
1. Check for multiple codes. Is CPC SPN 168/FMI 0/14/18 (battery voltage) code(s) present?
is done, troubleshoot the forward HVAC control module or the MSF (Modular Switch Field) modules.
2
148.3 SPN 986/FMI 19 - GHG17
NOTICE
This fault does not indicate a Common Powertrain Controller (CPC) issue; do not replace
the CPC.
J1939 CM1 SPN986 Signal from Source #1 or #2 is Erratic
SPN 986/FMI 19
Description J1939 Message Erratic
Dash Lamps None
This fault indicates the J1939 CM1 message is received by the CPC; however the “SPN 986 requested fan
percent speed ” is in error.
Check as follows:
1. Check for multiple codes. Is CPC SPN 168/FMI 0/14/18 (battery voltage) code(s) present?
module.
3
149.1 SPN 1033/FMI 2 - GHG17

Aftertreatment Control Module Engine Hours Data Erratic, intermittent or Incorrect
This fault usually occurs after reprogramming the CPC or ACM. The internal clocks of the CPC or ACM do not
match. After reprogramming either module, all fault codes must be cleared.
diagnosing a fault.
1
150.1 SPN 1033/FMI 15 - GHG17

SPN 1033/FMI 15
Description This Fault Occurs when the Internal Run Timer of the CPC or
MCM Do Not Match
Monitored Parameter Engine Run Timer
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

5.a Yes; replace the Motor Control Module (MCM) and reprogram with the latest software release.
1
150.2 SPN 1033/FMI 17 - GHG17

SPN 1033/FMI 17
Description This Fault Occurs when the Internal Run Timer of the CPC or
MCM Do Not Match
Monitored Parameter Engine Run Timer
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

5.a Yes; replace the Motor Control Module (MCM) and reprogram with the latest software release.
2
151.1 SPN 1071/FMI 3 - GHG17

SPN 1071/FMI 3
Description Fan Circuit Failed High
Dash Lamps None
Verification Ignition cycle
1

2. Disconnect the vehicle 10-pin interface connector.
3. Inspect the vehicle 10-pin interface connector for corroded, unseated (pushed out) or damaged pins, bent
or spread pins; inspect the connector seal for damage (signs of water or oil intrusion).
3.a If water or oil intrusion, damage, bent or spread pins are found, repair as necessary. Verify repairs.
3.b If the connector shows no signs of damage, Go to step 4.
4. Turn the ignition ON (key On, engine OFF).
5. Connect DiagnosticLink . Clear fault codes. Does the fault code become active?
6. Reconnect the vehicle 10-pin interface connector.
spread pins; inspect the connector seal for damage (signs of water or oil intrusion).
8.a If water or oil intrusion, bent or spread pins are found, repair as necessary. Verify repairs.
9. Cycle ignition. Clear fault codes. Does the fault code become active?
9.a Yes; repair short to power on fan control circuit from the vehicle10-pin interface connector pin 3 to the
fan control solenoid. Refer to Original Equipment Manufacturer (OEM) for wiring information.
9.b No; replace the fan control solenoid. Refer to Original Equipment Manufacturer (OEM) procedures.
11. Disconnect the 120–pin Motor Control Module (MCM) connector.
2
12.a If water or oil intrusion, damage, bent or spread pins are found, repair as necessary.
12.b If the connector shows no signs of damage, repair short to power on fan control circuit from MCM pin
33 to the vehicle 10-pin interface connector pin 3.
3
151.2 SPN 1071/FMI 4 - GHG17

SPN 1071/FMI 4
Description Fan Circuit Failed Low
Dash Lamps MIL, CEL
4

5. Connect DiagnosticLink . Clear fault codes. Does the fault code become active?
6. Reconnect the vehicle 10-pin interface connector.
9. Cycle ignition. Clear fault codes. Does the fault code become active?
9.a Yes; repair short to ground on fan control circuit from the vehicle 10-pin interface connector pin 3 to the
fan control solenoid. Refer to Original Equipment Manufacturer (OEM) for wiring information.
9.b No; replace the fan control solenoid. Refer to Original Equipment Manufacturer (OEM) procedures.
12. Inspect the 120–pin Motor Control Module (MCM) connector for corroded, unseated (pushed out) or
damaged pins, bent or spread pins; inspect the connector seal for damage (signs of water or oil intrusion).
5
12.a If water or oil intrusion, damage, bent or spread pins are found, repair as necessary. Verify repairs.
12.b If the connector shows no signs of damage, repair short to ground on fan control circuit from MCM pin
33 to the vehicle 10-pin interface connector pin 3.
6
151.3 SPN 1071/FMI 5 - GHG17

SPN 1071/FMI 4
Description Fan Circuit Failed Open
Dash Lamps None
7

1.a If SPN 647/FMI 5, SPN 1072/FMI 5 and SPN 1071/FMI 5 are active, repair the open in the wiring
between the pin 91 of the 120–pin Motor Control Module (MCM) connector and the fan and the Jake
Brake® solenoids. Verify repairs.
1.b If only SPN 1071/FMI 5 is active, Go to step 2.
4.b If the connector shows no signs of damage, reconnect 10-pin connector, Go to step 5.
7. Measure the resistance between MCM harness connector pin 33 and the vehicle 10-pin interface connector
pin 3.
7.a If the resistance is less than five ohms, Go to step 8.
7.b If the resistance is greater than five ohms, repair the open circuit on fan circuit pin 33 of the 120–pin
MCM connector to the vehicle 10-pin interface connector pin 3.
8. Measure the resistance between MCM harness connector pin 91 and the vehicle 10-pin interface connector
pin 1.
8.a If the resistance is less than five ohms, Go to step 9.
8.b If the resistance is greater than five ohms, repair the open circuit on fan power circuit pin 91 of the
120–pin MCM connector to the vehicle 10-pin interface connector pin 1.
8

11. Measure the resistance between the fan control solenoid pins.
11.a If the resistance is less than 10K ohms, repair the open circuit(s) between the fan control solenoid
connector and the vehicle 10-pin interface connector pin 3 and/or pin 1. Refer to Original Equipment
11.b If the resistance is greater than 10K , replace the fan control solenoid. Refer to Original Equipment
9
152.1 SPN 1072/FMI 3 - GHG17

SPN 1072/FMI 3
Description Jake Brake Stage 1 Short to Power
Typical Enabling Conditions Short to Battery Power Between Pin 1 on the Engine Brake
Solenoid and Pin 66 on the Motor Control Module 120-pin
Connector
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
1
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1. Disconnect the front fuel injector valve cover harness.

3. Measure the voltage between pin 13 and ground on the front fuel injector valve cover harness connector
(engine harness side). If you are using J-48671-10, measure either Jake Brake® pin 1 and ground. Is the
voltage greater than two volts?
3.a Yes; repair the short to power between pin 13 of the front fuel injector valve cover harness connector
and pin 66 of the 120-pin Motor Control Module (MCM) connector.
5. Disconnect the front Jake Brake .
6. Inspect the engine brake solenoid connector for signs of damaged, bent, spread, corroded or unseated
damage present?
2
8. Measure the voltage between pin 1 of the engine brake solenoid connector and ground. Is the voltage
greater than two volts?
8.a Yes; repair a short to power on the engine brake solenoid circuit pin 1 to pin 13 of the front fuel injector
valve cover harness connector. Go to step 9.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
9. Restore all connections and components. Cycle ignition and clear fault codes; idle the engine for one
minute. Does SPN 1072/FMI 3 fault code become active?
3
152.2 SPN 1072/FMI 4 - GHG17

Jake Brake Stage 1 Circuit Failed Low
SPN 1072/FMI 4
Description Jake Brake Stage 1 Short to Ground
Typical Enabling Conditions Short to Ground Between Pin 1 on the Jake Brake® Solenoid
and Pin 66 on the Motor Control Module 120-pin Connector
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
WARNING
PERSONAL INJURY
4
WARNING
PERSONAL INJURY
1. Disconnect the front fuel injector valve cover harness.

2. Measure the resistance between pin 13 and ground on the front fuel injector valve cover harness connector
(engine harness side). If you are using J-48671-10, measure either Jake Brake® pin 1 and ground. Is the
resistance greater than 15 ohms?
2.a Yes; repair the short to ground between pin 13 of the front fuel injector valve cover harness connector
and pin 66 of the 120-pin Motor Control Module (MCM) connector.
4. Disconnect the engine brake solenoid electrical connection.
damage present?
7. Measure the resistance between pin 1 of the engine brake solenoid connector and ground. Is the
7.a Yes; repair a short to ground on the engine brake solenoid circuit pin 1 to pin 13 of the front fuel
injector valve cover harness connector. Go to step 8.
7.b No; replace the engine brake solenoid. Go to step 8.
5
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
6
152.3 SPN 1072/FMI 5 - GHG17

SPN 1072/FMI 5
Description Jake Brake Stage 1 Open Circuit
Typical Enabling Conditions Open Circuit Between Pin 1 on the Jake Brake® Solenoid and
Pin 32 on the Motor Control Module 120-pin Connector
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
WARNING
PERSONAL INJURY
7
WARNING
PERSONAL INJURY
1. Disconnect the front electrical harness connector of the two-piece fuel injector wiring harness.
2. Measure the resistance between pin 13 and pin 14 on the valve cover side of the front fuel injector wiring
harness. If you are using J-48671-10, measure across Jake Brake® pin 1 and pin 2. Is the resistance

4. Measure the voltage between pin 14 on the engine harness side of the front fuel injector wiring harness and
ground. Is the voltage less than 11.5 volts?
4.a Yes; repair the cause of low voltage between pin 91 of the MCM 120-pin connector and pin 14 of the
front fuel injector wiring harness connector.
4.b No; repair the open between pin 13 of the front fuel injector wiring harness connector and pin 66 of the
Motor Control Module (MCM) 120-pin connector.
6. Disconnect the engine brake solenoid electrical connection.
damage present?
9. Measure the resistance across the engine brake solenoid. Is the resistance greater than 15 ohms?
8
9.a Yes; replace the engine brake solenoid. Go to step 10.

9.b No; replace the front injector harness. Go to step 10.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
9
1
153.2 SPN 1073/FMI 3 - GHG17

Jake Brake® stage 2 Circuit Failed High
Repair the short to battery power between pin 1 on the Jake Brake® solenoid and pin 32 on the Motor Control
2
153.3 SPN 1073/FMI 4 - GHG17

Jake Brake® Stage 2 Circuit Failed Low
SPN 1073/FMI 4
Description Jake Brake Stage 2 Circuit Failed Low
Monitored Parameter Jake Solenoid
Dash Lamps MIL, CEL
1. Disconnect the rear the two-piece fuel injector wiring harness.

2. Measure resistance between pins 13 and ground on the rear two-piece fuel injector wiring harness
connector. If you are using J-48671–10, measure across the Jake Brake® 2 pins.
2.a If the resistance is greater than 15 ohms, repair short to ground between pin 13 of the front two-piece
fuel injector wiring harness connector and pin 32 of the 120–pin Motor Control Module (MCM)
connector.
2.b If the resistance is less than 5 ohms, Go to step 3.
4. Disconnect the rear Jake Brake® electrical harness connector.
5. Measure resistance between either terminal on the Jake Brake® solenoid and ground.
5.a If the resistance is less than 5 ohms, replace the Jake Brake® solenoid.
Refer to section "Removal of the Camshafts"
3
5.b If the resistance is greater than 5 ohms, repair the short to ground between pins 13 and 14 of the rear
fuel injector valve cover harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter
System" .
4
153.4 SPN 1073/FMI 5 - GHG17

Jake Brake® Stage 2 Circuit Failed Open
1. Disconnect the rear electrical harness connector of the two-piece fuel injector wiring harness.
2. Measure the resistance between pin 13 and 14 on the valve cover side of the rear two-piece fuel injector
wiring harness . If you are using J-48671–10, measure across Jake Brake 2 pins.
2.a If the resistance is between 9 and 12 ohms, Go to step 3.

2.b If the resistance not between 9 and 12 ohms, Go to step 5.
4. Measure the voltage between pin 14 on the engine harness side of the valve cover harness and ground.
4.a If the voltage is less than 11.5 volts, repair the cause of low voltage between pin 62 of the Motor
Control Module (MCM) 120–pin connector and pin 14 of the valve cover harness connector.
4.b If the voltage is greater than 11.5 volts, repair the open between pin 13 of the valve cover harness
connector and pin 32 of the MCM 120–pin connector.
6. Disconnect the rear Jake Brake solenoid.
7. Measure the resistance across the Jake Brake solenoid.
7.a If the resistance is between 9 and 11 ohms, replace the two-piece fuel injector wiring harness. Refer to
section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
7.b If the resistance is NOT between 9 and 11 ohms, replace the Jake Brake solenoid.
5
154.1 SPN 1077/FMI 3 – GHG17

SPN 1077/FMI 3
Description Quantity Control Valve (QCV) Circuit Failed High
Monitored Parameter Quantity Control Valve (QCV) Circuit
Typical Enabling Conditions Always on
Dash Lamps MIL, CEL
Verification Parked Regen
1. Disconnect the QCV connector.

2. Inspect the harness connector for bent, spread or corroded pins.
2.a If the pins are bent, spread or corroded, repair as necessary.
2.b If connector shows no signs of damage, Go to step 3.
5. Measure the resistance between pin 1 of the QCV connector and pin 1 of the MCM 120-pin connector.
5.a If the resistance is greater than 5 ohms, repair the open circuit between pin 1 of the QCV connector
and pin 1 of the MCM 120-pin connector. Verify repairs.
6. Measure the resistance between pin 2 of the QCV connector and pin 2 of the MCM 120-pin connector.
6.a If the resistance is greater than 5 ohms, repair the open circuit between pin 2 of the QCV connector
and pin 2 of the MCM 120-pin connector. Verify repairs.
7. Measure the resistance between pins 1 and 2 of the QCV connector.
7.a If the resistance is greater than 10K ohms, replace the QCV.
7.b If the resistance is less than 10K ohms, repair the short circuit between pins 1 and 2 of the QCV
harness. Verify repairs.
1
154.2 SPN 1077/FMI 4 – GHG17

SPN 1077/FMI 4
Description Quantity Control Valve (QCV) Circuit Failed Low
Monitored Parameter Quantity Control Valve (QCV) Circuit
Dash Lamps MIL, CEL
1. Disconnect the QCV connector.

5. Measure the resistance between pin 1 of the QCV and battery ground.
5.a If the resistance is less than 10K ohms, repair the short to ground between pin 1 of the QCV harness
connector and pin 1 of the MCM 120-pin connector. Verify repairs.
5.b If the resistance is greater than 10K ohms, Go to step 6.
6. Measure the resistance between pin 2 of the QCV and battery ground.
6.a If the resistance is less than 10K ohms, repair the short to ground between pin 2 of the QCV harness
connector and pin 2 of the MCM 120-pin connector. Verify repairs.
6.b If the resistance is greater than 10K ohms, replace the QCV. Verify repairs.
2
154.3 SPN 1077/FMI 5 - GHG17

Quantity Control Valve Current Too Low
SPN 1077/FMI 5
Description Quantity Control Valve (QCV) Error, Current Too Low
Monitored Parameter Quantity Control Valve
Typical Enabling Conditions RP Closed Loop Control
Execution Frequency Current less than 200 mA
Dash Lamps MIL, CEL
3
Check as follows:
1. Disconnect the quantity control valve.
2. Measure the resistance across pins 1 and 2 of the quantity control valve.
2.a If the resistance is greater than 2 ohms, replace quantity control valve. Refer to section "Removal of the
Quantity Control Valve - Two-Filter System" .

4. Measure the resistance between pin 1 of the MCM 120-pin connector and pin 1 of the QCV.
4.b If the resistance is greater than 5 ohms, repair the open circuit between pin 1 of the 120 MCM
connector and pin 1 of the QCV. Verify repairs. Refer to section "Verify Repairs" .
4
5.a If the resistance is less than 5 ohms, replace the MCM. Refer to section "Removal of the Motor Control Module" .
5.b If the resistance is greater than 5 ohms, repair the open circuit between pin 2 of the MCM 120-pin
connector and pin 2 of the QCV. Verify Repairs. Refer to section "Verify Repairs" .
5
154.4 SPN 1077/FMI 6 - GHG17
Check as follows:
1. Disconnect the QCV.
2. Measure the resistance across pins 1 and 2 of the QCV.
2.a If the resistance is greater than 2 ohms, replace the QCV. Refer to section "Removal of the Quantity Control Valve
- Two-Filter System" .

4.b If the resistance is greater than 5 ohms, repair the open circuit between pin 1 of the 120-pin MCM
5.a If the resistance is less than 5 ohms, replace the MCM. Refer to section "Removal of the Motor Control Module" .
5.b If the resistance is greater than 5 ohms, repair the open circuit between pin 2 of the MCM 120-pin
6
154.5 SPN 1077/FMI 14 - GHG17

The Motor Control Module (MCM) monitors rail pressure during engine shut down and compares it to a stored
learned value. If the bleed-down rate has changed due to leakage and it is below the learned value, this code will
set.
SPN 1077/FMI 14
Description Leakage in High Pressure Fuel System Too High (Leak Down
Test)
Typical Enabling Conditions Key OFF
Execution Frequency Once When Enabling Conditions Met
Dash Lamps MIL, CEL
Verification FSIC Leak Test
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Start and run the engine until fuel temperature is greater than 35°C (95°F) and coolant temperature is
greater than 70°C (158°F).
2. Shut the engine down.
NOTICE
The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and
hardware are one-time-use components and MUST be replaced any time they are
removed. Refer to TS letter 16 TS-9Rev2 for the high pressure fuel line kit numbers.
7
3. Check for an external high pressure fuel system leak(s). Are any leaks present at the following
components?
• High Pressure Fuel Pump
• High Pressure Fuel Rail Feed Lines
• High Pressure Fuel Rail
• High Pressure Fuel Injector Lines
• Fuel Rail Pressure Sensor
• Pressure Limiting Valve
3.a Yes; repair leaks. Verify repairs.
4. Check the engine oil dipstick. Is there any fuel in the oil?
4.a Yes; Refer to section "Fuel in Oil" .
5. Check for leakage from the Pressure Limiting Valve (PLV). Refer to section "Pressure Limiting Valve Flow Test – Two-
Filter Fuel System" . Does the PLV flow test pass?

5.b No; replace the PLV and verify repairs. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
Note : DiagnosticLink® 8.06 or higher is necessary to complete this troubleshooting.
6. One cylinder at a time, remove the injector fuel transfer tube and cap the rail at each injector using J-
48704. Run the FSIC Leak Test. Refer to *section "FSIC Leak Test." Repeat for each injector. Record
results.
HP Leak Detection Test Results

#1 Capped #2 Capped #3 Capped #4 Capped #5 Capped #6 Capped
Leaking / Not Leaking / Not Leaking / Not Leaking / Not Leaking / Not Leaking / Not
Leaking Leaking Leaking Leaking Leaking Leaking
7. With any one injector capped off, does the FSIC Leak Test pass?
7.a Yes; replace that injector that passes the FSIC Leak Test when capped. Refer to section "Removal of the Fuel
Injector - Two-Filter System" and then run the HP Leak Detection Test again to verify repair.

8. Install all six rail caps. Crank engine for 10 seconds and then monitor rail pressure bleed down. Does rail
pressure bleed down under 100 bar in less than five minutes?
System" .
8.b No; replace all six injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" and then run the HP
Leak Detection Test again to verify repair.
9. Check for multiple codes. Are there any additional SPN 1077 codes present?
9.a Yes; service the additional fault codes first.
10. Is the Motor Control Module (MCM) below software level 6.4.0.5?
11.a Yes; update MCM software to latest software level and Go to step 4.
11.b No; update MCM software to latest software level and release vehicle.
11. Is the Motor Control Module (MCM) at software level 6.4.0.5?
8

12. Is the fuel map ZGS less than 007?
13. Using DiagnosticLink , go to the fault code in the Fault Codes panel. Under section "Extended Data Record
#6 DPF Data," check ’rpg_leak_div_int’. Is ‘rpg_leak_div_int’ greater than 2.25?
13.a Yes; update MCM software to latest software level and Go to step 6.
13.b No; update MCM software to latest software level and release vehicle.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
14. Start and run the engine until fuel temperature is greater than 35°C (95°F) and coolant temperature is
greater than 70°C (158°F).
15. Shut the engine down.
NOTICE
The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and
hardware are one-time-use components and MUST be replaced any time they are
removed. Refer to TS letter 16 TS-9Rev2 for the high pressure fuel line kit numbers.
16. Check for an external high pressure fuel system leak(s). Are any leaks present at the following
components?
• High Pressure Fuel Pump
• High Pressure Fuel Rail Feed Lines
• High Pressure Fuel Rail
• High Pressure Fuel Injector Lines
• Pressure Limiting Valve
9
16.a Yes; repair leaks. Verify repairs.

17. Check the engine oil dipstick. Is there any fuel in the oil?
17.a Yes; Refer to section "Fuel in Oil" .
18. Check for leakage from the Pressure Limiting Valve (PLV). Refer to section "Pressure Limiting Valve Flow Test – Two-
Filter Fuel System" . Does the PLV flow test pass?

18.b No; replace the PLV and verify repairs. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
Note : DiagnosticLink® 8.06 or higher is necessary to complete this troubleshooting.
19. One cylinder at a time, remove the injector fuel transfer tube and cap the rail at each injector using J-
48704. Run the FSIC Leak Test. Refer to *section "FSIC Leak Test." Repeat for each injector. Record
results.
HP Leak Detection Test Results

#1 Capped #2 Capped #3 Capped #4 Capped #5 Capped #6 Capped
Leaking / Not Leaking / Not Leaking / Not Leaking / Not Leaking / Not Leaking / Not
Leaking Leaking Leaking Leaking Leaking Leaking
20. With any one injector capped off, does the FSIC Leak Test pass?
20.a Yes; replace that injector that passes the FSIC Leak Test when capped. Refer to section "Removal of the Fuel
Injector - Two-Filter System" and then run the FSIC Leak Detection Test again to verify repair.

21. Install all six rail caps. Crank engine for 10 seconds and then monitor rail pressure bleed down. Does rail
pressure bleed down under 100 bar in less than five minutes?
System" .
21.b No; replace all six injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" and then run the
FSIC Leak Detection Test again to verify repair.
10
155.1 SPN 1089/FMI 9 – GHG17
parameter settings.
configuration?
1
156.1 SPN 1121/FMI 2 - GHG17

SPN 1121/FMI 2
Description Powertrain Message Missing
Monitored Parameter J1939 Powertrain Message
Dash Lamps CEL
Verification Idle
Check as follows:
2. Are there any SPN 168 (battery voltage) fault codes present?
parameter settings.
configuration?
1
156.2 SPN 1121/FMI 13 - GHG17

SPN 1121/FMI 13
Description Service Brake Signal Missing
Monitored Parameter Service Brake Input
Dash Lamps CEL
Check as follows:
module.
2
156.3 SPN 1121/FMI 19 - GHG17

SPN 1121/FMI 19
Description Service Brake Signal Erratic
Monitored Parameter Service Brake Input
Dash Lamps CEL
Check as follows:
module.
3
157.1 SPN 1136/FMI 3 - GHG17

MCM Internal Injector Supply Voltage Too High
SPN 1136 /FMI 3

Description Internal power supply voltage high
Monitored Parameter Internal power supply voltage
Typical Enabling Conditions Continuous
Monitor Sequence
Dash Lamps None
Verification
Check as follows:
1. Check for multiple codes. Are there any battery voltage faults present (SPN 168/FMI any) ?
1.a Yes; troubleshoot these codes first.
2. Disconnect the MCM 21-pin connector and inspect connector for corrosion, oil, fuel or water intrusion. Is
2.b No; replace the MCM.
1
157.2 SPN 1136/FMI 4 - GHG17

MCM Internal Injector Supply Voltage Too Low
SPN 1136 /FMI 4

Description Internal power supply voltage low
Monitored Parameter Internal power supply voltage
Monitor Sequence
Dash Lamps None
Verification
Check as follows:
2
158.1 SPN 1163/FMI 2 - GHG17

Motor Control Module ( MCM) Temperature Sensor Signal Not Plausible
SPN 1163/FMI 2
detects that the internal MCM temperature is greater than
20°C (36°F) degrees from the expected temperature after the
Monitored Parameter
MCM Temperature
Dash Lamps MIL
Verification
been changed?
5. Disconnect and inspect the 120-pin and 21-pin MCM electrical connector. Is there damage or corrosion
present?
5.b No; replace the MCM. Verify repair.
1
159.1 SPN 1172/FMI 3 - GHG17

Turbocharger Compressor Inlet Temperature Sensor or Circuit Failed High
SPN 1172/FMI 3
Description This Fault Code Sets When There is a Short to Power or an
Open in the Turbocharger Compressor Inlet Temperature
Circuit.
Monitored Parameter Turbocharger Compressor Inlet Temperature
Typical Enabling Conditions Ignition On
Dash Lamps MIL
1. Disconnect and inspect the Turbocharger Compressor Inlet Temperature electrical connector harness side.
Is there corrosion present?
1.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor and electrical connector. Verify
repair.
1

3. Inspect the Turbocharger Compressor Inlet Temperature electrical connector component side. Are any of
the pins or the connector damaged?
3.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor and electrical connector. Refer to
section "Description and Operation of the Turbocharger Compressor Inlet Temperature Sensor" . Verify repair.
3.b No; replace the Turbocharger Compressor Inlet Temperature electrical connector. Verify repair.
4. Use the appropriate flex probe and check the pins. Are there any spread pins?
4.a Yes; replace the Turbocharger Compressor Inlet Temperature electrical connector. Refer to section
"Description and Operation of the Turbocharger Compressor Inlet Temperature Sensor" . Verify repair.

6. Measure the voltage between pins 1 and 2 of the Turbocharger Compressor Inlet Temperature electrical
connector harness side. Is the voltage greater than 3.6 volts?
6.a Yes; repair the short to power between pin 2 of the Turbocharger Compressor Inlet Temperature
electrical connector and pin 86 of the MCM 120-pin electrical connector.
7. Measure the voltage between pins 1 and 2 of the Turbocharger Compressor Inlet Temperature electrical
connector harness side. Is the voltage between 2.5 and 3.5 volts?
7.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor. Verify repair.
8. Measure the voltage between pin 2 of the Turbocharger Compressor Inlet Temperature electrical connector
harness side and ground. Is the voltage between 2.5 and 3.5 volts?
8.a Yes; repair the circuits between pin 1 of the Turbocharger Compressor Inlet Temperature electrical
connector and pin 52 of the MCM 120-pin electrical connector.
8.b No; repair the circuits between pin 2 of the Turbocharger Compressor Inlet Temperature electrical
connector and pin 86 of the MCM 120-pin electrical connector.
2
159.2 SPN 1172/FMI 4 - GHG17

Turbocharger Compressor Inlet Temperature Circuit Failed Low
SPN 1172/FMI 4
Description This Fault Code Sets When There is a Short to Ground in the
Turbocharger Compressor Inlet Temperature Circuit.
Monitored Parameter Turbocharger Compressor Inlet Temperature
Dash Lamps MIL
1. Disconnect and inspect the Turbocharger Compressor Inlet Temperature electrical connector harness side.
Is there corrosion present?
1.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor and electrical connector. Verify
repair.
3
3. Inspect the Turbocharger Compressor Inlet Temperature electrical connector component side. Are any of
the pins or the connector damaged?
3.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor and electrical connector. Refer to
section "Description and Operation of the Turbocharger Compressor Inlet Temperature Sensor" . Verify repair.
3.b No; replace the Turbocharger Compressor Inlet Temperature electrical connector. Verify repair.
5. Is fault code SPN 1172/FMI 4 now inactive and SPN 1172/FMI 3 now active?
5.a Yes; replace the Turbocharger Compressor Inlet Temperature sensor. Refer to section "Description and
Operation of the Turbocharger Compressor Inlet Temperature Sensor" . Verify repair.
5.b No; repair the short to ground between pin 2 of the Turbocharger Compressor Inlet Temperature
sensor electrical connector harness side and pin 86 of the MCM 120-pin electrical connector. Verify
repair.
4
159.3 SPN 1172/FMI 21 - GHG17

Compressor Inlet Temperature Sensor Signal Not Plausible
SPN 1172/FMI 21
detects that the turbocharger compressor inlet temperature is
greater than 20°C (36°F) degrees from the expected
temperature after the engine has been turned off for 8 hours.
Monitored Parameter
Compressor inlet temperature
Dash Lamps MIL
operating temperature. Then verify that the engine
Compressor inlet temperature is within 10°C (18°F) of the
ambient air temperature.
Possible causes:
been changed?
5. Disconnect and inspect the compressor inlet temperature sensor electrical connector. Is there damage or
corrosion present?
5.b No; replace the compressor inlet temperature sensor. Verify repair.
5
160.1 SPN 1231/FMI 9 - GHG17

SPN 1231/FMI 9
or has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
programmed?
1

present?
present?
2

3

harness connector.
harness connector.
4

harness connector.
harness connector.
5
161.1 SPN 1231/FMI 9 - GHG17

SPN 1231/FMI 9
or has Stopped Arriving
Dash Lamps MIL, CEL
Check as follows:
programmed?
1

present?
present?
2

3

harness connector.
harness connector.
4

harness connector.
harness connector.
5
162.1 SPN 1237/FMI 4 - GHG17

SPN 1237/FMI 4
Description Input 1/15 Short To Ground
Monitored Parameter 1 15 DI Selection
Dash Lamps CEL

5. Measure the resistance between pin 15 of the CPC connector #1 and ground. Is the resistance more than
10k ohms?
5.a Yes; replace the stop engine override switch.
5.b No; repair the short to ground on the wire between pin 15 of the CPC connector #1 and the stop engine
override switch.
1
163.1 SPN 1243/FMI 14 - GHG17

SPN 1243/FMI 14
Description This Fault Code Indicates a Missing Message from the
Antilock Brake System (ABS) Module.
Monitored Parameter J1939 Communication
Dash Lamps CEL
configuration?
3.a Yes; refer to the OEM diagnostics for troubleshooting the loss of communication to the ABS module.
3.b No; check for proper parameter configuration of the CPC against the server information.
1
164.1 SPN 1322/FMI 10 – GHG17

SPN 1322/FMI 10
Description This Fault Code Sets Once the Motor Control Module (MCM)
Detects a Misfire on Multiple Cylinders Within One Rotation of
Crankshaft With all Conditions Met
Monitored Parameter Injection Quantity
Monitor Sequence Always When Enabling Conditions Are Met
Typical Duration 1000 Revolutions
Dash Lamps MIL
Verification Ensure the Ignition Has Been Off for a Minimum of Five
Minutes Prior to the Last Ignition On. Meet All Enabling
Conditions. 15-Minute Road Test
The entry conditions for this code are:

• Engine speed is above low idle
• All cylinders are active, no fault reactions
• Engine speed/torque is steady
This fault can occur due to the conditions listed below:
• Cylinder kit failure
• Valve train failure
• Lash adjustments
• Fuel injector
• High pressure fuel line (rail to fuel injector)
• Debris entering fuel injector (intermittent faults)
• Fuel quality
Required Service Tools
W470589009800 DD13/15 Cam Gear Cover
Check as follows:
1
logged?
3. Using DiagnosticLink Standard, perform the Relative Cylinder Compression Test listed under service
routines. Refer to section "Relative Cylinder Compression Test" . Is low compression found and all cylinders within
10%?
3.a Yes; the issue is related to a mechanical failure/issue for that cylinder. Repair as necessary.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Start and bring the engine up to operating temperature of 60°C (140°F).

Note : For Idle Speed Balance (ISB) values to update, the engine speed must be at idle.
5. Using DiagnosticLink Standard, read parameter ISB values under the instrumentation section. Is the value
for any cylinder at its maximum limit of +100?
5.b No; fault may be intermittent. Obtain information from customer on driving habits, recent repairs,
number of occurrences when fault code set, or situations when the code occurred. Try to retest engine
within these parameters.
6. Inspect high pressure fuel line from rail to fuel injector for damage. Is damage found?
6.a Yes; replace the high pressure fuel injector line if necessary. Go to step 7.
6.b No; replace the fuel injector for the cylinder identified. Go to step 7.
7. Verify repairs. Is misfire concern resolved?
7.a Yes; testing is completed. Clear faults and release vehicle.
7.b No; perform the Aerated Fuel Test. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
2
164.2 SPN 1322/FMI 11 – GHG17

SPN 1322/FMI 11
Description This Fault Will Occur Once The MCM Sees The Injection
Duration Compensates More Than A Set Threshold Within
Multiple Rotations Of Crankshaft With All Conditions Met
Monitored Parameter Injection Quantity
Dash Lamps MIL
Conditions. 15-Minute Road Test
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
The entry conditions for this code are:

• Engine speed is above low idle
• All cylinders are active, no fault reactions
• Engine speed/torque is steady
This fault can occur due to the conditions listed below:
• Cylinder kit failure
• Valve train failure
• Lash adjustments
• Fuel injector
• High pressure fuel line (rail to fuel injector)
3
• Debris entering fuel injector (intermittent faults)

• Fuel quality
W470589009800 DD13/15 Cam Gear Cover
Check as follows:
If code becomes active during the road test with over ¼ tank of fuel Go to step 3.
logged?
3. Using DiagnosticLink Standard, perform the Relative Cylinder Compression Test listed under service
routines. Refer to section "Relative Cylinder Compression Test" . Is low compression found and all cylinders within
10%?
3.a Yes; the issue is related to a mechanical failure/issue for that cylinder. Repair as necessary.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
4
WARNING
ENGINE EXHAUST

5. Using DiagnosticLink Standard, read parameter ISB values under the instrumentation section. Is the value
for any cylinder at its maximum limit of +100?
5.b No; fault may be intermittent. Obtain information from customer on driving habits, recent repairs,
number of occurrences when fault code set, or situations when the code occurred. Try to retest engine
within these parameters.
6. Inspect high pressure fuel line from rail to fuel injector for damage. Is damage found?
6.a Yes; replace the high pressure fuel injector line if necessary. Go to step 7.
6.b No; replace the fuel injector for the cylinder identified. Go to step 7.
7. Verify repairs. Is misfire concern resolved?
7.a Yes; testing is completed. Clear faults and release vehicle.
7.b No; perform the Aerated Fuel Test. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" .
5
164.3 SPN 1322/FMI 31 - GHG17

SPN 1322/FMI 31
Detects That Multiple Cylinders Have Low rpm Speed with the
Injector Commanded to Max Fueling for a Count of Two with
All Conditions Met
Monitored Parameter Engine rpm
Execution Frequency Once Per Drive Cycle When Enabling Conditions are Met
Dash Lamps CEL, MIL
Verification Ensure the ignition has been off for a minimum of five minutes
prior to the last ignition on. Meet all enabling conditions. Let
the Engine Idle for five minutes. (Fault code status will
become pending with one detected failure and active with the
second).
Note : DO NOT use the Idle Speed Balance (ISB) test in DiagnosticLink® for ANY misfire at idle testing.
Check as follows:
Possible causes:
• Valve Lash Out Of Adjustment
• Valve Train Damage/Failure
• Bent Valve
• Valve Face/Seat Damage
• Stuck Jake Brake
• Bearing Failure
• Bent Connecting Rod
• Cylinder Liner Damage
• Piston Ring Damage
• Failed Cylinder Head Gasket
• Failed Fuel Injector
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
6
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
To avoid injury from a falling component, ensure an appropriately rated lifting device is
used. Moving the component without an appropriately rated lifting device could result in
the component falling, which could cause serious personal injury and component damage.
Never stand beneath a suspended load.
WARNING
PERSONAL INJURY
1. Does the engine exhibit knocking noise while running?

2. Remove the Exhaust Gas Recirculation (EGR) hot pipe and check for raw fuel. Was raw fuel found?
2.a Yes; perform the following:
Refer to section "Cleaning of the DD13 Exhaust Gas Recirculation System"
2.b No; reinstall EGR hot pipe and Go to step 3.

3. Refer to section "Aerated Fuel Test – Two-Filter Fuel System" . Was the fuel system found to be aerated?
3.a Yes; make necessary repairs. Verify repairs.
3.b No; Refer to section "Different Engine Noise" .
4. Are there any of the following faults present?
• SPN 651/FMI any
• SPN 3659/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
7
• SPN 164/FMI any

Activity data. Life-To-Date data can be found by selecting the "View" drop down menu, then selecting "Life-
To-Date" and then selecting "Engine." In the resulting page view, look at the Peak Engine rpm and the date
6. View past warranty and repair history to determine if both camshafts were replaced after the engine
overspeed. Were the camshafts replaced?
6.b No; replace both camshafts. Inspect the engine brake rocker arms for loose actuator piston retainers
and loose or missing return springs. Verify repairs.
7. Connect a battery charger to the vehicle to maintain sufficient battery voltage while cranking. Use
DiagnosticLink to perform the Relative Cylinder Compression test. Refer to section "Relative Cylinder Compression
Test" . Is the relative compression reading for all cylinders within 10% of the highest cylinder reading?

9. Disconnect the battery charger.
11. Visually inspect the rocker arms, rollers on the rocker shafts and the lobes on the camshafts. Are the rocker
arms, rollers, or camshafts damaged?
11.a Yes; replace the damaged components. Perform verification in fault code chart header to verify repairs.
12. Check the valve lash clearance for all cylinders. Refer to section "Setting the Valve and Engine Brake Lash" . Is the
valve lash within specification?
12.b No; adjust the valve lash to the correct clearance. Perform verification in fault code chart header to
verify repairs.
13. Check the engine brake lash. Refer to section "Setting the Valve and Engine Brake Lash" . Is the engine brake lash
14. Inspect the engine brake piston actuator. Is the engine brake piston actuator constantly engaged or stuck in
the extended position?
14.a Yes; replace the engine brake rocker arm. Perform verification in fault code chart header to verify
repairs.
14.b No; set the correct engine brake lash. Refer to section "Setting the Valve and Engine Brake Lash" . Perform
verification in fault code chart header to verify repairs.
15. Connect the battery charger to maintain proper cranking speed.
16. Perform the Mechanical Cylinder Compression test. Refer to section "Mechanical Cylinder Compression Test" . Is the
mechanical cylinder compression reading for any cylinder 344 kPa (50 psi) lower than any of the other
cylinders?
8
16.a Yes; disconnect the battery charger and remove the cylinder head. Refer to section "Symptom Diagnostics -
Low Engine Compression" to check for the cause of the loss of compression.

17. Remove and inspect the engine oil filter. Refer to section "Replacement of the Oil Filter" . Is there an excessive
amount of metal present in the oil filter?
17.a Yes; remove the oil pan and inspect the bearings. Repair as necessary.
17.b No; replace the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" . Perform
9
165.1 SPN 1323/FMI 10 - GHG17

SPN 1323/FMI 10
Detects a Misfire on Cylinder #1 with all Conditions Met
Dash Lamps MIL
Verification Ensure Ignition Has Been Off for a Minimum of Five Minutes
Prior to the Last Ignition On. Meet All Enabling Conditions
During a 15 Minute Road Test
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Note : DO NOT use the Idle Speed Balance (ISB) test in DiagnosticLink® for ANY misfire testing.
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY
logged?
2

• SPN 651/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
it occurred. Is the maximum engine speed greater than the values shown in the chart below?
Peak Engine RPM

12 Lobe Intake Camshaft 2800 rpm

9. Connect a battery charger to the vehicle to maintain sufficient battery voltage while cranking.
10. Use DiagnosticLink to perform the Relative Cylinder Compression test. Refer to section "Relative Cylinder
Compression Test" . Is the relative compression reading for cylinder #1 within 10% of the highest cylinder
reading?
3

arms, rollers or camshafts damaged?
15. Check the valve lash clearance for cylinder #1. Refer to section "Setting the Valve and Engine Brake Lash" . Is the
verify repairs.
17.a Yes; replace the engine brake rocker arm. Refer to section "Removal of the Camshafts" and Refer to section
"Removal of the Exhaust Rocker Shaft Assembly" . Perform verification in fault code chart header to verify
repairs.
mechanical cylinder compression reading for cylinder #1 344 kPa (50 psi) lower than any of the other
cylinders?

20.a Yes; remove the oil pan and inspect the bearings starting with the bearings near cylinder #1. Repair as
necessary.
20.b No; replace the fuel injector in cylinder #1. Refer to section "Removal of the Fuel Injector Cup - Two-Filter System" .
Perform verification in fault code chart header to verify repairs.
4
165.2 SPN 1323/FMI 31 - GHG17

Idle Smoothness Control/Cylinder #1 Misfire At Idle
SPN 1323/FMI 31
Detects That Cylinder #1 Has Low rpm Speed with the
Injector Commanded to Max Fueling for a count of two with all
conditions met.
Execution Frequency Once per drive cycle when enabling conditions are met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 651/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
repairs.
cylinders?
7
necessary.
18.b No; replace the fuel injector in cylinder #1. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
8
166.1 SPN 1324/FMI 10 - GHG17

SPN 1324/FMI 10
Detects a Misfire on Cylinder #2 with All Conditions Met
Dash Lamps MIL
Verification Ensure the Ignition has been Off for a Minimum of Five
Conditions During a 15 Minute Road Test
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY
logged?
2

• SPN 652/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


reading?
3

verify repairs.
repairs.
cylinders?

necessary.
4
166.2 SPN 1324/FMI 31 - GHG17

SPN 1324/FMI 31
conditions met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 652/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
repairs.
cylinders?
7
necessary.
8
167.1 SPN 1325/FMI 10 - GHG17

SPN 1325/FMI 10
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

logged?
2.b fuel sloshing in the tank may have caused aerated fuel and set this code. Road test vehicle. If code
• SPN 653/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
2
Peak Engine RPM


reading?
verify repairs.
repairs.
cylinders?

3
necessary.
4
167.2 SPN 1325/FMI 31 - GHG17

SPN 1325/FMI 31
conditions met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 653/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
repairs.
cylinders?
7
necessary.
8
168.1 SPN 1326/FMI 10 - GHG17

SPN 1326/FMI 10
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY
logged?
2
• SPN 654/FMI any

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


reading?
3

verify repairs.
repairs.
cylinders?

necessary.
4
168.2 SPN 1326/FMI 31 - GHG17

SPN 1326/FMI 31
conditions met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 654/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
repairs.
17. Perform the Mechanical Cylinder Compression test. Refer to section "Mechanical Cylinder Compression Test" , Is the
cylinders?
7
18. Remove and inspect the engine oil filter. Refer to section "Replacement of the Oil Filter" Is there an excessive
necessary.
18.b No; replace the fuel injector in cylinder #4. Refer to section "Removal of the Fuel Injector - Two-Filter System"
8
169.1 SPN 1327/FMI 10 - GHG17

SPN 1327/FMI 10
Detects a Misfire on Cylinder #5 With All Conditions Met
Dash Lamps MIL
Verification Ensure the Ignition has been Off for a Minimum of Five
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY
logged?
2
• SPN 655/FMI any

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


reading?
3

verify repairs.
17.a Yes; replace the engine brake rocker arm. Refer to section "Removal of Camshaft and Rocker
Shaft/Engine Brake Assembly" . Perform verification in fault code chart header to verify repairs.
cylinders?

necessary.
4
169.2 SPN 1327/FMI 31 - GHG17

SPN 1327/FMI 31
conditions met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 655/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
Shaft/Engine Brake Assembly". Perform verification in fault code chart header to verify repairs.
cylinders?

7
necessary.
8
170.1 SPN 1328/FMI 10 - GHG17

SPN 1328/FMI 10
Detects a Misfire On Cylinder #6 With All Conditions Met
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
1

CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY
logged?
2
• SPN 656/FMI any

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


reading?
3

verify repairs.
cylinders?

necessary.
4
170.2 SPN 1328/FMI 31 - GHG17

SPN 1328/FMI 31
conditions met.
Dash Lamps CEL, MIL
second).
Check as follows:
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
5
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 656/FMI any
• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
6
reading?
verify repairs.
cylinders?

7
necessary.
8
171.1 SPN 1482/FMI 9 - GHG17

SPN 1482/FMI 9
Dash Lamps None
parameter settings.
configuration?
3.b No; reprogram the CPC with the correct information, as necessary. To verify repair, Go to step 4.
4. Clear fault codes. Turn ignition OFF, and disconnect DiagnosticLink . Wait five minutes for all modules to
1
SPN 1483 (CPC3) (GHG17)
172.1 SPN 1483/FMI 2 - GHG17

Check as follows:
1. Are any battery voltage faults present?
2. Is the MCM connected?
2.b No; make connection to Motor Control Module (MCM) and verify fault is inactive. If fault is still active,
Go to step 3.
3. Are any other MCM fault codes present?

3.b No; reprogram MCM to latest settings.
1
173.1 SPN 1484/FMI 9 - GHG17

SPN 1484/FMI 9
Description This Diagnostic Is Typically J1939 Message Was Lost
Monitored Parameter J1939 Message
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Check for proper configuration of the Common Powertrain Controller (CPC) against the server information.
Does the CPC have the proper configuration?
4. Clear fault codes. Turn ignition OFF and disconnect DiagnosticLink . Wait five minutes for all modules to
1
173.2 SPN 1484/FMI 13 - GHG17

SPN 1484/FMI 13
Description J1939 Message Was Lost
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2
174.1 SPN 1590/FMI 9 - GHG17

SPN 1590/FMI 9
Description Adaptive Cruise Control Message Not Received
Monitored Parameter PGR043 Adaptive Cruise Control Enable
Typical Enabling Conditions Key On, CPC Online, CAN Network Online, Adaptive Cruise
Control System Equipped, 10 Seconds After the Engine Has
Been Cranked
Typical Duration Two seconds
Dash Lamps None
Verification Engine Running For One Minute
WARNING
ENGINE EXHAUST
3. Verify that the vehicle is equipped with an Adaptive Cruise Control system. Is the vehicle equipped with
Adaptive Cruise?
4. Verify that the " Adaptive Cruise Control Enable" parameter PGR043 is disabled; refer to the Application
and Installation (A&I) manual. Is parameter PGR043 disabled?
4.a Yes; replace the Common Powertrain Controller (CPC). Verify repair.
4.b No; change the "Adaptive Cruise Control Enable" parameter PGR043 to disabled. Verify repair.
5. Is the vehicle equipped with Detroit Assurance?
6. For vehicles equipped with Detroit Assurance, parameter PGR043 should be set to 0 (zero) disable. Is
parameter PGR043 set to disable?
6.a Yes; replace the CPC. Verify repair.
6.b No; change parameter PGR043 to disable. Verify repair.
1
Fig 174.1, Adaptive Cruise Control
Fig 174.2, Adaptive Cruise Control Options
2
7. Does the display on the Adaptive Cruise Control module illuminate when the ignition is in the ON position?
7.a Yes; refer to the Adaptive Cruise Control maintenance manual and Original Equipment Manufacturer
(OEM) for further diagnostic information.
7.b No; verify power and ground to the Adaptive Cruise Control module. Refer to Original Equipment
Manufacturer (OEM) for wiring information.
3
174.2 SPN 1590/FMI 19 - GHG17

SPN 1590/FMI 19
Description Adaptive Cruise Control Message not Received or Signal
Error
Monitored Parameter Adaptive Cruise Control
Dash Lamps None
Check as follows:
WARNING
ENGINE EXHAUST
Note : This fault code may set if driver does not wait for gauge sweep after turning the ignition on.
also present?
1.a Yes; troubleshoot those faults first.
2. Verify that the vehicle is equipped with an Adaptive Cruise Control system. Is the vehicle equipped with
Adaptive Cruise?
3. Verify that the "Adaptive Cruise Control Enable" parameter PGR043 is disabled; refer to the Application and
Installation (A&I) manual. Is parameter PGR043 disabled?
3.b No; change the "Adaptive Cruise Control Enable" parameter PGR043 to disabled. Verify repair.
4. Is the vehicle equipped with Detroit Assurance?
5. For vehicles equipped with Detroit Assurance, parameter PGR043 should be set to 0 (zero) disable. Is
parameter PGR043 set to disable?
5.b No; change parameter PGR043 to disable. Verify repair.
4
Fig 174.3, Adaptive Cruise Control
Fig 174.4, Adaptive Cruise Control Options
5
6. Does the display on the Adaptive Cruise Control module illuminate when the ignition is in the ON position?
6.a Yes; refer to the Adaptive Cruise Control maintenance manual and Original Equipment Manufacturer
(OEM) for further diagnostic information.
6.b No; verify power and ground to the Adaptive Cruise Control module. Refer to Original Equipment
Manufacturer (OEM) for wiring information.
6
175.1 SPN 1592/FMI 9 – GHG17

SPN 1592/FMI 9
Description This Fault Code Indicates a Missing Message from the
Antilock Brake System (ABS) Module.
Dash Lamps CEL
Verification Key OFF for Five Minutes, then Key ON, Engine OFF
configuration?
3.b No; check for proper parameter configuration of the CPC against the server information.
1
175.2 SPN 1592/FMI 13 - GHG17

SPN 1592/FMI 13
Description This code will Set when the J1939 Wheel Speed Signal is Not
Received.
Monitored Parameter Wheel Speed Sensor Signal
Dash Lamps CEL
Check as follows:
configuration?
3.a Yes; determine which modules are configured for the vehicle and their communication status. Once
this is done, follow the appropriate module communication troubleshooting procedures for the affected
3.b No; make corrections to the configuration of the CPC.
2
175.3 SPN 1592/FMI 19 – GHG17

SPN 1592/FMI 19
Description This code will Set when the J1939 Wheel Speed Signal is Not
Received
Monitored Parameter Wheel Speed Sensor Signal
Dash Lamps CEL
Check as follows:
configuration?
3.b No; make corrections to the configuration of the CPC.
3
176.1 SPN 1623/FMI 9 - GHG17

SPN 1623/FMI 9
Description This Diagnostic is Tachograph Output Shaft Speed Signal
Erratic
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1
176.2 SPN 1623/FMI 13 - GHG17

SPN 1623/FMI 13
Description This Diagnostic Is Tachograph Output Shaft Speed Signal Is
Not Available
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2
177.1 SPN 1624/FMI 9 - GHG17

SPN 1624/FMI 9
Description J1939 Message Not Available
Dash Lamps CEL
4.a Yes; check for proper CPC configuration.
1
177.2 SPN 1624/FMI 13 - GHG17

SPN 1624/FMI 13
Description Tachograph Vehicle Speed Signal is Missing
Dash Lamps CEL
2
177.3 SPN 1624/FMI 19 - GHG17

SPN 1624/FMI 19
Description Tachograph Vehicle Speed Signal is Erratic
Dash Lamps CEL
3
SPN 1624 (CPC3) (GHG17)
178.1 SPN 1624/FMI 2 – GHG17

Check as follows:
1. Note that this fault only pertains to vehicles with manual transmissions.
2. Are any ABS or Vehicle Speed Sensor (VSS) faults present?
3. Disconnect the vehicle speed sensor.
4. Inspect VSS harness connector for corroded, bent, spread or damaged pins. Is pin damage found?
4.b No; replace the vehicle speed sensor.
1
178.2 SPN 1624/FMI 3 – GHG17

Check as follows:
3.b No; repair open circuit between VSS sensor and pin 29 of the CPC3 connector #4. Refer to EZ Wiring
module 283 for schematic details.
2
178.3 SPN 1624/FMI 4 – GHG17

Check as follows:
3.b No; repair short to ground between VSS sensor and pin 29 of the CPC3 connector #4. Refer to EZ
Wiring module 283 for schematic details.
3
179.1 SPN 1636/FMI 0 - GHG17

Charge Air Cooler Low Efficiency
This code sets when the Motor Control Module (MCM) detects very high charge air and air intake manifold
temperatures.
SPN 1636/FMI 0
Description Charge Air Cooler (CAC) Low Efficiency
Monitored Parameter Intake Manifold And Charge Air Cooler Outlet Temperature
Sensors
Typical Enabling Conditions Coolant temperature above 65°C (149°F)
Execution Frequency Always enabled.
Typical Duration 10
Dash Lamps MIL, CEL
Verification Road test the vehicle with coolant temperature above 65°C
(149°F)
Note : The Intake Air Temperature and Charge Air Cooler Temperature can increase if the vehicle is driven on
steep inclines in lower gears.
Possible causes:
• Low vehicle speed with high engine load
• External CAC restriction
• Internal CAC restriction
• Fluid intrusion into the CAC
Check as follows:
1. Is the vehicle equipped with a plow?
2. Remove the plow and test drive the vehicle. Does fault code SPN 1636/FMI 16 or SPN 1636/ FMI 0
become active?
2.b No; the plow is restricting the air flow through the CAC. Advice the customer to operate the vehicle with
the plow angled to allow air flow through the CAC.
3. Is the vehicle equipped with a winter front?
4. Remove the winter front and road test the vehicle. Does fault code SPN 1636/FMI 16 or SPN 1636/ FMI 0
become active?
4.b No; the winter front is restricting the air flow through the CAC. Refer to TS letter 14TS-11 for winter front
information.
5. Use a flashlight to shine through the radiator and CAC assemblies. Can the light from the flashlight be seen
through the other side of the assembly?
1

5.b No; clean the CAC assembly as necessary.
6. Remove and inspect the piping to the CAC. Are there signs of fluid intrusion?
6.a Yes; diagnose and repair the cause of the fluid intrusion. Refer to OEM literature and flush the CAC.
Verify repair.
6.b No; refer to OEM literature and perform the CAC restriction test. Repair as necessary. Verify repair.
2
179.2 SPN 1636/FMI 3 - GHG17

Intake Manifold Temperature Circuit Failed High
SPN 1636/FMI 3
Description Intake Manifold Temperature Circuit Failed High
Monitored Parameter Intake Manifold Temperature Sensor
Dash Lamps MIL, CEL
3
Check as follows:
2. Disconnect and inspect the Intake Manifold Temperature sensor electrical connector for signs of damaged,
bent spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any
damaged found?
2.a Yes; repair as necessary. If corrosion is present replace the sensor and the harness pig tail. Verify
repair.
4. Measure the voltage between pins 1 and 2 of the Intake Manifold Temperature sensor connector (harness
side). Is the voltage between 2.5 and 3.5 volts?
4.a Yes; replace the Intake Manifold Temperature sensor. Refer to section "Removal of the Intake Manifold Air
4

5. Measure the voltage between pin 2 of the Intake Manifold Temperature connector, harness side and
ground. Is the voltage between 2.5 and 3.5 volts?
5.a Yes; repair the wire between pin 1 of the Intake Manifold Temperature Sensor connector and pin 52 of
the 120-pin Motor Control Module (MCM) connector . Verify repair.
5.b No; repair the wire between pin 2 of the Intake Manifold Temperature sensor connector and pin 106 of
the 120-pin MCM connector. Verify repair.
5
179.3 SPN 1636/FMI 4 - GHG17

Intake Manifold Temperature Circuit Failed Low
SPN 1636/FMI 4
Description Intake Manifold Temperature Circuit Failed Low
Dash Lamps MIL, CEL
6
Check as follows:
1. Connect DiagnosticLink . Go to step 2.
2. Disconnect and inspect the Intake Manifold Temperature sensor electrical connector for signs of damaged,
bent spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any
damaged found?
repair.
3. Turn the ignition on (key ON, engine OFF). Go to step 4.
4. Check the fault codes. Is fault code SPN 1636/FMI 3 now present?
4.a Yes; replace the Intake Manifold Temperature sensor. Refer to section "Removal of the Intake Manifold Air
7
5. Turn the ignition off. Go to step 6.

6. Disconnect and inspect the 120-pin Motor Control Module (MCM) connector. Go to step 7.
7. Measure the resistance between pin 2 of the Intake Manifold Temperature sensor connector, harness side
and ground. Is the resistance greater than 10K ohms?
7.b No; repair the short to ground between pin 2 of the Intake Manifold Temperature sensor connector and
pin 106 of the 120-pin MCM connector. Verify repair.
8
179.4 SPN 1636/FMI 14 - GHG17

Intake Manifold Temperature Sensor Signal Not Plausible
SPN 1636/FMI 14
detects that the intake manifold temperature is greater than
Monitored Parameter
Intake Manifold Temperature
Typical Enabling Conditions Key ON, engine OFF, battery voltage greater than 11.08 volts,
Dash Lamps MIL
Engine Reaction 25% derate, regen disabled
operating temperature. Then verify that the intake manifold
temperature is within 10°C (18°F) of the Charge Air Cooler
outlet temperature.
been changed?
5. Disconnect and inspect the intake manifold temperature sensor electrical connector for signs of damage,
bent, spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any
damage found?
5.a Yes; replace the intake manifold temperature sensor and the harness pig tail. Verify repair.
5.b No; replace the intake manifold temperature sensor. Verify repair.
9
179.5 SPN 1636/FMI 16 - GHG17

Charge Air Cooler Efficiency Low
SPN 1636/FMI 16
Description This fault code sets when the Charge Air Cooler (CAC) outlet
temperature is greater than the modeled temperature.
Monitored Parameter Charge Air Cooler outlet temperature.
Typical Enabling Conditions Ambient temperature greater than -8°C (17.6°F), ambient air
pressure greater than 755 mbar (10.9 psi), engine speed
between 900 to 1650 rpm, vehicle speed greater than 45
km/hr.
Dash Lamps MIL, CEL
Engine Reaction 10% derate
Verification Road test the vehicle with the engine speed between 900 and
1650 rpm.
Check as follows:
Possible causes:
• Low vehicle speed with high engine load
• External CAC restriction (such as a plow, winter front or dirt) Refer to 14TS-11 for information on winter
front usage and effect on vehicle performance
• Internal CAC restriction
1. Is the vehicle equipped with a plow?
2. Remove the plow and test drive the vehicle. Does fault code SPN 1636/FMI 16 become active?
2.b No; the plow is restricting the air flow through the CAC. Advise the customer to operate the vehicle with
the plow angled to allow air flow through the CAC.
3. Is the vehicle equipped with a winter front?
4. Remove the winter front and road test the vehicle. Does fault code SPN 1636/FMI 16 become active?
4.b No; the winter front is restricting the air flow through the CAC. Refer to TS letter 14TS-11 for winter front
information.
5. Use a flashlight to shine through the radiator and CAC assembly. Can the light from the flashlight be seen
through the other side of the assembly?
5.b No; clean the CAC assembly as necessary.
6. Remove and inspect the piping to the CAC. Are there signs of fluid intrusion?
6.a Yes; diagnose and repair the cause of the fluid intrusion. Refer to OEM literature and flush the CAC.
Verify repair.
6.b No; refer to OEM literature and perform the CAC restriction test. Repair as necessary. Verify repair.
10
180.1 SPN 1637/FMI 2 - GHG17

Coolant Out Temperature Signal Not Plausible
SPN 1637/FMI 2
Description This fault Code Sets when the Motor Control Module (MCM)
Detects that the Engine Coolant Outlet Temperature is
Greater than 20°C (36°F) From the Expected Temperature
After the Engine has Been Turned Off for 8 Hours.
Monitored Parameter
Coolant Outlet Temperature
Engine rpm at Zero, Ambient Temperature Less than 40°C
(104°F), Engine OFF for No Less than 8 Hours.
Execution Frequency Once Per Cool Down Cycle
Dash Lamps MIL
Verification Road Test the Vehicle for 30 Minutes Until the Coolant
Reaches Operating Temperature. Then Verify that the Engine
Coolant Outlet Temperature is Within 20°C (36°F) of the
Engine Coolant Inlet Temperature.
Possible causes:
been changed?
6. Monitor and record the engine coolant outlet temperature.
1
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

9. Monitor engine coolant outlet temperature. Has the temperature increased from the previously recorded
value?
10. Compare the engine coolant outlet temperature to the engine coolant inlet temperature. Is the difference
greater than 20°C (36°F)?
11. Disconnect and inspect the engine coolant outlet temperature sensor electrical connector. Is there damage
or corrosion present?
11.b No; replace the engine coolant outlet temperature sensor. Verify repair.
2
181.1 SPN 1639/FMI 2 - GHG17

SPN 1639/FMI 2
Description This Code Sets When a Fan Speed Deviation is Detected
Monitored Parameter Fan Speed Sensor
Dash Lamps CEL
Verification Engine Running With Fan Engaged
2. Check for multiple codes. Are fault codes SPN 1071/FMI Any or SPN 647/FMI Any present?
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

4. Monitor fan speed. Engage fan with manual override switch or air conditioner. Does fan speed increase
with engine speed?
4.a Yes; replace the fan speed sensor. Refer to Original Equipment Manufacturer (OEM) procedures.
4.b No; replace fan drive. Refer to OEM procedures.
2
182.1 SPN 1659/FMI 7 - GHG17

Thermostat cool down
SPN 1659/FMI 7
Description This Fault Sets when the engine coolant temperature is not
maintained to match a modeled temperature range.
Monitored Parameter Inlet coolant temperature and outlet coolant temperature
Ambient temp greater than -8°C (18°F)
Ambient pressure greater than 755 mbar (11 psi)
Vehicle speed greater than 45 km/hr (27 mph)
Engine run time after engine start greater than 5 min.
Dash Lamps MIL
Verification Road test the vehicle for 40 minutes.
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 110/FMI 3, SPN 110/FMI 4, SPN 110/FMI 14, SPN
4193/FMI 2, SPN 4193/FMI 3, SPN 4193/FMI 4, or SPN 4193/FMI 17 present?
4. Is this vehicle a bus?
5.a Yes; isolate the components and retest. If the fault code returns, replace the thermostat. Refer to section
"Removal of the Engine Coolant Thermostat and Seal" .
5.b No; replace the thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
1
182.2 SPN 1659/FMI 17 - GHG17

Coolant temperature low pre fail
SPN 1659/FMI 17
Description This Fault Sets when the engine coolant temperature has not
increased to match a modeled temperature range.
Monitored Parameter Coolant temperature
Ambient temp greater than -8°C (18°F)
Ambient pressure greater than 755 mbar (11 psi)
Vehicle speed greater than 45 km/hr (27 mph)
Engine run time after engine start greater than 5 min.
Dash Lamps None
Verification None
This fault code is an informational/silent fault code. This fault code sets when the coolant temperature is not within
a calibrated threshold, which starts another monitor to determine if there is a cooling system concern present.
Check as follows:
3. Check for other fault codes. Is fault code SPN 110/FMI 18 also present?
3.b No; erase the fault code and release the vehicle.
2
182.3 SPN 1659/FMI 31- GHG17

SPN 1659/FMI 31 - GHG17
Description Engine coolant temperature not matched
Monitored Parameter Outlet coolant temperature
Dash Lamps None
Verification None
This fault code is an informational/silent fault code. This fault code sets when the coolant temperature is not within
a calibrated threshold, which starts another monitor to determine if there is a cooling system concern present.
Check as follows:
3. Check for other fault codes. Is fault code SPN 110/FMI Any or SPN 4193/FMI Any also present?
3.a Yes; diagnose other fault codes first.
3.b No; erase the fault code and release the vehicle.
3
183.1 SPN 1663/FMI 7 - GHG17

SPN 1663/FMI 7
Description Optimized Idle Safety Loop Faulted
Monitored Parameter Optimized Idle Safety Loop (Parking Brake, Hood Tilt Switch,
Neutral Safety Switch and Vehicle Speed)
Typical Enabling Conditions Fault is Set Active if a Maximum Number of Vehicle Speed
Sensor Pulses During an Optimized Idle Engine Start is
Exceeded or the Vehicle Speed is Above 0.25 Km/H or the
Engine Torque is Above a Calibratable Threshold For 2
Seconds
Execution Frequency
Typical Duration
Dash Lamps CEL
Verification Run an Optimized Idle Mode
Note : When creating log files for optimized idle issues using DiagnosticLink®, add the J1939 connection. This will
create larger log files but the information needed will be available to reduce troubleshooting time.
Check as follows:
1. Open DiagnosticLink .
2. Go to the tools drop-down menu and select options.
3. Select the connection tab.
4. Is there a check mark in the box next to J1939ECU?
4.b No; click on the box so the check mark will appear, then Go to step 5.
Note : If fault code SPN 1663/FMI 7 is inactive, it may indicate that the vehicle moved during optimized idle
operation or that noise was detected on the Vehicle Speed Sensor (VSS).
5. Turn the ignition ON (key ON, engine OFF)
6. Connect to DiagnosticLink.
Note : The Optimized Idle Safety Loop is made up of the parking brake, hood tilt switch, neutral safety switch and
vehicle speed.
7. Use DiagnosticLink to monitor the Optimized Idle Safety Loop. Cycle the switches that make up the safety
loop and make sure they operate correctly. Is a failure present with the Optimized Idle Safety Loop?
7.a Yes; repair the failed Optimized Idle Safety Loop component.
8. Use DiagnosticLink to monitor the following:
Latest OI Dropout Reason t0
Latest OI Dropout Reason t-1
9. The value indicated by the Latest OI Dropout Reason indicates the failure causing the code to come active.
"t0" indicates the most recent and "t-4" indicates the least recent. Repair the failure as indicated by the
Latest OI Dropout Reason.
1
184.1 SPN 1669/FMI 9 - GHG17

SPN 1669/FMI 9
Description ACM PT-CAN 4 High Short to Ground or CAN 4 Low Short to
Power
Dash Lamps MIL, CEL
1
2
Check as follows:
Go to step 3.
3. Is the aftertreatment system a 1-BOX™ configuration?
3.b No; for a Two-Box option, Go to step 6.
4. Turn the ignition OFF and disconnect the ACM 120-pin connector.
5. Measure the resistance between pins 40 and 41 on the ACM connector, component side. Is the resistance
5.a Yes; replace the aftertreatment harness.
7. Disconnect the inlet NOx sensor four-way electrical harness connector.
3
8. Check the resistance between pins 1 and 2 of the inlet NOx sensor electrical connector, aftertreatment
harness side. Is the resistance greater than 10k ohms?
8.b No; repair or replace the harness as necessary.
9. Check the resistance between pins 3 and 4 of the inlet NOx sensor, harness side. Is the resistance greater
than 10k ohms?
10. Disconnect the outlet NOx sensor four-way electrical harness connector.
11. Check the resistance between pins 1 and 2 of the outlet NOx sensor electrical connector, aftertreatment
12. Check the resistance between pins 3 and 4 of the outlet NOx sensor electrical connector, aftertreatment
13. Disconnect the soot sensor four-way electrical harness connector.
14. Check the resistance between pins 2 and 3 of the soot sensor electrical connector, aftertreatment harness
side. Is the resistance greater than 10k ohms?
15. Check the resistance between pins 1 and 4 of the soot sensor electrical connector, aftertreatment harness
side. Is the resistance greater than 10k ohms?
17. Measure the resistance between pins 40 and 41 on the ACM connector, component side. Is the resistance
17.a Yes; replace the aftertreatment harness.
4
185.1 SPN 1681/FMI 9 – GHG17

SPN 1681/FMI 9
Description Battery Main Switch Message is Missing
Monitored Parameter Battery Main Switch
Dash Lamps CEL
Verification Idle
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
configuration?
1
186.1 SPN 1716/FMI 9 - GHG17

SPN 1716/FMI 9
Monitored Parameter This Code Will Set When the J1939 ERC1 Message is Not
Received
Dash Lamps CEL
Verification Idle
diagnosing a fault.
Check as follows:
1
186.2 SPN 1716/FMI 13 – GHG17

SPN 1716/FMI 13
Description 5-Stage Retarder Message is Missing or Not Plausible
Monitored Parameter This code will set when the Evobus Five-Stage Retarder
Signal is Not Received
Dash Lamps CEL
Verification Idle
Module (MCM) faults. DignosticLink® Standard makes the distinction between the MCM and CPC when
diagnosing a fault.
Check as follows:
2
187.1 SPN 1761/FMI 1 - GHG17

Diesel Exhaust Fluid (DEF) Tank Level 0 Condition - Empty Tank - Speed Limited
SPN 1761/FMI 1
Description DEF Tank Level 0 - Empty(Speed Limited)
Monitored Parameter DEF Tank Level
Typical Enabling Conditions DEF Tank Level less than 2.5%
Typical Duration 10 Minutes
Dash Lamps MIL, CEL
This fault indicates that the DEF tank level is empty and the warning lamps have been ignored. A 25% engine
derate and 5 mph speed limit is in effect. DEF must be added to the DEF tank (minimum ¼ tank). After refill, idle
engine for five minutes; if fault does not go inactive or dash lamp stays ON, refer to OEM literature for DEF level
sensor diagnostics.
1
187.2 SPN 1761/FMI 2 – GHG17

Diesel Exhaust Fluid (DEF) Tank Level Sensor Circuit Data Erratic, Intermittent or Incorrect
1.a If SPN 1761/3 and 3031/3 are present, Go to step 2.
1.b If SPN 1761/3 is present, Go to step 9.
2. Disconnect the DEF tank temperature/level sensor.
3. Inspect the DEF tank temperature/level sensor connector for bent, spread or corroded pins.
3.a If bent, spread or corroded pins are found, repair as necessary.
3.b If no connector issues are found, Go to step 4.
5. Measure the voltage between pin 2 on the harness side of the DEF tank temperature/level sensor and
ground.
5.a If voltage is present, repair short to power between pin 2 on the harness side of the DEF tank
temperature/level sensor and pin 102 of the Aftertreatment Control Module (ACM).
5.b If no voltage is present Go to step 6.
8. Measure the resistance between pin 2 on the harness side of the DEF tank temperature/level sensor and
pin 102 of the ACM.
8.a If the resistance is greater than 5 ohms, repair wire between pin 2 on the harness side of the DEF tank
temperature/level sensor and pin 102 of the ACM.
8.b If the resistance is less than 5 ohms, refer to OEM literature for DEF tank temperature/level sensor
replacement.
9. Disconnect the DEF tank temperature/level sensor.
10. Inspect the DEF tank temperature/level sender connector for bent, spread or corroded pins.
12. Measure the voltage between pin 1 on the harness side of the DEF tank temperature/level sensor and
ground.
12.a If voltage is greater than 3.00 volts, repair short to power between pin 1 on the harness side of the DEF
tank temperature/level sensor and pin 109 of the ACM.
12.b If voltage is between 2.0 and 2.95, refer to OEM literature for DEF temperature/level sensor
replacement.
12.c If voltage is less than 2.5 volts, repair wire between pin 1 on the harness side of the DEF
temperature/level sensor and pin 109 of the ACM.
2
187.3 SPN 1761/FMI 3 - GHG17

SPN 1761/FMI 3
Description Diesel Exhaust Fluid (DEF) Tank Level Sensor Circuit Failed
High
Monitored Parameter DEF Tank Level Sensor
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3
4
Note : When there is no signal from the DEF level/temperature sensor, the vehicle will go into the low DEF level
derate.
Check as follows:
1. Disconnect and inspect the DEF tank level/temperature sensor connector. Are there any bent, spread, or
corroded pins?
3. Measure the voltage between pin 2 of the DEF tank level/temperature sensor, harness side connector and
ground. Is there any voltage present?
3.a Yes; repair the short to power between pin 2 of the DEF tank level/temperature connector and pin 102
of the 120-pin ACM connector. Verify repair.
5
4. Measure the voltage between pin 1 of the DEF tank temperature/level sensor, harness side connector and
ground. Is there 3.0 volts?
6. Measure resistance between pin 2 of the DEF tank level/temperature sensor connector and ground. Is the
6.a Yes; replace the DEF tank temperature/level sensor. Refer to section "Removal of the 13- and 23-Gallon Diesel
Exhaust Fluid Tank Header Unit" . Verify repair.

7. Disconnect and inspect the 120-pin Aftertreatment Control Module (ACM), harness side, connector. Are
there any bent, spread, or corroded pins?
8. Measure the resistance between pin 2 of the DEF tank level/temperature sensor, harness side connector
and pin 102 of the 120-pin ACM connector. Is the resistance less than five ohms?
8.b No; repair the wire between pin 2 of the DEF tank level/temperature sensor connector and pin 102 of
the 120-pin ACM connector. Verify repair.
9. Install a test ACM. Is SPN 1761/FMI 3 still present?
9.b No; replace the ACM. Verify repair.

10. Disconnect and inspect the 120-pin ACM connector. Are there any bent, spread, or corroded pins?
11. Measure the resistance between pin 1 of the DEF tank level/temperature sensor, harness side, connector
and pin 109 of the 120-pin ACM harness side connector. Is the resistance less than five ohms?
the 120-pin ACM connector.
6
187.4 SPN 1761/FMI 4 - GHG17

SPN 1761/FMI 4
Description Diesel Exhaust Fluid (DEF) Tank Level Sensor Circuit Failed
Low
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7
8
derate.
Check as follows:
2. Disconnect and inspect the Diesel Exhaust Fluid (DEF) tank temperature/level sensor connector. Is there
any damage, corrosion, or water present?
3. Measure the resistance from pin 1 of the DEF tank temperature/level sensor harness side connector and
3.b No; repair the wire between pin 1 of the DEF tank temperature/level sensor connector and pin 109 of
9
4. Install a test ACM. Is code SPN 1761/FMI 4 still present?

10
187.5 SPN 1761/FMI 9 – GHG17

Diesel Exhaust Fluid (DEF) Tank Signal Not Available via CAN
1. Has the Aftertreatment Control Module (ACM) been recently reprogrammed?
1.a Yes; clear fault codes. If they do not become active, release the vehicle. If fault returns, verify proper
ACM fuel map. ACM is looking for DEF tank Controller Area Network (CAN) signal, except vehicle may
be hardwired.
4. Reconnect DiagnosticLink. Are fault codes active?
6. Disconnect the DEF tank header harness connector.
7. Inspect DEF tank header for bent, spread or corroded pins.
8. Measure the resistance across pins 1 and 2 of the DEF tank header harness connector.
8.a If the resistance is between 40 and 80 ohms, Go to step 11.
8.b If the resistance is not between 40 and 80 ohms, Go to step 9.
of the ACM 120-pin connector.
10.a If the resistance is 50 to 70 ohms, repair the shorted DEF CAN harness.
10.b If the resistance is not between 50 to 70 ohms, replace the ACM.
11. Measure and record the resistance between the ACM 120-pin connector pins 48 and 49 to engine ground.
11.a If the resistance is greater than 10K ohms on both wires, replace the DEF tank header. Verify repairs.
11.b If the resistance is less than 10K ohms, repair the short in the harness between ACM 120-pin
connector pins 48 or 49 and ground.
11
187.6 SPN 1761/FMI 18 - GHG17

Diesel Exhaust Fluid (DEF) Tank Level 1 Condition - Empty Tank
SPN 1761/FMI 18
Description DEF Tank Level 1 - Empty
Monitored Parameter DEF Tank Level
Typical Enabling Conditions DEF Tank Level less than 2.5%
Dash Lamps MIL, CEL
This fault indicates that the DEF tank level is empty. A 25% engine derate and 55 mph speed limit is in effect.
DEF must be added to the DEF tank (minimum ¼ tank). After refill, idle engine for five minutes; if fault does not go
inactive or dash lamp stays on, refer to OEM literature for DEF level sensor diagnostics.
12
187.7 SPN 1761/FMI 31 - GHG17

Diesel Exhaust Fluid (DEF) Tank Level 3 Condition - Tank Level Very Low
This fault indicates that the DEF tank level is very low. DEF must be added to the DEF tank (minimum ¼ tank).
After refill, idle engine for five minutes; if fault does not go inactive or dash lamp stays on, refer to OEM literature
for DEF level sensor diagnostics.
13
188.1 SPN 1814/FMI 9 - GHG17

VDC1 Message was Not Received or Has Stopped Arriving
SPN 1814/FMI 9
Description VDC1 Message Missing
Monitored Parameter
Dash Lamps CEL
diagnosing a fault.
Check as follows:
1. Check for multiple codes. Are Common Powertrain Controller (CPC) SPN 168/FMI (any) (battery voltage)
(Charging System) faults present?
2. Are Controller Area Network (CAN) line faults SPN 625/FMI (any) present?
3.a Yes; ensure the parameters are configured correctly for the vehicle application; refer to the Application
and Installation Manual for the correct parameter configuration.
module.
1
189.1 SPN 1845/FMI 9 - GHG17

J1939 TCFG2 Message is Missing
SPN 1845/FMI 9
Description J1939 TCFG2 signal is Missing
Monitored Parameter This codes sets when the J1939 message is not received
Dash Lamps CEL
Check as follows:
module.
1
190.1 SPN 2000/FMI 9 - GHG17

Communication loss with a Common Powertrain Controller (CPC) module (CPC heartbeat message is no longer
arriving)
SPN 2000/FMI 9
Description CPC Module has Lost Communication
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps
Engine Reaction MIL, CEL
Verification Limp mode, Shut-down condition
1
Check as follows:
Go to step 3.

2
WARNING
ELECTRICAL SHOCK
usage.
21 of the CPC connector cavity #3, component side. Is the resistance 110 to 130 ohms?

4.b No, replace the CPC.
5. Disconnect the MCM 21 pin connector and inspect connector for corrosion, oil, fuel or water intrusion. Is
3

6. Measure and record the resistance between CPC connector #3, pin 19 and MCM 21-pin connector pin 19.
6.b No, repair the wire between CPC connector #3, pin 19 and MCM 21-pin connector pin 19.
7. Measure and record the resistance between CPC connector #3, pin 21 and MCM 21-pin connector pin 13.
7.b No, repair the wire between CPC connector #3, pin 21 and MCM 21-pin connector pin 13.
4
5
9. Measure the voltage between MCM 21-pin connector pins 7, 11, 12, 14, and 15 (ignition/battery voltage)
and ground. Is voltage within 1.5 volts of the battery voltage?
9.b No, Repair the circuit in question.
11. Measure the resistance between MCM 21-pin connector pins, 5, 6, 8 and 9 of the negative battery post. Is
11.b No, Repair the circuit in question.
12. Install a test MCM. Is communication restored (fault inactive)?
12.a Yes. replace the MCM.
12.b No, replace the CPC.
6
191.1 SPN 2003/FMI 9 - GHG17

SPN 2003/FMI 9
Description J1939 Signal Missing
Monitored Parameter This code sets when the J1939 message is not received
Dash Lamps CEL
Check as follows:
2.a Yes; troubleshoot and repair Controller Area Network (CAN) line.
1
192.1 SPN 2011/FMI 9 - GHG17
3. Has the Common Powertrain Controller (CPC) been recently programmed? Check for proper configuration
of the CPC against the server information. Does the CPC have the proper configuration?
3.b No; correct the information as necessary. Verify repair.
1
193.1 SPN 2017/FMI 9 - GHG17

SPN 2017/FMI 9
Description J1939 Message is Missing from Source Address 17 (dec)
Dash Lamps None
Check as follows:
1
194.1 SPN 2023/FMI 9 - GHG17

SPN 2023/FMI 9
Dash Lamps None
Check as follows:
1
195.1 SPN 2025/FMI 9 - GHG17

SPN 2025/FMI 9
Dash Lamps None
Check as follows:
1
196.1 SPN 2033/FMI 9 - GHG17

SPN 2033/FMI 9
Dash Lamps None
Check as follows:
1
197.1 SPN 2042/FMI 9 - GHG17

SPN 2042/FMI 9
Description J1939 message is Missing from Source Address 42 (dec)
Monitored Parameter CAN communication
Typical Enabling Conditions Always enabled
Dash Lamps None
Check as follows:
3. Has the Common Powertrain Controller (CPC) been recently reprogrammed? Check for proper
configuration of the CPC against the server information. Does the CPC have the proper configuration?
1
198.1 SPN 2049/FMI 9 - GHG17

SPN 2049/FMI 9
Dash Lamps None
Check as follows:
1
199.1 SPN 2596/FMI 9 - GHG17

J1939 CM1 Message (Maximum Vehicle Speed Limit) is Missing or Not Available
SPN 2596/FMI 9
Description Maximum Vehicle Speed Limit is Missing
Monitored Parameter J1939 Powertrain Message
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
1
200.1 SPN 2623/FMI 2 - GHG17

Accelerator Pedal "In-Range" Fault
SPN 2623/FMI 2
Description Pedal Position Sensors Deviation Too High
Monitored Parameter GAS1, GAS2
Dash Lamps None
1
Fig 200.2, Dual-Channel Analog Pedal

Function CPC Pinout Connector Pinout Comments Connector
Body
APS1 1/7 A Sensor 1
GND1 1/4 B APS 1 GND
GND2 3/2 E APS2 GND
APS2 4/14 F Sensor 2
Check as follows:
2. Connect DiagnosticLink ; are any SPN 91/FMI 0, FMI 2, FMI 4, or FMI 8 fault codes active?
4. Disconnect the AP.
damage found?
2

6.a Yes; repair a short to power between pin B of the AP harness connector and pin 4 of the CPC #1
7.a Yes; repair a short to power between pin A of the AP harness connector and pin 7 of the CPC #1
9.a Yes; repair a short to power between pin F of the AP harness connector and pin 14 of the CPC #4
10.a Yes; repair a short to power between pin E of the AP harness connector and pin 2 of the CPC #3
11.a Yes; repair a short to power between pin F of the AP harness connector and pin 2 of the CPC #2
12. Reconnect the AP.
voltage sweep smoothly in relation to pedal travel? Do the percentages sweep smoothly in relation to pedal
travel?
15. Clear codes and cycle ignition OFF.
17.a Yes; replace the AP, clear codes and verify repair. Refer to Original Equipment Manufacturer's (OEM)
literature.
18. Gently wiggle pedal and harness connector to simulate road vibration.
NOTICE
3
NOTICE
A second technician may be required to monitor values during wiggle testing.
20. Cycle AP slowly several times with a full sweep from top to bottom of travel. Do the percentages sweep
smoothly in relation to pedal travel?
literature.
21. Gently wiggle the Common Powertrain Controller (CPC) harness connectors to simulate road vibration.
23. Cycle AP slowly several times with a full sweep from top to bottom of travel. Do the percentages sweep
smoothly in relation to pedal travel?
damage found?
4
200.2 SPN 2623/FMI 8 - GHG17

2-Channel Accelerator Pedal Signal 2 Missing
SPN 2623/FMI 8
Description Channel 2 Sensor Signal Failed (High Or Low)
Typical Enabling Conditions Always ON
Dash Lamps CEL
WARNING
ENGINE EXHAUST
5
Fig 200.4, Dual-Channel Analog Pedal

Function CPC Pinout Connector Pinout Comments Connecto
r Body
APS1 1/7 A Sensor 1
GND2 3/2 E APS2 GND
APS2 4/14 F Sensor 2
Check as follows:
damage found?
4.a Yes; repair the short to power between pin B of the AP harness connector and pin 4 of the CPC
connector #1. Verify repair.
6

7. Measure the resistance between pin D of the AP harness connector and pin 3 of the CPC connector #3. Is
7.a Yes; reconnect the CPC connector #3. Go to step 8.
7.b No; repair the open circuit between pin D of the AP harness connector and pin 3 of the CPC connector
#3. Verify repair.
8. Measure the voltage between pin D of the AP harness connector and ground. Is the voltage between 4.5
and 5.5 volts?
8.a Yes; repair the open circuit between pin E of the AP harness connector and pin 2 of the CPC connector
#3. Verify repair.
9. Measure the voltage between pin D of the AP harness connector and ground. Is voltage greater than 5.5
volts?
9.a Yes; repair the short to battery power between pin D of the AP harness connector and pin 3 of the CPC
10.a Yes; repair the short to power between pin E of the AP harness connector and pin 2 of the CPC
12. Measure the resistance between pin F of the AP harness connector and pin 14 of the CPC connector #4. Is
12.b No; repair the open circuit between pin F of the AP harness connector and pin 14 of the CPC
13. Measure the resistance between pin F of the AP harness connector and ground. Is the resistance greater
than 10K ohms?
13.b No; repair the short to ground circuit between pin F of the AP harness connector and pin 14 of the CPC
connector #4 . Verify repair.
14.a Yes; repair the short to power between pin F of the AP harness connector and pin 14 of the CPC
16. Measure the resistance between pin F of the AP harness connector and pin 2 of the CPC connector #2. Is
16.b No; repair the open circuit between pin F and pin 2 of the CPC connector #2 . Verify repair.
17.a Yes; repair the short to power between pin F of the AP harness connector and pin 2 of the CPC
17.b No; replace the AP. Refer to Original Equipment Manufacturer (OEM) literature. Verify repair.
7
200.3 SPN 2623/FMI 14 - GHG17

2-Channel Accelerator Pedal GAS1 and GAS2 Signal Missing
SPN 2623/FMI 14
Description PWM Pedal Signal is Missing
Dash Lamps None
Check as follows:
1. Turn the ignition ON (key ON, engine OFF) .
2. Connect DiagnosticLink® and check for multiple codes. Are there any SPN 168 (battery voltage) fault
codes present?
4. Check for proper configuration of the CPC against the server information . Does the CPC pedal type have
8
SPN 2623 (CPC3) (GHG17)
201.1 SPN 2623/FMI 8 - GHG17

Check as follows:
damage found?
1

al
Har
nes
s
Con
nect
or
Bod
y
APS1 2/3 A SENSOR 1
GND2 2/14 E APS2 GND The
ima
ge
abo
ve
is
the
front
side
look
ing
into
the
pins
on
the
Har
nes
s
Con
nect
or.
APS2 2/4 F SENSOR 2 Har
nes
s
Con
nect
or
and
Seal
(P/N
:
120
663
17)
Ter
min
al
Fem
ale
(P/N
:
121
038
81)
4. Measure the voltage between pins D and E of the AP harness connector. Is the voltage between 4.5 and
5.5 volts?
4.a Yse; Go to step 6.
and 5.5 volts?
2
5.a Yes; repair the open circuit between pin E of the AP harness connector and pin 14 of the CPC3
5.b No; repair the circuit between pin D of the AP harness connector and pin 21 of the CPC3 connector #2.
Verify repair.
6. Measure the voltage between pin F of the AP harness connector and ground. Is any voltage present?
6.a Yes; repair the short to power between pin F of the AP harness connector and pin 4 of the CPC3
8. Disconnect the CPC3 connector #2.
9. Inspect the CPC3 connector #2 and the harness connector for signs of damaged, bent, spread, corroded or
any damage found?
10. Measure the resistance between pin F of the AP harness connector and pin 4 of the CPC3 connector #2. Is
10.b No; repair the circuit between pin F of the AP harness connector and pin 4 of the CPC3 connector #2.
Verify repair.
than 10K ohms?
11.a Yes; replace the AP. Verify repair.
11.b No; repair the shorted circuit between pin F of the AP harness connector and pin 4 of the CPC3
connector #2.
3
202.1 SPN 2630/FMI 3 - GHG17

SPN 2630/FMI 3
Description Charge Air Cooler (CAC) Short to Voltage or Open
Monitored Parameter CAC Outlet Temperature Sensor
Dash Lamps CEL
Note : The Charge Air Cooler (CAC) outlet temperature sensor is referred to as the intake air temperature sensor
in some documentation.
1
WARNING
PERSONAL INJURY
Check as follows:
3. Check for multiple codes. Are there any additional circuit failed high (FMI 3) codes for fuel rail pressure
sensor and the oil separator speed sensor?
3.a Yes; repair short to power or open circuit between pin 102 of the Motor Control Module (MCM) 120-pin
connector and the CAC outlet temperature sensor, fuel rail pressure sensor and oil separator speed
sensor.
4. Disconnect the CAC outlet temperature sensor.
6. Measure the voltage between pin 3 of the CAC outlet temperature sensor and ground. Is the voltage less
than 2.75 volts?
6.a Yes; repair the open circuit between pin 3 of the CAC outlet temperature sensor harness connector
and pin 119 of the MCM 120-pin connector.
7. Measure the voltage between pin 4 of the CAC outlet temperature sensor harness connector and ground.
Is the voltage less than 2.75 volts?
7.b No; repair the short to power between pin 4 of the CAC outlet temperature sensor harness connector
8. Measure the resistance between pin 4 of the CAC outlet temperature sensor harness connector and
ground. Is the resistance less than five ohms?
8.b No; repair the open circuit between pin 4 of the CAC outlet temperature sensor harness connector and
9. Disconnect the MCM 120-pin connector and measure the resistance between pins 4 and 3 of the coolant
outlet temperature sensor harness connector. Is the resistance greater than 10k ohms?
9.a Yes; replace CAC Outlet Temperature Sensor. Refer to section "Removal of the Intake Pressure/Temperature
Sensor" .
9.b No; repair the short between pins 102 and 119 of the MCM 120-pin connector.
2
202.2 SPN 2630/FMI 4 - GHG17

Intake air temperature circuit failed low
Repair the short to ground between pin 2 of the intake air temperature sensor harness connector and pin 119 of
the Motor Control Module (MCM) 120–pin connector.
3
202.3 SPN 2630/FMI 14 - GHG17

Charge Air Cooler Outlet Sensor Signal Not Plausible
SPN 2630/FMI 14
detects that the charge air cooler temperature is greater than
Monitored Parameter
Charge Air Cooler outlet temperature
Typical Enabling Conditions Key ON, engine OFF, battery voltage greater than 11.08 volts,
Dash Lamps MIL
operating temperature. Then verify that the Charge air cooler
outlet temperature is within 15°C (27°F) of the intake air
temperature.
been changed?
5. Disconnect and inspect the Charge Air Cooler outlet temperature sensor electrical connector. Is there
damage or corrosion present?
5.b No; replace the Charge Air Cooler outlet temperature sensor. Verify repair.
4
203.1 SPN 2631/FMI 1 - GHG17

Low Air Flow
SPN 2631/FMI 1
Description Insufficient Air Flow
Monitored Parameter Smoke Mode Operation
Typical Enabling Conditions General Enabling Condition: Engine is in Smoke Mode
Specific Enabling Conditions: See Table Below
Engine Parameter Min Max
Engine Coolant Outlet Temperature 65°C
(149°F)
Barometric Pressure (mbar) 755
Ambient Temperature -8°C
(18°F)
Dash Lamps MIL, CEL
Verification Once engine is at standard operating temperature, operate engine on
highway, coast for 30 seconds and then snap throttle and keep throttle at
100% for a minimum of 15 seconds.
Check as follows:
2. Are any other faults including SPN 51/FMI (any) also present?
restrictions. Are any air intake system leaks or restrictions found?
4. Compare intake manifold pressure to ambient pressure (Baro). Is the intake manifold pressure within 0.4
ambient pressure (Baro)?
5. Disconnect intake manifold pressure/temperature sensor.
6. Inspect intake manifold pressure/temperature sensor connector for bent, spread or corroded pins. Is
damage present?
6.b No; replace the intake manifold pressure/temperature sensor. Refer to section "Removal of the Intake
Pressure/Temperature Sensor" .
7. Using DiagnosticLink, monitor Exhaust Gas Recirculation (EGR) delta p voltage (pin 109).
8. Is the EGR delta p voltage between 0.55 and 0.83 volts?
1

9. Remove the EGR delta p sensor from the mounting pad, leave electrical harness connected.
10. Is the EGR delta p voltage between 0.55 and 0.83 volts?
10.b No; replace the EGR delta p sensor. Refer to section "Removal of the Delta P Sensor" .
11. Inspect the EGR delivery pipe delta p pressure ports for blockage. Is excessive build-up or blockage found?
11.a Yes; clean the venturi pipe and reinstall the sensor.
12. Remove the EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for excessive build-up
or blockage. Is excessive build-up or blockage found?
Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe"
Refer to section "Removal of the Exhaust Gas Recirculation Venturi"
12.a Yes; clean piping and replace EGR cooler.

13. Using SCR voltage service routine, monitor the Diesel Oxidation Catalyst (DOC) inlet pressure (pin 87) and
Diesel Particulate Filter (DPF) outlet pressure (pin 72) voltages with key ON, engine OFF.
14. Are the DOC inlet and DPF outlet pressure sensors voltages between .44 to .56 volts?
15. Is the voltage from step 14 greater than .56 volts?
15.a Yes; replace the suspect sensor.
15.b No; inspect electrical connections between suspect sensor connector and Aftertreatment Control
Module (ACM) for bent, spread, or corroded pins. Repair as necessary.
16. Inspect the DOC and DPF pressure sensor tubes and elbows for leaks, kinks, or blockage. Is damage
present?
17. Disconnect the turbo inlet elbow and outlet pipe, and inspect for signs of oil residue/contamination or
foreign debris. Is contamination found?
17.a Yes; determine the source of the contaminations and repair as necessary.
WARNING
HOT EXHAUST
18. Perform a parked regeneration. Obtain a Regeneration log file and monitor the DOC Inlet and DPF Outlet
Pressures. Refer to section "Performing a Parked Regeneration - GHG17" . Does the DOC inlet pressure ever go to
zero during the regeneration?
18.a Yes; replace the DOC Inlet Pressure Sensor.
19. Does the DOC Inlet pressure decrease during the regeneration?
19.a Yes; the DOC was plugged during the time the code logged causing a restriction. Clear the code and
release the vehicle.
2
19.b No; the DOC is plugged. Perform a DOC Face Plug Cleaning service routine. Verify repairs.
3
203.1 SPN 2631/FMI 1 - GHG17

Low Air Flow
SPN 2631/FMI 1
Description This Fault Code Sets When the Engine is in Smoke Mode Control for an
Excess Amount of Time Due to Inadequate Clean Airflow into the Engine
Monitored Parameter Smoke Mode Operation
Typical Enabling Conditions General Enabling Condition: Engine is in Smoke Mode
Specific Enabling Conditions: See Table Below
(149°F)
(18°F)
Dash Lamps MIL, CEL
Verification Once Engine is at Standard Operating Temperature, Operate Engine on
Highway, Coast for 30 Seconds and then Snap Throttle and Keep
Throttle at 100% for a Minimum of 15 Seconds.
Check as follows:
3. Is the vehicle equipped with a DD16 engine
4. Check for multiple fault codes. Are there any ITV fault codes present?
5. Compare the Barometric pressure reading in the MCM to the local Barometric pressure. Is the Barometric
pressure reading in the MCM within 6 kPa (1 psi) of the local Barometric pressure?
5.b No; Replace the MCM.
6. Compare the intake manifold pressure sensor reading to the barometric pressure reading. Is the intake
manifold pressure sensor reading within 10.3 kPa (1.5 psi) of the barometric pressure reading?
7. Disconnect and inspect the intake manifold pressure sensor electrical connector. Is there any damage or
corrosion present?
7.b No; replace the intake manifold pressure sensor.
8. Monitor the EGR Delta Pressure sensor voltage. Is the voltage between 0.55 and 0.83 volts?
4

10. Disconnect and inspect the EGR Delta Pressure sensor electrical connector. Is there any damage,
corrosion or fretting present?
10.a Yes; replace the EGR Delta Pressure sensor and the pigtail. Verify repair.
11. Remove EGR Delta Pressure sensor from the mounting pad.
12. Reconnect the EGR Delta Pressure sensor electrical connector while the sensor is still removed.
14. Monitor the EGR Delta Pressure sensor voltage again. Is the voltage between 0.55 and 0.83 volts?
14.a Yes; clean the EGR Delta Pressure ports.
14.b No; replace the EGR Delta Pressure sensor.
15. Monitor the Diesel Oxidation Catalyst (DOC) inlet pressure sensor voltage. Is the voltage between 0.44 and
0.56 volts?
15.b No; replace the DOC inlet pressure sensor.
For 1-Box™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" . Verify repair.
For 2-Box (2V2), Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" .Verify repair.
16. Disconnect and inspect the turbocharger inlet elbow and outlet pipe. Are there signs of oil residue, fluid
contamination or debris?
16.a Yes; replace the turbocharger. If the oil has contaminated the ATD, replace the ATD.
17. Remove and inspect the EGR delivery pipe, crossover pipe and hot pipe. Are there any restrictions
present?
17.a Yes; clean the EGR system components and reinstall the components.
17.b No; reinstall the components. Go to step 18.
18. Disconnect and inspect the DOC inlet pressure sensor hose and sensor. Are there any restrictions
present?
18.a Yes; clean/replace the hose sensor as necessary.
WARNING
HOT EXHAUST
19. Perform a parked regeneration. Obtain a Regeneration log file and monitor the DOC Inlet and DPF Outlet
Pressures. Refer to section "Performing a Parked Regeneration - GHG17" . Does the DOC inlet pressure ever go to
zero during the regeneration?
19.a Yes; replace the DOC Inlet Pressure Sensor.
For 1-Box™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" .
For 2-Box (2V2), Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" .
20. Does the DOC Inlet pressure decrease during the regeneration?
20.a Yes; the DOC was plugged during the time the code logged causing a restriction. Clear the code and
release the vehicle.
5
20.b No; the DOC is plugged. Perform a DOC Face Plug Cleaning service routine or use the air cleaning
procedure. Refer to section "GHG17 Diesel Oxidation Catalyst Face Cleaning" and Refer to section "Diesel Oxidation
Catalyst Air Cleaning" . Verify repairs.
6
204.1 SPN 2646/FMI 3 - GHG17

SPN 2646/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
204.2 SPN 2646/FMI 4 - GHG17

SPN 2646/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4
204.3 SPN 2646/FMI 5 - GHG17

SPN 2646/FMI 5
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5

6
205.1 SPN 2659/FMI 0 - GHG17

Exhaust Gas Recirculation Flow Target Error Diagnostic - High Flow
SPN 2659/FMI 0
Description This fault code sets when the difference between the actual
EGR flow and the commanded EGR flow is higher than a
calibrated threshold.
Monitored Parameter EGR Mass Flow
Typical Enabling Conditions Desired EGR mass flow greater than .08, EGR in closed-loop
control, CAC outlet temperature greater than 0°C (32°F),
engine speed 1080 to 2500 rpm, engine torque 200 to 2500
N·m (148 to 1844 lb·ft), coolant temperature greater than 65°C
(149°F), ambient temperature greater than -8°C (18°F)
ambient, barometric pressure greater than 755 mbar (11 psi).
Execution Frequency Always Enabled.
Dash Lamps MIL, CEL
Engine Reaction 25% derate
Verification Start engine, warm up such that coolant temperature greater
than 65°C (149°F), ensure ambient temperature greater than -
8°C (18°F) ambient and ambient barometric pressure greater
than 755 mbar (11 psi).
Check as follows:
• SPN 411/FMI 2, FMI 3, FMI 4, FMI 13
• SPN 1636/FMI 3, FMI 4
• SPN 2791/FMI 2, FMI 7, FMI 9, FMI 11, FMI 12, FMI 13, FMI 14, FMI 16, FMI 18, FMI 31
• SPN 3563/FMI 3, FMI 4, FMI 10
4. Check the DPF Zone; is the DPF zone zero?
4.b No; perform a parked regeneration.
5. Monitor the EGR delta pressure voltage at Key ON, Engine OFF. Is the voltage between 0.55 and 0.83
volts?
7. Disconnect and inspect the EGR Delta Pressure sensor electrical connector. Is there damage, corrosion or
fretting present?
7.a Yes; replace the Delta Pressure sensor and the pigtail. Refer to section "Removal of the Delta P Sensor" . Verify
repair.
1
8. Remove and inspect the EGR Delta Pressure sensor ports. Is there a restriction or contamination present?
8.a Yes; clean the Delta Pressure sensor and clean the ports in the venturi pipe. Refer to section "Cleaning of the
Exhaust Gas Recirculation Venturi Pipe Delta P Sensor Ports" . Verify repair.

9. Reconnect the EGR Delta Pressure sensor connector while the sensor is still removed from the venturi
pipe.
11. Monitor the EGR Delta Pressure voltage at Key ON, Engine OFF. Is the voltage between 0.55 and 0.83
volts?
11.a Yes; clean the ports on the venturi pipe. Refer to section "Cleaning of the Exhaust Gas Recirculation Venturi Pipe
Delta P Sensor Ports" . Verify repair.
11.b No; replace the Delta Pressure sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
12. Compare the barometric pressure reading to the local barometric pressure for your area. Is the barometric
pressure within 69 mbar (1 psi) of the barometric pressure for your area?
13. Compare the Intake Manifold Pressure sensor reading to the Barometric pressure sensor reading. Is the
Intake Manifold Pressure sensor reading within 103 mbar (1.5 psi) of the Barometric pressure reading?
14. Disconnect and inspect the Intake Manifold Pressure sensor electrical connector. Is there damage,
14.b No; replace the Intake Manifold Pressure sensor. Refer to section "Removal of the Intake Pressure/Temperature
15. Compare the intake manifold temperature to the Charge Air Cooler outlet temperature. Is the intake
manifold temperature within plus or minus 10°C (18°F) of the Charge Air Cooler outlet temperature?
16. Disconnect and inspect the Intake Manifold Temperature sensor electrical connector. Is there any damage,
16.b No; replace the Intake Manifold Temperature sensor. Refer to section "Removal of the Intake Manifold Air
Temperature Sensor" .Verify repair.
17. Remove the EGR Delta Pressure sensor and inspect the ports. Is there a restriction or contamination
present?
17.a Yes; clean the Delta Pressure sensor and clean the ports in the venturi pipe. Refer to section "Cleaning of the
Exhaust Gas Recirculation Venturi Pipe Delta P Sensor Ports" . Verify repair.

18. Remove and inspect the EGR hot pipe. Are there any restrictions present in the EGR hot pipe?
18.a Yes; clean the EGR system.
Refer to section "Cleaning of the Exhaust Gas Recirculation Venturi" .
Then Go to step 19.
19. Move EGR pull rod back and forth while watching the EGR valve. Does the EGR flap move when the pull
rod is moved back and forth?
19.a Yes; replace the Delta p sensor. Refer to section "Removal of the Delta P Sensor" Verify repair.
2
19.b No; replace the EGR valve. Verify repair.

Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe"
Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve"
Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve"
Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" for the DD13 and DD15 engines.
3
205.2 SPN 2659/FMI 18 - GHG17

SPN 2659/FMI 18
Description This Fault Code Sets When the Difference Between the
Actual Exhaust Gas Recirculation (EGR) Flow and the
Commanded EGR Flow is Lower Than a Calibrated Threshold
Typical Enabling Conditions esired EGR mass flow greater than .08, EGR in closed-loop
control, CAC outlet temperature greater than 0°C (32°F),
engine speed 1080 to 2500 rpm, engine torque 200 to 2500
N·m (148 to 1844 lb·ft), coolant temperature greater than 65°C
(149°F), ambient temperature greater than -8°C (18°F)
ambient, barometric pressure greater than 755 mbar (11 psi)
Dash Lamps MIL
Verification Start engine, warm up so that coolant temperature is greater
than 65°C (149°F), ensure ambient temperature greater than -
8°C (18°F) ambient and ambient barometric pressure greater
than 755 mbar (11 psi)
Check as follows:
• SPN 411/FMI 2, FMI 3, FMI 4, FMI 13
• SPN 1636/FMI 3, FMI 4
• SPN 2791/FMI 2, FMI 7, FMI 9, FMI 11, FMI 12, FMI 13, FMI 14, FMI 16, FMI 18, FMI 31
• SPN 3563/FMI 3, FMI 4, FMI 10
4. Is the vehicle equipped with a DD13 engine?
WARNING
HOT EXHAUST
4.b No; performa parked regeneration.

5. Monitor the EGR delta P voltage at Key ON, Engine OFF. Is the voltage between 0.55 and 0.83 volts?
7. Disconnect and inspect the EGR delta P sensor electrical connector. Is there damage, corrosion or fretting
present?
4
7.a Yes; replace the EGR delta P sensor and the pigtail. Refer to section "Removal of the Delta P Sensor" . Verify
repair.
8. Remove the EGR delta P sensor and inspect the ports. Refer to section "Removal of the Delta P Sensor" . Is there a
restriction or contamination present?
8.a Yes; clean the EGR delta P sensor and clean the ports in the venturi pipe.
9. Reconnect the EGR delta P sensor connector while the sensor is still removed from the venturi pipe.
11. Monitor the EGR delta P voltage at Key ON, Engine OFF. Is the voltage between 0.55 and 0.83 volts?
11.a Yes; clean the ports on the venturi pipe.
11.b No; replace the delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
pressure within 69 mbar (1 psi) of the barometric pressure for your area?
13. Compare the intake manifold pressure sensor reading to the barometric pressure sensor reading. Is the
intake manifold pressure sensor reading within 103 mbar (1.5 psi) of the barometric pressure reading?
14. Disconnect and inspect the intake manifold pressure sensor electrical connector. Is there damage,
15. Compare the intake manifold temperature to the Charge Air Cooler (CAC) outlet temperature. Is the intake
manifold temperature within plus or minus 10°C (18°F) of the CAC outlet temperature?
16. Disconnect and inspect the intake manifold temperature sensor electrical connector. Is there any damage,
16.b No; replace the intake manifold temperature sensor. Refer to section "Removal of the Intake Manifold Air
17. Remove the EGR delta P sensor and inspect the ports. Is there a restriction or contamination present.
17.a Yes; clean the delta P sensor and clean the ports in the venturi pipe. Refer to section "Cleaning of the Exhaust
Gas Recirculation Venturi Pipe Delta P Sensor Ports" Verify repair.

18. Remove and inspect the EGR hot pipe. Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe" . Are there
any restrictions present in the EGR hot pipe?
18.a Yes; clean the EGR system. Verify repair.

5

19.b No; replace the EGR valve. Verify repair.
Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve" .
Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe" .
Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve" .
Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" .
20. Remove and inspect the EGR crossover tube, mixer pipe and venturi pipe. Are there any restrictions
present?

21. Inspect the EGR cooler. Are there any restrictions present in the EGR cooler?
21.b No; replace the Delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
6
206.1 SPN 2791/FMI 2 - GHG17

EGR Valve Actuator, Position Deviation Error
SPN 2791/FMI 2
Description The fault code sets when the Motor Control module (MCM)
detects that the Exhaust Gas Recirculation (EGR) Valve
Position is Incorrect.
Monitored Parameter EGR Position Error
Typical Enabling Conditions Engine running
Dash Lamps MIL, CEL
Verification Engine idle
Check as follows:
2. Visually inspect the EGR system hardware, clamps and connections. Are there any components that will
interfere with the travel of the pull rod?
2.a Yes; install the components correctly, (replace any clamps that need readjustment), and perform the
EGR Slow Learn routine. Verify repair.
3. Verify the orientation of the pull rod. Is the "S" stamped on the pull rod facing toward EGR actuator and the
"V" stamped on the pull rod facing toward the EGR valve?
3.b No; remove the pull rod and install the pull rod correctly. Perform the EGR Slow Learn routine. Verify
repair.
4. Move the pull rod toward the rear of the engine by hand, and then release the pull rod. Does the pull rod
move?
5. Monitor the EGR actuator while turning the ignition ON (key ON, engine OFF). Does the EGR actuator
move when the ignition is first turned on?
5.b No; replace the EGR actuator.
7. Disconnect and inspect the pull rod from the EGR actuator. Are the bearings or inserts in the pull rod
missing?
7.a Yes; replace the pull rod. Verify repair.
8. Rotate the bearings in the pull rod in the normal direction of movement when installed. Do the bearings
move?
8.b No; replace the pull rod.
1
9. Move the EGR valve back and forth by hand using the pull rod. Does the EGR valve move from end stop to
end stop?
9.b No; replace the EGR valve.
10. Install the pull rod back onto the EGR actuator.
11. Use DiagnosticLink to perform the EGR Slow Learn routine.
12.a Yes; replace the EGR valve actuator.
12.b No; the concern was corrected by performing the Slow Learn routine. No further diagnostics or repairs
are needed; release the vehicle to the customer.
2
206.2 SPN 2791/FMI 7 - GHG17

EGR Valve Actuator, Fail Safe Mode, Motor On
SPN 2791/FMI 7
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
3

11. Use DiagnosticLink® to perform the EGR Slow Learn routine.
4
206.3 SPN 2791/FMI 9 - GHG17

SPN 2791/FMI 9
Description The Fault Code Sets When the Motor Control Module (MCM)
Does Not Receive a Message from the Exhaust Gas
Recirculation (EGR) Valve Actuator
Monitored Parameter MCM Communication From the EGR Valve Actuator
Typical Enabling Conditions Ignition ON
Dash Lamps MIL, CEL
Check as follows:
1. Check for low battery voltage fault codes. Is fault code 520296/FMI 3 present?
1.a Yes; diagnose the low battery voltage fault code first.
2. Check for multiple EGR fault codes. Are there any other EGR valve actuator fault codes also active?
3. Turn then ignition OFF.
5
4. Disconnect and inspect the EGR valve actuator electrical connector components side. Are there any
damaged, corroded, or spread pins?
5. Inspect the EGR valve actuator electrical connector harness side. Are there any damaged, corroded, or
spread pins?
7. Measure the voltage between pins 1 and 2. Is the voltage greater than 11 volts?
8. Measure the voltage between pin 1 and ground. Is the voltage greater than 11 volts?
8.a Yes; repair the ground circuit between pin 2 of the EGR valve actuator electrical connector harness
side and the circuit splice.
8.b No; repair the voltage circuit between pin 1 of the EGR valve actuator electrical connector harness side
and the circuit splice.
10. Measure the resistance between pins 3 and 4 of the EGR valve actuator electrical connector harness side.
Is the resistance between 55 and 65 ohms?
10.a Yes: replace the EGR valve actuator.
11. Disconnect and inspect the 120-pin MCM electrical connector components side. Are there any damaged or
corroded pins?
12. Inspect the 120-pin MCM electrical connector harness side. Are there any damaged, corroded or spread
pins?
13. Measure the resistance between pin 3 of the EGR valve actuator electrical connector harness side and pin
74 of the 120-pin MCM electrical connector harness side. Is the resistance less than five ohms?
13.b No; repair the communication circuit between pin 3 of the EGR valve actuator electrical connector
harness side and pin 74 of the 120-pin MCM electrical connector harness side.
6
206.4 SPN 2791/FMI 11 - GHG17

EGR Valve Actuator Common Fault
SPN 2791/FMI 11
Description The Faults Code Sets when the Motor Control Module (MCM)
Detects that the Exhaust Gas Recirculation (EGR) Valve
Position is Incorrect or a High Coolant Temperature has Been
Detected.
Dash Lamps MIL, CEL
Verification Engine Idle and Perform Several Neutral Run Ups.
WARNING
ENGINE EXHAUST
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 2791/FMI 10, SPN 110/FMI 0 or SPN 110/FMI 2
present?
repair.
7. Move the pull rod toward the rear of the engine by hand. Does the pull rod move?
9. Monitor the EGR actuator when the ignition is turned ON (key ON, engine OFF). Does the EGR actuator
7

missing?
move?
end stop?
8
206.5 SPN 2791/FMI 12 - GHG17

EGR Valve Actuator Frozen
SPN 2791/FMI 12
Description
The fault code sets when the Motor Control module (MCM)
detects Exhaust Gas Recirculation (EGR) Valve Position
Incorrect when the ambient temperature is below 2°C (35°F).
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
9

10
206.6 SPN 2791/FMI 13 - GHG17

Smart Remote Actuator 3 (EGR), Calibration Error
SPN 2791/FMI 13
Description This fault code becomes active when the EGR Actuator
Calibration-span is out of range or when there is a learn time
out.
Monitored Parameter EGR Position
Typical Enabling Conditions Ignition on
Dash Lamps MIL, CEL
Verification Idle engine for five minutes
Check as follows:
2. Visually inspect the EGR system hardware, clamps and connections. Are there any components that
repair.
move?
missing?
move?
end stop?
11

12.b No; the concern was corrected by the slow learn routine. No further diagnostics or repairs are needed;
release the vehicle to the customer.
12
206.7 SPN 2791/FMI 14 - GHG17

EGR Valve Actuator, Wrong Fail Safe Calibration
SPN 2791/FMI 14
Description This fault code sets when the EGR Actuator Calibration-span
is out of range or when there is a learn time-out.
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
13

14
206.8 SPN 2791/FMI 16 - GHG17

EGR Valve Actuator Learn Cycle Too Large
SPN 2791/FMI 16
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
15

16
206.9 SPN 2791/FMI 18 - GHG17

EGR Valve Actuator Learn Cycle Too Small
SPN 2791/FMI 18
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
17

18
206.10 SPN 2791/FMI 31 - GHG17

EGR Valve Actuator Slow Response
SPN 2791/FMI 31
Position does not reach the commanded position within a
calibrated time.
Dash Lamps MIL, CEL
Check as follows:
repair.
move?
missing?
move?
end stop?
19

20
207.1 SPN 2797/FMI 3 - GHG17

Fuel Injector Needle Control Valve for cylinder 1, 2, 3 shorted to Battery power
SPN 2797/FMI 3
Description Injector Needle Control Valve Cylinder 1, 2, 3 Shorted to
Battery
Monitored Parameter Injector Needle Control Valve Cylinder 1, 2, 3
Dash Lamps MIL, CEL
1. Disconnect the front fuel injector harness 14–pin connector. Refer to section "Removal of the Two-Piece Fuel Injector
Wiring Harness - Two-Filter System" .

3. Measure the voltage between pin 1 on the Motor Control Module (MCM) side of the front fuel injector
harness 14–pin connector and ground.
3.a If there is voltage present, repair the short to power between pin 1 of the front fuel injector harness
14–pin connector and pin 25 of the 120–pin MCM connector.
3.b If there is no voltage present, replace the under valve cover fuel injector harness. Refer to section "Removal
of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
1
207.2 SPN 2797/FMI 4 - GHG17

Fuel Injector Needle Control Valve Cylinder 1, 2, 3 Shorted to Ground
SPN 2797/FMI 4
Ground
Typical Enabling Conditions Engine rpm = Idle or Higher
Dash Lamps MIL, CEL
1. Disconnect the front fuel injector harness 14–pin connector. Refer to section "Removal of the Two-Piece Fuel Injector
Wiring Harness - Two-Filter System" .
2. Inspect the front fuel injector harness 14–pin connector for bent or spread pins. Inspect the connector seal
for damage (signs of water or oil intrusion). Is there evidence of water or oil intrusion, bent or spread pins?
3. Measure the resistance between pin 1 on the rocker cover side of the front fuel injector harness 14–pin
connector and ground. If you are using J-48671–10, measure between pin 3 the fuel injector #1 and
ground. Is resistance greater than 10k ohms?
2

5. Disconnect fuel injector #1.
6. Measure the resistance between pin 1 on the rocker cover side of the front fuel injector harness 14–pin
connector and ground. If you are using J-48671–10, measure between pin 3 of the fuel injector #1 and
ground. Is the resistance greater than 10k ohms?
6.a Yes; replace fuel injector #1. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
8. Measure the resistance between pin 1 on the valve cover side of the front fuel injector harness 14–pin
10. Measure the resistance between pin 1 on the valve cover side of the front fuel injector harness 14–pin
10.b No; replace the front injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-
Filter System" .

12. Inspect the MCM 120-pin connector for bent or spread pins; inspect the connector seal for damage (signs
of water or oil intrusion). Is there evidence of water or oil intrusion, bent or spread pins?
13. Measure the resistance between pin 25 on the MCM 120–pin connector and ground. If you are using J-
48671–10, measure between pin 3 of the fuel injector #1 and ground. Is resistance greater than 10k ohms?
3
13.a Yes; replace the MCM. Refer to section "Removal of the Motor Control Module"
13.b No; repair the short to ground between pin 25 of the Motor Control Module (MCM) 120-pin connector
and pin 1 of the front fuel injector harness 14-pin connector.
4
208.1 SPN 2798/FMI 3 - GHG17

Injector Needle Control Valve Cylinder 4, 5, 6 shorted to Battery
SPN 2798/FMI 3
Description Injector Needle Control Valve Cylinder 4, 5, 6 shorted to
Battery
Dash Lamps MIL, CEL

3. Measure the voltage between pin 1 on the Motor Control Module (MCM) side of the rear fuel injector
harness 14–pin connector and ground.
3.a If there is voltage present, repair the short to power between pin 1 of the rear fuel injector harness 14-
pin connector and pin 19 of the 120-pin MCM connector.
3.b If there is no voltage present, replace the under valve cover fuel injector harness. Refer to section "Removal
of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
1
208.2 SPN 2798/FMI 4 - GHG17

Injector Needle Control Valve Cylinder 4, 5, 6 Shorted to Ground
SPN 2798/FMI 4
Ground
Typical Enabling Conditions Engine rpm = Idle or Higher
Dash Lamps MIL, CEL

2. Inspect the rear fuel injector harness 14-pin connector for bent or spread pins; inspect the connector seal
for damage (signs of water or oil intrusion). Is there evidence of water or oil intrusion, bent, or spread pins?
3. Measure the resistance between pin 1 on the rocker cover side of the rear fuel injector harness 14-pin
connector and battery ground. If you are using J-48671–10, measure between pin 3 of the fuel injector #4
and battery ground. Is the resistance greater than 10k ohms?
2
A Engine Harness Side

B Valve Cover Side

pin 3 and ground. Is the resistence greater than 10k ohms?
6.a Yes; replace fuel injector #4.
Refer to section "Removal of the Fuel Injector - Two-Filter System" .
8.a Yes, replace the #5 fuel injector.
10.b No; replace the rear injector harness.
3
12. Inspect the MCM 120-pin connector for bent or spread pins; inspect the connector seal for damage (signs
of water or oil intrusion). Is there evidence of water or oil intrusion, bent or spread pins?
13. Measure the resistance between pin 19 on the MCM 120–pin connector and ground. If you are using J-
48671–10, measure between pin 3 of the fuel injector #1 and ground. Is the resistance greater than 10k
ohms?
13.b No; repair the short to ground between pin 19 of the Motor Control Module (MCM) 120-pin connector
and pin 1 of the front fuel injector harness 14-pin connector.
4
209.1 SPN 2882/FMI 13 - GHG17

SPN 2882/FMI 13
Description J1939 Signal is Missing
Dash Lamps None
1
210.1 SPN 2900/FMI 9 - GHG17

J1939 ETC7 Message is Missing
SPN 2900/FMI 9
Description J1939 Signal is Missing
Dash Lamps None
1
211.1 SPN 3031/FMI 3 - GHG17

SPN 3031/FMI 3
Description Diesel Exhaust Fluid (DEF) Tank Temperature Sensor Circuit
Failed High
Monitored Parameter DEF Tank Temperature Sensor
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1
2
Note : When there is no signal from the DEF tank level/temperature sensor, the vehicle will go into the low DEF
level derate.
Check as follows:
1. Disconnect and inspect the DEF tank level/temperature sensor connectors. Are there any bent, spread or
corroded pins?
3. Measure the voltage between pin 4 of the DEF tank level/temperature sensor connector harness side and
ground. Is there voltage present?
3.a Yes; repair the short to power between pin 4 of the DEF tank level/temperature connector and pin 102
of the 120-pin Motor Control Module (MCM) connector. Verify repair.
3
4. Measure the voltage between pin 3 on the harness side of the DEF tank temperature/level sensor
connector and ground. Is there 3.0 volts?
6. Measure resistance between pin 4 of the DEF tank level/temperature sensor connector, harness side, and
ground. Is the resistance less than five ohms?

7. Disconnect and inspect the 120-pin Aftertreatment Control Module (ACM) harness side connector. Are
there any spread or damaged pins?
8. Measure the resistance between pin 4 of the DEF tank level/temperature sensor connector and pin 102 of
the 120-pin ACM connector. Is the resistance less than five ohms?
the 120-pin ACM connector. Verify repair.

10. Disconnect and inspect the 120-pin ACM connector. Are there any bent, spread, or corroded pins?
11. Measure the resistance between pin 3 of the DEF tank level/temperature sensor connector and pin 103 of
the 120-pin ACM connector. Is the resistance less than five ohms?
4
211.2 SPN 3031/FMI 4 - GHG17

SPN 3031/FMI 4
Description Diesel Exhaust Fluid (DEF) Tank Temperature Sensor Circuit
Failed Low
Dash Lamps MIL, CEL
Engine Reaction 25 Percent Derate. After Four Hours, Engine Will be Idled
After Ignition Key Cycle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5
6
derate.
Check as follows:
2. Disconnect and inspect the DEF tank level/temperature sensor connectors, harness side. Is there any bent,
spread or corroded pins?
3. Measure the resistance from pin 3 of the DEF tank temperature/level sensor connector and ground. Is the
3.b No; repair the wire between pin 3 of the DEF tank temperature/level sensor connector and pin 103 of
the 120-pin Aftertreatment Control Module (ACM) connector. Verify repair.
7
4. Install a test ACM. Is code SPN 3031/FMI 4 still present?

4.b No; replace the ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repair.
8
211.3 SPN 3031/FMI 10 – GHG17

Diesel Exhaust Fluid Tank Temperature Erratic
1. Are there any cooling system issues or complaints?
1.a Yes; service cooling system issues or complaints.
Note : Perform Output Component Test, which can be run only once per key cycle.
4. Perform Output Component Test service routine. Does fault SPN 3031 FMI 3 or 4 become active during the
routine?
4.a Yes; repair those faults first, clear codes, verify repairs and release vehicle.
5. Using DiagnosticLink monitor parameter AS021 DEF Tank Temperature.
6. Remove the Diesel Exhaust Fluid (DEF) tank filler cap. Using an external thermometer (ex. Infrared
temperature gun) to compare the actual DEF temperature (liquid) to the DiagnosticLink reported tank
temperature. Is the reported AS021 DEF Tank Temperature 10°C (50°F) higher/lower than the externally
measured temperature?
7. Disconnect the DEF Tank header temperature/level harness connector, inspect connector harness for bent,
spread or corroded pins.
7.b If no pin damage is found, replace the DEF Tank header assembly. Refer to section "Removal of the 13- and
23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
8. Disconnect the DEF Tank header coolant valve harness connector, inspect connector harness for bent,
spread or corroded pins.
8.b If no pin damage is found, replace the DEF Tank header assembly. Refer to section "Removal of the 13- and
23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
9
211.4 SPN 3031/FMI 19 – GHG17

Diesel Exhaust Fluid Tank Temperature Signal Erratic via Controller Area Network
1. Has the Aftertreatment Control Module (ACM) been recently reprogrammed?
1.a Yes; clear fault codes. If they do not become active, release vehicle. If fault returns, verify proper ACM
Fuelmap. ACM is looking for Diesel Exhaust Fluid (DEF) tank Controller Area Network (CAN) signal,
except vehicle may be hardwired.
2. Turn the ignition OFF (key OFF, engine OFF) and disconnect DiagnosticLink , Wait five minutes for all
modules to power down.
4. Reconnect DiagnosticLink ; are fault codes active?
5. Turn ignition OFF (key OFF, engine OFF) and wait five minutes before proceeding.
7. Measure the resistance across pins 1 and 2 of the DEF tank header harness connector.
7.b If the resistance is between 60 +/- 20 ohms, Go to step 10.
7.c If the resistance is less than 5 ohms, Go to step 8.
of the ACM 120-pin.
9.a If the resistance is 60 +/- 10 ohms, repair the shorted DEF CAN harness.
9.b If the resistance is not between 60 +/- 10 ohms, replace the ACM.
10. Measure and record the resistance between the ACM 120-pin connector pins 48 and 49 to engine ground.
10.a If the resistance is greater than 10K ohms on both wires, replace DEF tank header. Verify repairs.
10.b If the resistance is less than 10K ohms, repair the short in the harness between ACM 120-pin
connector pins 48 or 49 and ground.
10
212.1 SPN 3056/FMI 2 - GHG17

Selective Catalyst Reduction inlet NOx Sensor - Error.
SPN 3056/FMI 2
Description Selective Catalyst Reduction (SCR) Inlet NOx Sensor - Error
Monitored Parameter SCR Inlet NOx
Typical Enabling Conditions 1000-1800 rpm, 35-100% load, steady cruise
Dash Lamps MIL
Engine Reaction
Verification 1000-1800 rpm, 35-100% load, steady cruise, 8 minutes
3. Monitor (chart) the following parameters:
• ASL102 engine speed
• AS018 SCR inlet temperature
• AS019 SCR outlet temperature
• AS035 SCR inlet NOx sensor
• AS036 SCR outlet NOx sensor
• AS101 NOx conversion efficiency
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Start the engine and perform a parked regeneration. Does the NOx conversion efficiency rise above 70%
(0.70) during the regeneration?
4.a Yes; clear faults and release vehicle.
4.b No; replace the SCR inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx
Sensor" .
1
2
213.1 SPN 3057/FMI 2 - GHG17

Selective Catalyst Reduction outlet NOx Sensor - Error.
SPN 3057/FMI 2
Description Selective Catalyst Reduction (SCR) Outlet NOx Sensor - Error
Monitored Parameter SCR Outlet NOx
Typical Enabling Conditions 1000-1800 rpm, 35-100% load, steady cruise
Dash Lamps MIL
Engine Reaction
Verification 1000-1800 rpm, 35-100% load, steady cruise, 8 minutes
2. Is SPN 5357 FMI 16 or 18 also present?
3. Monitor (chart) the following parameters.
• AS018 SCR inlet temperature
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4.a Yes, clear faults and release vehicle.
4.b No, replace the SCR outlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx
Sensor" .
1
2
214.1 SPN 3058/FMI 9 - GHG17

Exhaust Gas Recirculation Slow Response - Low Box
SPN 3058/FMI 9
Description This Fault Code Sets when Actual EGR Flow vs. Desired
EGR Flow is Greater than a Calibrated Threshold While the
Engine rpm is Between 600 and 900 rpm.
Monitored Parameter EGR delta P Sensor, Intake Manifold Pressure Sensor, Intake
Manifold Temperature Sensor
Typical Enabling Conditions Low Engine to High Engine Load
Monitor Sequence One Second After Acceleration Load, Actual EGR Flow vs.
Desired EGR Flow is Greater than a Calibrated Threshold
Dash Lamps MIL, CEL
Verification Road Test With a Trailer While Performing Multiple
Accelerations, Engine Load Needs to Increase Above 50%
During Acceleration and the Engine rpm is Between 600 and
900 rpm.
WARNING
ENGINE EXHAUST
Check as follows:
3. Check for multiple codes. Are any of the following codes present?
• SPN 411 / FMI 2, FMI 3, FMI 4, FMI 13
• SPN 1636 / FMI 0, FMI 3, FMI 4, FMI 14, FMI 16
• SPN 2630 / FMI 3, FMI 4, FMI 14
• SPN 2791 / FMI 2, FMI 7, FMI 9, FMI 11, FMI 12, FMI 13, FMI 14, FMI 16, FMI 18, FMI 31
• SPN 3563 / FMI 3, FMI 4, FMI 10 FMI 16, FMI 18, FMI 21
• SPN 2659 / FMI 0, FMI 18
• SPN 521018 / FMI 0
• SPN 521019 / FMI 0
• SPN 521020 / FMI 0
4. Check the Diesel Particulate Filter (DPF) zone. Is the DPF zone greater than zero?
4.a Yes; perform a parked regeneration and Go to step 5.
1

5. Road test with a trailer while performing multiple accelerations, (engine load needs to increase above 50%
during acceleration). Does fault code SPN 3058 FMI 10 become active?
5.b No; the back pressure in the exhaust was the cause of the concern. Release the vehicle to the
customer.
6. Use DiagnosticLink to monitor the Exhaust Gas Recirculation (EGR) delta P sensor voltage. Is the voltage
8. Disconnect and inspect the delta P sensor electrical connector harness side. Are there any bent, damaged
or corroded pins?
8.a Yes; replace the EGR delta P electrical connector. Refer to technical Service letter 10 TS-8 . Verify
repair.
9. Inspect the delta P sensor electrical connector component side. Are there any bent, damaged or corroded
pins?
9.a Yes; replace the delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
11. Reconnect the EGR delta P electrical connector while the EGR delta P sensor is still removed.
13. Monitor the EGR delta P sensor voltage again. Is the voltage between 0.55 and 0.83 volts?
13.b No; replace the EGR delta P sensor. Verify repair.
14. Inspect the EGR delta P sensor ports. Are the EGR delta P sensor ports restricted?
14.a Yes; replace the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
14.b No; clean the EGR venturi ports. Refer to Service Letter 14 TS-2 and Refer to section "Cleaning of the Exhaust
Gas Recirculation Venturi Pipe Delta P Sensor Ports" . Verify repair.
15. Inspect the EGR and exhaust system for leaks. Are there any leaks present?
15.a Yes; repair the EGR/exhaust leaks. Verify repair.
16. Check for leaks between the turbocharger outlet pipe and the intake manifold. Are there any leaks present?
16.a Yes; repair the leaks. Verify repair.
17. Check the Charge Air Cooler for leaks. Refer to Original Equipment Manufacturer (OEM) for CAC testing
procedures. Does the CAC pass the leak test?
17.b No; replace the CAC. Refer to OEM literature for CAC replacement procedures. Verify repair.
18. Remove and inspect the EGR delta P sensor ports. Are there any restrictions present?
19. Inspect the EGR venturi ports. Are there any restrictions present?
19.a Yes; clean the EGR venturi ports. Refer to section "Cleaning of the Exhaust Gas Recirculation Venturi" . Verify
repair.
2
19.b No; clean the EGR system.

For DD13 engines : Refer to section "Cleaning of the DD13 Exhaust Gas Recirculation System" .
3
214.2 SPN 3058/FMI 10 - GHG17

Exhaust Gas Recirculation Slow Response
SPN 3058/FMI 10
Description This Fault Code Sets When Actual EGR Flow vs. Desired
EGR Flow is Greater than a Calibrated Threshold.
Monitored Parameter EGR delta P Sensor, Intake Manifold Pressure Sensor, Intake
Manifold Temperature Sensor
Typical Enabling Conditions Low Engine to High Engine Load
Monitor Sequence One Second After Acceleration Load, Actual EGR Flow vs.
Desired EGR Flow is Greater than a Calibrated Threshold
Dash Lamps MIL, CEL
Verification Road Test With a Trailer While Performing Multiple
Accelerations, Engine Load Needs to Increase Above 50%
During Acceleration
WARNING
ENGINE EXHAUST
Check as follows:
3. Check for multiple codes. Are any of the following codes present?
• SPN 411 / FMI 2, FMI 3, FMI 4, FMI 13
• SPN 1636 / FMI 0, FMI 3, FMI 4, FMI 14, FMI 16
• SPN 2630 / FMI 3, FMI 4, FMI 14
• SPN 2791 / FMI 2, FMI 7, FMI 9, FMI 11, FMI 12, FMI 13, FMI 14, FMI 16, FMI 18, FMI 31
• SPN 3563 / FMI 3, FMI 4, FMI 10 FMI 16, FMI 18, FMI 21
• SPN 2659 / FMI 0, FMI 18
• SPN 521018 / FMI 0
• SPN 521019 / FMI 0
• SPN 521020 / FMI 0
4. Check the Diesel Particulate Filter (DPF) zone. Is the DPF zone greater than zero?
4.a Yes; perform a parked regeneration and Go to step 5.
5. Road test with a trailer while performing multiple accelerations, (engine load needs to increase above 50%
during acceleration). Does fault code SPN 3058 FMI 10 become active?
4
5.b No; the back pressure in the exhaust was the cause of the concern. Release the vehicle to the
customer.
6. Use DiagnosticLink to monitor the Exhaust Gas Recirculation (EGR) delta P sensor voltage. Is the voltage
8. Disconnect and inspect the delta P sensor electrical connector harness side. Are there any bent, damaged
or corroded pins?
8.a Yes; replace the EGR delta P electrical connector. Refer to technical Service letter 10 TS-8 . Verify
repair.
9. Inspect the delta P sensor electrical connector component side. Are there any bent, damaged or corroded
pins?
9.a Yes; replace the delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repair.
11. Reconnect the EGR delta P electrical connector while the EGR delta P sensor is still removed.
13. Monitor the EGR delta P sensor voltage again. Is the voltage between 0.55 and 0.83 volts?
13.b No; replace the EGR delta P sensor. Verify repair.
14. Inspect the EGR delta P sensor ports. Are the EGR delta P sensor ports restricted?
14.b No; clean the EGR venturi ports. Refer to Service Letter 14 TS-2 and Refer to section "Cleaning of the Exhaust
Gas Recirculation Venturi Pipe Delta P Sensor Ports" . Verify repair.
15. Inspect the EGR and exhaust system for leaks. Are there any leaks present?
15.a Yes; repair the EGR/exhaust leaks. Verify repair.
16. Check for leaks between the turbocharger outlet pipe and the intake manifold. Are there any leaks present?
16.a Yes; repair the leaks. Verify repair.
17. Check the Charge Air Cooler for leaks. Refer to Original Equipment Manufacturer (OEM) for CAC testing
procedures. Does the CAC pass the leak test?
17.b No; replace the CAC. Refer to OEM literature for CAC replacement procedures. Verify repair.
18. Remove and inspect the EGR delta P sensor ports. Are there any restrictions present?
19. Inspect the EGR venturi ports. Are there any restrictions present?
19.a Yes; clean the EGR venturi ports. Refer to section "Cleaning of the Exhaust Gas Recirculation Venturi" . Verify
repair.
19.b No; clean the EGR system.
5
6
215.1 SPN 3061/FMI 1 - GHG17

Cold start emission reduction strategy fault condition for boi main
SPN 3061/FMI 1
Description This fault code sets when the point of injection does not match
a modeled threshold when the engine is cold.
Monitored Parameter Injector timing
Typical Enabling Conditions 600 rpm/base idle, Coolant temperature less than 87°C
(188°F)
Dash Lamps None
Verification Run the engine at 600 rpm or base idle for five minutes with
the coolant temperature below 87°C (188°F)
This is an informational only code.

Check as follows:
3. Diagnose the fuel system fault codes that are present.
1
215.2 SPN 3061/FMI 2 - GHG17

Cold start emission reduction strategy fault condition EGR position
SPN 3061/FMI 2
Description This fault code sets when the point of injection does not match
a modeled threshold when the engine is cold.
Monitored Parameter EGR position
Typical Enabling Conditions 600 rpm/base idle, Coolant temperature less than 87°C
(188°F)
Dash Lamps None
Verification Run the engine at 600 rpm or base idle for five minutes with
the coolant temperature below 87°C (188°F)
This is an informational only code.

Check as follows:
3. Diagnose the Exhaust Gas Recirculation (EGR) system fault codes that are present.
2
216.1 SPN 3187/FMI 9 – GHG17

CPC Has Lost Communication With the DT12 Shift Stalk Lever
Shift Lever Pin Number Signal Description CPC4 Connector Pin

2 LIN 2/4 LIN COM

11.5 and 12 volts?
6. Inspect CPC connector #2 for bent, spread, or corroded pins. Is there any pin damage?
connector.
connector.
11.a Yes; refer to OEM literature for chassis side harness information on Ignition supply voltage to pin 3 of
the CPC connector #2.
connector.
1
SPN 3187 (CPC3) (GHG17)
217.1 SPN 3187/FMI 4 - GHG17

This fault indicates the CPC3 has lost communication with the DT12 shift stalk lever.

2 LIN 3/47 LIN COM

4. Inspect CPC3 connector #3 for bent, spread, or corroded pins. Is pin damage present?
5. Measure the resistance between pin 21 of the CPC3 connector #3 and chassis ground. Is resistance less
than five ohms?
5.a Yes; repair short to ground between pin 21 of the CPC3 connector #3 and pin 1 of the shift stalk lever
harness connector.
5.b No; replace the shift stalk lever.
1
217.2 SPN 3187/FMI 12 - GHG17


2 LIN 3/47 LIN COM

11.5 and 12 volts?
7. Measure the resistance between pin 47 of the CPC3 connector #3 and pin 2 of the shift stalk lever harness
7.b No; repair wire between pin 47 of the CPC3 connector #3 and pin 2 of the shift stalk lever harness
connector.
connector.
the CPC3 connector #3.
connector.
2
218.1 SPN 3216/FMI 3 - GHG17

Selective Catalyst Reduction Inlet NOx Sensor Circuit Failed High
SPN 3216/FMI 3
Description This Codes Sets When There is a Short to Power on the SCR
NOx Inlet Circuit Between the Sensor and the CPU
Monitored Parameter SCR Inlet NOx Sensor
Typical Enabling Conditions Dewpoint Enabled
Dash Lamps MIL, CEL
Check as follows:
1. Disconnect the Selective Catalyst Reduction (SCR) inlet NOx sensor.
2. Inspect the SCR inlet NOx sensor and harness side connector for bent, spread, or corroded pins. Is any
damage found?
2.b No; replace the SCR inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx
Sensor" .
1
218.2 SPN 3216/FMI 4 - GHG17

Selective Catalyst Reduction Inlet NOx Sensor Circuit Failed Low
SPN 3216/FMI 4
Description This Codes Sets When There is a Short to Ground on the
SCR NOx Inlet Circuit Between the Sensor and the CPU
Dash Lamps MIL, CEL
1. Disconnect the Selective Catalyst Reduction (SCR) inlet NOx sensor.

damage found?
2.b No; replace the SCR inlet NOx sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor"
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor"
2
218.3 SPN 3216/FMI 10 – GHG17

SPN 3216/FMI 10
Description High NOx at Idle
Monitored Parameter NOx
Typical Enabling Conditions Zero vehicle speed, rpm less than 900, EGR closed
Dash Lamps MIL
1. Are any Exhaust Gas Recirculation (EGR) system faults also present?
1.a Yes; repair the EGR system faults first.
2. Visually inspect the entire air inlet, Charge Air Cooler (CAC), and EGR piping and hose for visible signs of
leaks or damage. Is any damage or leaks found?
3.a If a faulty fuel injector is identified, repair as necessary.
3.b If no fuel injector issues are present, Go to step 4.
4. Check the Aftertreatment System (ATS) for visible exhaust leaks or damage. Are exhaust leaks or damage
found?
WARNING
HOT EXHAUST
6. Perform a High Idle Regeneration; retain the log file and submit it to the Detroit™ Customer Support Center
at 800-445-1980.
3
218.4 SPN 3216/FMI 13 - GHG17

Selective Catalyst Reduction Inlet NOx Sensor Signal Not Available
SPN 3216/FMI 13
Description Selective Catalyst Reduction (SCR) Inlet NOx Sensor Signal
Not Available
Monitored Parameter SCR Inlet NOx Sensor Signal
Dash Lamps MIL
Note : If fault occurred during high idle regeneration, clear fault and release vehicle.
Check as follows:
1. Is the SPN 3216/FMI 13 currently active?
2. Check the SPN 3216/FMI 13 Diagnostic Trouble Code (DTC) occurrence counter.
2.a If the DTC occurrence counter is five or less, clear the fault and release the vehicle.
2.b If the DTC occurrence counter is greater than five, Go to step 3.
3. Disconnect the SCR inlet NOx sensor.
4. Inspect the SCR inlet NOx sensor harness for bent, spread, or corroded pins.
4.a If the pins are bent, spread, or corroded, repair as necessary.
4

6. Measure the voltage between pins 1 and 4 on the harness side of the SCR inlet NOx sensor connector.
6.a If the voltage is less than 11.5 volts, Go to step 7.
6.b If the voltage is greater than 11.5 volts, Go to step 8.
7. Measure the voltage between pin 1 on the harness side of the SCR inlet NOx sensor connector and engine
ground.
7.a If the voltage is less than 11.5 volts, repair the wire between pin 1 on the harness side of the SCR inlet
NOx sensor connector and pin 50 of the Aftertreatment Control Module (ACM) 120-pin connector.
7.b If the voltage is greater than 11.5 volts, repair the wire between pin 4 on the harness side of the SCR
inlet NOx sensor connector and pin 51 of the ACM 120-pin connector.
9. Measure the resistance between pins 2 and 3 on the harness side of the SCR inlet NOx sensor connector.
9.a If the resistance is between 50 and 70 ohms, replace the SCR inlet NOx sensor.
For 1-BOX™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
For 2-BOX, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
11. Inspect the ACM 120-pin harness connector for signs of damage, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector.
11.a If signs of damage are present, repair as necessary.
11.b If no signs of damage are present, Go to step 12.
12. Measure the resistance between pins 2 and 3 on the harness side of the SCR inlet NOx sensor connector.
12.a If the resistance is less than 10K ohms, repair the short between pins 2 and 3 on the harness side of
the SCR inlet NOx sensor connector and pins 52 and 53 of the ACM 120-pin connector. Refer to section
"Verify Repairs" .

13. Measure the resistance between pin 2 on the harness side of the SCR inlet NOx sensor connector and pin
53 of the ACM 120-pin connector.
13.a If the resistance is greater than 5 ohms, repair the wire between pin 2 on the harness side of the SCR
inlet NOx sensor connector and pin 53 of the ACM 120-pin connector.
14. Measure the resistance between pin 3 on the harness side of the SCR inlet NOx sensor connector and pin
inlet NOx sensor connector and pin 52 of the ACM 120-pin connector. Refer to section "Verify Repairs" .
15. Test the ACM internal resistor; measure the resistance between pins 52 and 53 on the ACM.
5
15.a If the resistance is between 50 and 70 ohms, replace the SCR inlet NOx Sensor.
For 2-BOX, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
15.b If the resistance is NOT between 50 and 70 ohms, replace the ACM.
6
218.5 SPN 3216/FMI 16 – GHG17

SPN 3216/FMI 16
Description NOx Sensor Plausibility Check
Monitored Parameter Aftertreatment Inlet NOx Sensor
Typical Enabling Conditions General Enabling Condition: Engine is not in regeneration and operating at high speed
(Common Subset for all and loads
Engines)
Specific Enabling Conditions: (see below):
Engine Speed (rpm) 1350 1600
Torque (N·m) 1100 1500
Battery Voltage (Volts) 11.08
Engine Coolant Outlet 70°C (158°F)
Temperature
Ambient Temperature -8°C (17.6°F)
Barometric Pressure (mbar) 755 mbar (11 psi)
Time Since DPF regen (min.) 15
Beginning of Injection (BOI) - 10
Degrees of Crankshaft
Rotation
EGR Mass (Kg/min) 5
Typical Duration 150 Seconds (Two-Cycle)
Dash Lamps MIL
Verification Parked SCR Efficiency Test
2. Are any of the following faults present SPN 3216/FMI 3,4,10,13 or SPN 2659/FMI 0, 18 or SPN 4752/FMI
0, 15?
• AS018 Selective Catalyst Reduction (SCR) inlet temperature
NOTICE
Do not attempt to operate engine with the DEF lines disconnected. DEF pump runs and
circulates DEF through the system at a limited rate (default) to aid in system cooling.
4. Disconnect the Diesel Exhaust Fluid (DEF) Dosing Unit electrical connector only. Leave Dosing Unit bolted
to Aftertreatment and DEF lines connected.
7
5. Inspect the DEF dosing unit harness connector for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are any signs
of damage present?
Note : Running the engine with a disconnected DEF Dosing Unit will induce fault codes.
WARNING
HOT EXHAUST
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
6. Start the engine and perform a full parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17"
.
7. Monitor the inlet NOx sensor and outlet NOx sensor. During the last seven minutes of the parked regen,
are the sensors reading within 50 ppm of each other?
7.b No; replace the Inlet NOx Sensor.
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
8

9. Perform Charge Air Cooler (CAC) inspection and leak test. Refer to OEM literature for procedure. Is there
any damage found?
10. Visually inspect the entire Exhaust Gas Recirculation (EGR) and exhaust system (turbine housing, exhaust
manifold, etc.) for evidence of external leakage (e.g. soot, coolant deposits at joints). Is there evidence of
external leakage?
11. Remove the delta P sensor from the mounting pad; leave the electrical harness connected.
12. Inspect the delta P sensor for moisture inside the ports. Shake moisture out if necessary; do not replace the
sensor.
13. Inspect the delta P venturi ports for clogging and blockage. A layer of soot on the delta P sensor is OK. Is
there any blockage found?
13.a Yes; clean venturi ports. Do not replace delta P sensor. Go to step 26.
15. Using DiagnosticLink, monitor delta P voltage (pin 109).
16. Is the delta P voltage between 0.55 and 0.83 volts?
18. Disconnect the delta P sensor harness connector.
9
19. Inspect the delta P sensor harness connector for loose, bent, spread, or corroded pins. Is there any pin
damage found?
19.b No; replace delta P sensor. Refer to section "Removal of the Delta P Sensor" . Go to step 25.
20. Compare Inlet Manifold Pressure (IMP) value with the barometric pressure value. Are the values within 10.3
kPa (1.5 psi) of each other?
21. Disconnect the intake pressure/temperature sensor.
22. Inspect the intake pressure/temperature sensor and wiring connector for signs of damaged, bent, spread,
connector. Is there any sign of damage present?
22.b No; replace intake pressure/temperature sensor. Refer to section "Removal of the Intake Pressure/Temperature
23. Remove EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for excessive build-up or
blockage. Is there excessive build-up or blockage?
23.a Yes; clean piping and replace EGR cooler. Refer to section "Removal of the DD13 Exhaust Gas Recirculation Cooler
Water Manifold Assembly" . Go to step 25.
23.b No; re-install the EGR cooler, crossover pipe and delivery pipe. Go to step 24.
24. Disconnect the inlet NOx sensor harness connector.
25. Inspect the inlet NOx sensor and wiring connector for signs of damaged, bent, spread, corroded or
any pin damage found?
26. Turn the ignition OFF and allow for all modules to power down, then turn the ignition back ON and start the
engine. Go to step 27.
27. Verify repairs by performing a Parked SCR Efficiency Test. Refer to section "GHG17 Perform Parked SCR Efficiency
Test" .
10
218.6 SPN 3216/FMI 18 – GHG17

SPN 3216/FMI 18
Typical Enabling Conditions (Common Subset for General Enabling Condition: Engine is not in regen and operating
all Engines) at high speed and loads
Specific Enabling Conditions:
Torque (Nm) 1100 1500
(158°F)
(17.6°F)
Beginning of Injection (BOI) - Degrees of 10
Crankshaft Rotation
EGR Mass (Kg/min) 5
Typical Duration 150 Seconds (2 Cycle)
Dash Lamps MIL
Verification Warm Up Engine and Ensure Engine is Not in Regen Mode. Drive a
Fully-Loaded Trailer on Highway and Maintain Above Enabling
Conditions for 150 Seconds
2. Are any other faults also present?
NOTICE
4. Disconnect the Diesel Exhaust Fluid (DEF) dosing unit electrical connector only. Leave dosing unit bolted
to aftertreatment and DEF lines intact.
11
Note : SPN 3361/FMI 5 will set when the DEF dosing unit electrical connector is disconnected. The fault code can
be cleared using DiagnosticLink after the DEF dosing unit electrical connector is reconnected.
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are there any
Note : Running the engine with a disconnected DEF dosing unit will induce a fault code.
WARNING
HOT EXHAUST
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
6. Start the engine and perform a complete parked regen. Refer to section "Performing a Parked Regeneration - GHG17" .
NOTICE
It may require 30 minutes or longer for the outlet NOx sensor to turn on. Do not replace
either sensor unless directed by the troubleshooting.
7. Monitor the inlet NOx sensor and outlet NOx sensor. During the last five minutes of the parked regen, are
the sensors reading within 50 ppm of each other?
7.a Yes; check for turbocharger type.
If Asymmetrical Turbocharger (AT), Go to step 8.
If Turbo Compound (TC), Go to step 16.
7.b No; replace the inlet NOx sensor.
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
9. Ensure the vehicle air supply is at least 6.0 bar (87 psi). Inspect the air line connection to the wastegate
solenoid. Are there any leaks or kinks in the air line connection?
9.a Yes; repair or replace as necessary. Go to step 35.
12

10. Inspect the wastegate actuator and the plumbing to and from the actuator. Verify wastegate opens and
closes. Is there any binding or damage found?
Note : Wastegate control does not respond at 50 percent. To cycle wastegate, use either 0 percent or 95 percent.
12. Using DiagnosticLink, activate wastegate control from Service Routines Activate Outputs Panel. Run slide
control up to 95% - (Click Set). Wastegate will open with air psi available. Observe wastegate linkage
movement. Does wastegate open when commanded?
13. Move slide control down to 0. Observe wastegate linkage movement. Does wastegate close when
commanded?
14. Disconnect the wastegate solenoid harness connector.
15. Inspect the wastegate solenoid and harness connector for signs of damaged, bent, spread, corroded, or
15.b No; replace the wastegate solenoid.
Refer to section "Removal of the DD13 Wastegate Solenoid." Go to step 35.
Refer to section "Removal of the GHG17 DD15 Asymmetrical Turbocharger Wastegate Solenoid."
Go to step 35.

any damage found?
manifold, etc.) for evidence of external leakage (e.g. soot, coolant deposits at joints). Is there any external
leakage found?
sensor.
13

damage found?
28. Compare Intake Manifold Pressure (IMP) value with the barometric pressure value. Are the values within
10.3 kPa (1.5 psi) of each other?
connector. Are there any signs of damage present?
30.b No; replace IMP sensor. Refer to section "Removal of the Intake Pressure/Temperature Sensor" . Go to step 35.
31. Remove EGR cooler hot pipe, EGR crossover pipe and delivery pipe; inspect for excessive build-up or
blockage of soot. Is there any excessive build-up or blockage of soot?

32. Inspect the EGR valve for physical damage (broken butterfly, etc.). Is the EGR valve damaged?
32.a Yes; replace the center section of the exhaust manifold.
Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" . Go to step 34.
Refer to section "Removal of the DD16 Exhaust Manifold" . Go to step 35.
33. Disconnect the NOx inlet sensor harness connector.
34.b No; refer to 15 TS-17 for additional MCM programming.
35. Verify repairs by warming up engine and ensure engine is not in regeneration mode. Drive with a fully
loaded trailer on highway and maintain a steady speed and load for ten minutes.
14
Fig 219.1, SCR Inlet NOx Sensor Circuit
1
219.2 SPN 3216/FMI 16 – GHG17

Selective Catalyst Reduction Inlet NOx Sensor - Drift High
SPN 3216/FMI 16
Typical Enabling Conditions General Enabling Condition: Engine is not in regeneration and operating at high speed
(Common Subset for all and loads
Engines)
Specific Enabling Conditions: (see below):
Torque (N·m) 800 1400
Engine Coolant Outlet 70°C (158°F)
Temperature
Ambient Temperature -8°C (17.6°F)
Barometric Pressure (mbar) 755 mbar (11 psi)
Beginning of Injection (BOI) - 10
Degrees of Crankshaft
Rotation
EGR Mass (Kg/min) 5
Typical Duration 150 seconds (Two-Cycle)
Dash Lamps MIL
Check as follows:
NOTICE
2
4. Disconnect the Diesel Exhaust Fluid (DEF) Dosing Unit electrical connector only. Leave Dosing Unit bolted
to Aftertreatment and DEF lines connected.
5. Inspect the DEF Dosing Unit harness connector for signs of damaged, bent, spread, corroded or unseated
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are any signs
of damage present?
Note : Running the engine with a disconnected DEF Dosing Unit will induce fault codes.
WARNING
HOT EXHAUST
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
6. Start engine and begin a “GHG17 Perform Performance Check - Low Temp ATD.” Refer to section "GHG17
Perform Performance Check - Low Temperature ATD" . After thirty minutes, are the NOx sensor values within 50 ppm
of each other?
6.b No; replace the Selective Catalyst Reduction Inlet NOx Sensor. Refer to section "Removal of the Selective
Catalytic Reduction Inlet NOx Sensor" . Verify repairs.

any damage found?
manifold, etc.) for evidence of external leakage (e.g. soot, coolant deposits at joints). Is there evidence of
external leakage?
sensor.
3
18. Inspect the delta P sensor harness connector for loose, bent, spread or corroded pins. Is there any pin
damage found?
19. Compare Inlet Manifold Pressure (IMP) value with the barometric pressure value. Are the values within 10.3
kPa (1.5 psi) of each other?
connector. Is there any sign of damage present?
21.b No; replace intake pressure/temperature sensor. Refer to section "Removal of the Intake Pressure/Temperature
22. Remove EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for excessive build-up or
blockage. Is there excessive build-up or blockage?

23.a Yes; replace the center section of the exhaust manifold. Go to step 26.
Refer to section "Removal of the DD13 and DD15 Exhaust Manifold"
Refer to section "Removal of the DD16 Exhaust Manifold"

24. Disconnect the inlet NOx sensor harness connector.
26. Verify repairs by performing a Parked SCR Efficiency Test. Refer to section "GHG17 Perform Parked SCR Efficiency
Test" .
4
219.3 SPN 3216/FMI 18 – GHG17

SPN 3216/FMI 18
Typical Enabling Conditions (Common Subset for General Enabling Condition: Engine is not in regen and operating
all Engines) at high speed and loads
Specific Enabling Conditions:
Torque (Nm) 1100 1500
(158°F)
(17.6°F)
Beginning of Injection (BOI) - Degrees of 10
Crankshaft Rotation
EGR Mass (Kg/min) 5
Typical Duration 150 Seconds (2 Cycle)
Dash Lamps MIL
Verification Warm Up Engine and Ensure Engine is Not in Regen Mode. Drive a
Fully-Loaded Trailer on Highway and Maintain Above Enabling
Conditions for 150 Seconds
NOTICE
4. Disconnect the Diesel Exhaust Fluid (DEF) dosing unit electrical connector only. Leave dosing unit bolted
to aftertreatment and DEF lines intact.
5
(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are there any
Note : Running the engine with a disconnected DEF dosing unit will induce a fault code.
WARNING
HOT EXHAUST
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
NOTICE
7.a Yes; check for turbocharger type.
If Asymmetrical Turbocharger (AT), Go to step 8.
If Turbo Compound (TC), Go to step 16.
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
9. Ensure the vehicle air supply is at least 6.0 bar (87 psi). Inspect the air line connection to the wastegate
solenoid. Are there any leaks or kinks in the air line connection?
9.a Yes; repair or replace as necessary. Go to step 35.
6

closes. Is there any binding or damage found?
Note : Wastegate control does not respond at 50 percent. To cycle wastegate, use either 0 percent or 95 percent.
control up to 95% - (Click Set). Wastegate will open with air psi available. Observe wastegate linkage
movement. Does wastegate open when commanded?
13. Move slide control down to 0. Observe wastegate linkage movement. Does wastegate close when
commanded?
15. Inspect the wastegate solenoid and harness connector for signs of damaged, bent, spread, corroded, or
Refer to section "Removal of the DD13 Wastegate Solenoid." Go to step 35.
Refer to section "Removal of the GHG17 DD15 Asymmetrical Turbocharger Wastegate Solenoid."
Go to step 35.

any damage found?
manifold, etc.) for evidence of external leakage (e.g. soot, coolant deposits at joints). Is there any external
leakage found?
sensor.
7

damage found?
28. Compare Intake Manifold Pressure (IMP) value with the barometric pressure value. Are the values within
10.3 kPa (1.5 psi) of each other?
connector. Are there any signs of damage present?
30.b No; replace IMP sensor. Refer to section "Removal of the Intake Pressure/Temperature Sensor" . Go to step 35.
31. Remove EGR cooler hot pipe, EGR crossover pipe and delivery pipe; inspect for excessive build-up or
blockage of soot. Is there any excessive build-up or blockage of soot?

32.a Yes; replace the center section of the exhaust manifold.
Refer to section "Removal of the DD13 and DD15 Exhaust Manifold" . Go to step 34.
Refer to section "Removal of the DD16 Exhaust Manifold" . Go to step 35.
33. Disconnect the NOx inlet sensor harness connector.
34.b No; refer to 15 TS-17 for additional MCM programming.
35. Verify repairs by warming up engine and ensure engine is not in regeneration mode. Drive with a fully
loaded trailer on highway and maintain a steady speed and load for ten minutes.
8
219.4 SPN 3216/FMI 21 – GHG17

Selective Catalyst Reduction (SCR) Inlet NOx Sensor - Drift (Low Box)
SPN 3216/FMI 21
Description Selective Catalyst Reduction (SCR) Inlet NOx Sensor - Drift
(Low Box).
Monitored Parameter Engine Out NOx
Typical Enabling Conditions EGR Mass Flow greater than .08 kg/s, Engine Speed 1450 to
1900 rpm, Engine Torque 1400 to 2100 N·m (1.03 to 1.55 lb
ft), Battery Voltage greater than 11 V, Coolant Temperature
greater than 65°C (149°F), Ambient Temperature greater than
-8°C (18°F) Ambient, Barometric Pressure greater than 755
mbar, Engine Not in Regeneration Mode.
Typical Duration 1.2 Seconds
Dash Lamps MIL
Verification Warm Up Engine Such That Coolant Temperature greater
than 65°C (149°F), Ensure Engine is not in Regeneration
Mode, Ensure Ambient Temperature greater than -8°C (18°F),
Barometric Pressure greater than 755 mbar.
leaks or damage. Is damage present?
3. Perform an Idle Speed Balance (ISB) test. Refer to section "Checking Idle Speed Balance" . Is a faulty fuel injector
identified?
4. Check the Aftertreatment System (ATS) for visible exhaust leaks or damage. Is damage present?
4.b No; replace the NOx inlet sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
9
220.1 SPN 3217/ FMI 2 - GHG17

Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1. Connect DiagnosticLink . Are there any other fault codes?

1.a Yes; repair other fault codes first.
2. Check the ACM software level and fuel maps. The ACM software should be 7.56.7.0 with fuel map ZGS002
or higher. Is the software and fuel map up to date?
2.b No, connect to the server and update the ACM software and fuel map. Verify the repair and release the
vehicle.
3. Since no other active faults are present and the software is up to date, replace the Inlet NOx sensor. Refer to
section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
SPN 3217/FMI 2
Monitor Sequence Inlet NOx Sensor
Dash Lamps MIL
Verification Road Test at Operating Temperature with Engine Above 1200
rpm, Above 40% Load, in DEF Dosing Mode. Not in Regen or
EGR Mode.
Description Goal of this Diagnostic is to Detect the Engine Out Lambda
Signal Lower Than Expected in Engine No-Fueling Mode
Monitored Parameter Inlet NOx Sensor
Dash Lamps MIL
rpm, Above 40% Load, while Not in Regeneration.
Check as follows:
1
3. Check for multiple fault codes. Are there any aftertreatment system fault codes present?
4. Check the Aftertreatment Control Module (ACM) software level. Is the ACM software level lower than
7.56.7.0?
4.a Yes; update the ACM software to the latest available on the server.
5. Is the ACM software level 7.56.7.0?
5.b No; clear the fault codes then update the ACM using the latest software available on the server. Verify
repair.
6. Is the fuel map ZGS 002 or higher?
6.a Yes; replace the SCR inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx
6.b No; clear the fault codes, then update the ACM using the latest software available on the server. Verify
repair.
2
220.2 SPN 3217/FMI 3 - GHG17

SPN 3217/FMI 3
Description This Code Sets When There is a Short to Power on the SCR
Inlet NOx Circuit Between the Sensor and ECU
Dash Lamps MIL, CEL
Check as follows:
1. Disconnect the SCR Inlet NOx sensor.
2. Inspect the SCR Inlet NOx sensor and harness side connector for bent, spread, or corroded pins. Is any
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

2.b No; replace the SCR Inlet NOx sensor.
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
3
SPN 3217/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

4
220.3 SPN 3217/FMI 5 - GHG17

Selective Catalyst Reduction Inlet NOx Sensor Circuit Failed Open
SPN 3217/FMI 5
Description This Codes Sets When There is an Open on the SCR NOx
Inlet Circuit Between the Sensor and the ECU
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

5
SPN 3217/FMI 5
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

6
220.4 SPN 3217/ FMI 7 - GHG17

SPN 3217/FMI 7
Description Goal of This Diagnostic is to Detect The Engine Out Lambda
Monitor Sequence Inlet NOx Sensor vs. Outlet NOx Sensor
Dash Lamps MIL
Verification Road Test at Operating Temperature With Engine Above
1200 rpm, Above 40% Load, in DEF Dosing Mode. Not in
Regen or EGR Mode
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY

2. Was another emission component-related fault code repaired prior to this step?
2.a Yes; perform a parked regeneration to verify repairs and clear fault codes.
leaks or damage. Was any damage or leaks found?
5. Check Aftertreatment System (ATS) for visible exhaust leaks or damage. Is there any damage found?
6. Use DEF test strip A0005850202 to check for diesel fuel or oil contamination of the DEF fluid; Refer to section
"Checking Diesel Exhaust Fluid Quality" . Do the test strips or visual inspection indicate that the DEF is
contaminated?
7
6.a Yes; for diesel fuel or oil contamination, refer to 13 TS-17 and refer to appropriate Original Equipment
Manufacturer (OEM) literature for DEF tank cleaning/flushing procedures. Refill the DEF tank with new
DEF. Verify repair.
7. Using the refractometer from DEF Test Kit W060589001900, measure the DEF urea percentage. Is DEF
urea percentage between 31 and 34 percent?
7.b No; clean/flush the DEF tank and the DEF system. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
Refill the DEF tank with new DEF. Verify repair.
8. Unbolt the DEF doser from the aftertreatment; do not disconnect the DEF lines or electrical connector.
9. Use the graduated cylinder provided in DEF test kit W060589001900, perform a DEF quantity test. Refer to
section "Diesel Exhaust Fluid Quantity Test - GHG17" .
10. Monitor the amount of DEF dispensed. Is the amount of DEF dispensed between 108 and 132 mL (3.7 and
4.5 oz.)?
10.b No; replace the DEF dosing unit. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " . Verify
repair.
11. Reinstall the DEF doser. Go to step 14.
12. Disconnect the DEF doser electrical connector.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
the NOx sensors reading within 50 ppm of each other?
14.b No; replace the SCR inlet NOx sensor and connect the DEF doser electrical connector. Verify repair.
15. Disconnect the DEF dosing unit electrical connector. Go to step 16.
8
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
16. Start the engine and perform a parked regeneration and monitor the NOx efficiency. Is the NOx efficiency
above 80%?
16.a Yes; this fault was likely caused by the DEF build-up in the exhaust which was cleared by the parked
regeneration procedures. Release the vehicle.
Note : Excessive DEF build-up in the exhaust can be caused by a vehicle with a high speed, high average drive
load.
17. Perform a low temperature Aftertreatment Device (ATD) check using DiagnosticLink to check for a drifted
temperature sensor. Refer to section "GHG17 Perform Performance Check - Low Temperature ATD" . Monitor the SCR
inlet and SCR outlet temperatures; they should be within 25°C (45°F) during the last five minutes of this
test. Replace the drifted SCR temperature sensor and verify repair.
SPN 3217/FMI 7
Dash Lamps MIL
Regen or EGR Mode
Check as follows:
WARNING
PERSONAL INJURY
9
WARNING
PERSONAL INJURY

contaminated?
DEF. Verify repair.
4.5 oz.)?
repair.
10
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
above 80%?
load.
11
12
220.1 SPN 3217/ FMI 2 - GHG17

SPN 3217/FMI 2
Description Goal of this Diagnostic is to Detect the Engine Out Lambda
Dash Lamps MIL
rpm, Above 40% Load, while Not in Regeneration.
Check as follows:
3. Check for multiple fault codes. Are there any aftertreatment system fault codes present?
4. Check the Aftertreatment Control Module (ACM) software level. Is the ACM software level lower than
7.56.7.0?
4.a Yes; update the ACM software to the latest available on the server.
5. Is the ACM software level 7.56.7.0?
5.b No; clear the fault codes then update the ACM using the latest software available on the server. Verify
repair.
6. Is the fuel map ZGS 002 or higher?
6.a Yes; replace the SCR inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx
6.b No; clear the fault codes, then update the ACM using the latest software available on the server. Verify
repair.
13
220.2 SPN 3217/FMI 3 - GHG17

SPN 3217/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

14
220.3 SPN 3217/FMI 5 - GHG17

SPN 3217/FMI 5
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

15
220.4 SPN 3217/ FMI 7 - GHG17

SPN 3217/FMI 7
Dash Lamps MIL
Regen or EGR Mode
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY

contaminated?
16
DEF. Verify repair.
4.5 oz.)?
repair.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
17
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
above 80%?
load.
18
221.1 SPN 3223/FMI 7 - GHG17

SPN 3223/FMI 7
Description NOx Inlet Sensor failure to activate
Monitored Parameter NOx Inlet Sensor
Typical Enabling Conditions NOx Raw count
Typical Duration Always ON
Dash Lamps MIL
Verification Once engine is at standard operating temperature, drive at
highway speed with loaded trailer above 1130 rpm
continuously for twenty minutes.
Check as follows:
2. Disconnect the Selective Catalytic Reduction (SCR) inlet NOx sensor harness connector.
3. Inspect the SCR inlet NOx sensor and harness connector for signs of damaged, bent, spread, corroded or
unseated (pushed out) pins, signs of moisture in the connector or wire damage near the connector. Are any
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go to step 4. to verify
repairs.
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go to step 4. to verify
repairs.
4. Using DiagnosticLink, monitor parameter AS105: NOx Sensor Dewpoint enabled Inlet while performing
verification drive.
5. Drive vehicle for ten minutes after AS105: NOx Sensor Dewpoint enabled Inlet parameter changes state
from zero to one and fault code goes inactive. Does AS105: NOx Sensor Dewpoint enabled Inlet parameter
change state from zero to one and fault code stay inactive?
5.a Yes; clear fault codes. Release vehicle.
5.b No; replace Aftertreatment Control Module (ACM). Refer to OEM procedures. Verify repairs.
1
222.1 SPN 3226/FMI 10 - GHG17

Outlet NOx Sensor Signal Erratic
SPN 3226/FMI 10
Description Outlet NOx sensor reading jumping greater than 100 Parts
Per Million (ppm) per seconds.
Monitored Parameter Selective Catalyst Reduction (SCR) Outlet NOx Sensor
Typical Enabling Conditions Coolant Temperature greater than 65°C (149°F), Engine rpm
600-2000
Dash Lamps MIL
Verification Drive cycle with condition meet
Check as follows:
1. Disconnect the outlet NOx sensor.
2. Inspect NOx sensor harness connector for bent, spread or corroded pins. Was any damage found?
3. Replace the SCR outlet NOx sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
For 2-Box, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
1
222.2 SPN 3226/FMI 13 - GHG17

SPN 3226/FMI 13
Description Selective Catalyst Reduction (SCR) Outlet NOx Sensor Signal
Not Available
Monitored Parameter SCR Outlet NOx Sensor Signal
Dash Lamps MIL
Engine Reaction
Note : If fault occurred during high idle regeneration, clear fault and release vehicle.
Check as follows:
1. Is SPN 3226/FMI 13 currently active?
2. Check the SPN 3226/FMI 13 Diagnostic Trouble Code (DTC) occurrence counter.
2.a If the DTC occurrence counter is five or less, clear the fault and release the vehicle.
2.b If the DTC occurrence counter is greater than five, Go to step 3.
3. Disconnect the SCR outlet NOx sensor.
4. Inspect the sensor harness for bent, spread, or corroded pins. Are any of the pins damaged?
2

6. Measure the voltage between pins 1 and 4 on the harness side of the SCR outlet NOx sensor connector. Is
the voltage less than 11.5 volts?
7. Measure the voltage between pin 1 on the harness side of the SCR outlet NOx sensor connector and
engine ground. Is the voltage less than 11.5 volts?
7.a Yes; repair the wire between pin 1 on the harness side of the SCR outlet NOx sensor connector and
pin 42 of the Aftertreatment Control Module (ACM) 120-pin connector.
7.b No; repair the wire between pin 4 on the harness side of the SCR outlet NOx sensor connector and pin
9. Measure the resistance between pins 2 and 3 on the harness side of the SCR outlet NOx sensor
connector. Is the resistance between 50 to 70 ohms?
9.a Yes; replace the SCR outlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx
Sensor" .

(pushed out) pins and signs of moisture in the connector or wire damage near the connector. Are there
signs of damage to the harness connector?
12. Measure the resistance between pins 2 and 3 on the harness side of the SCR outlet NOx sensor
connector. Is the resistance less than 1K ohm?
12.a Yes; repair short between pins 2 and 3 on the harness side of the SCR outlet NOx sensor connector
and pins 40 and 41 of the ACM 120-pin connector.
13. Measure the resistance between pin 2 on the harness side of the SCR outlet NOx sensor connector and
pin 41 of the ACM 120-pin connector. Is the resistance greater than five ohms?
pin 41 of the ACM 120-pin connector.
pin 40 of the ACM 120-pin connector. Is the resistance greater than five ohms?
15. Test ACM internal resistor; measure the resistance between pins 40 and 41 on the ACM 120-pin connector.
Is the resistance between 50 to 70 ohms?
3
15.a Yes; replace the SCR outlet NOx Sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx
Sensor" .
15.b No; replace the ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .
4
222.3 SPN 3226/FMI 20 - GHG17

SPN 3226/FMI 20
Description Selective Catalyst Reduction (SCR) Outlet NOx Sensor – Drift
Low
Monitored Parameter Engine Out NOx
Typical Enabling Conditions The Following Must Be True for greater than 30s: Fuel Mass
is 0, Diesel Particulate Filter (DPF) Outlet Temperature
greater than 200°C (392°F), Battery Voltage greater than 10V
DC, Engine Speed 500 to 2100 rpm
Dash Lamps MIL
Verification Parked Regeneration
3. Check for multiple fault codes. Are there any other fault codes present for the SCR outlet NOx sensor?
WARNING
HOT EXHAUST
4. Inspect the Aftertreatment System (ATS) for exhaust leaks. Are there any leaks present?
4.a Yes; repair the exhaust leaks. Verify repair.
5. Inspect the ATS for damage. Is there any damage present?
5.b No; replace the SCR outlet NOx sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .Verify repair.
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .Verify repair.
5
222.4 SPN 3226/FMI 21 - GHG17

SPN 3226/FMI 21
Description NOx Outlet Sensor Drift High
Monitored Parameter Selective Catalyst Reduction (SCR) Outlet NOx
Typical Enabling Conditions Coolant Temperature greater than 70°C (158°F), Engine rpm
greater than 1500 and Torque greater than 80%
Dash Lamps MIL
1. Check Aftertreatment System (ATS) for visible exhaust leaks or damage. Is damage present?
contaminated?
WARNING
HOT EXHAUST
DEF. Verify repair.
urea percentage between 31 to 34 percent?
Note : Fault code SPN 3361/FMI 5 will become present when the Diesel Exhaust Fluid (DEF) doser electrical
connector is disconnected. This code can be cleared using DiagnosticLink once the DEF doser electrical
connector is reconnected.
5. Perform a DEF Quantity Test service routine; Refer to section "Diesel Exhaust Fluid Quantity Test - GHG17" .
6. Monitor the amount of DEF dispensed into the DEF-safe container included in DEF test kit
W060589001900. Is the amount of DEF dispensed between 108 to 132 mL?
6.a Yes; reinstall the DEF Dosing Unit using a new gasket and bolts, as these parts are one-time-use
components. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " . Go to step 7.
6.b No; replace the DEF Dosing Unit using a new gasket and bolts, as these parts are one-time-use
components. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " . Verify repair.
7. Replace the SCR outlet NOx sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" . Verify repair.
6
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" . Verify repair.
7
223.1 SPN 3227/FMI 2 - GHG17

SPN 3227/FMI 2
Description Goal of this Diagnostic is to Detect the Tail Pipe Out Lambda
Signal Lower Than Expected in Engine No Fueling Mode
Monitored Parameter Outlet NOx Sensor
Monitor Sequence Outlet NOx Sensor
Dash Lamp MIL
rpm, Above 40% Load, in DEF Dosing Mode. Not in Regen or
EGR Mode
Check as follows:
WARNING
PERSONAL INJURY

2. Check the ACM software level and fuel maps. The ACM software should be 7.56.7.0 with fuel map ZGS002
or higher. Is the software and fuel map up to date?
2.b No, connect to the server and update the ACM software and fuel map. Verify the repair and release the
vehicle.
3. Since no other active faults are present and the software is up to date, replace the Outlet NOx sensor. Refer
to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
1
223.2 SPN 3227/FMI 3 - GHG17

Selective Catalyst Reduction Outlet NOx Sensor Circuit Failed High
SPN 3227/FMI 3
Outlet NOx Circuit Between the Sensor and ECU
Monitored Parameter SCR Outlet NOx Sensor
Dash Lamps MIL, CEL
Check as follows:
1. Disconnect the SCR Outlet NOx sensor.
2. Inspect the SCR Outlet NOx sensor and harness side connector for bent, spread, or corroded pins. Is any
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

2.b No; replace the SCR Outlet NOx sensor.
2
223.3 SPN 3227/FMI 5 - GHG17

Selective Catalyst Reduction Outlet NOx Sensor Circuit Failed Open
SPN 3227/FMI 5
Description This Code Sets When There is an Open on the SCR Outlet
NOx Circuit Between the Sensor and the ECU
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

3
224.1 SPN 3236/FMI 9 – GHG17

Exhaust Mass Signal Not Available via Controller Area Network
1. Has the Aftertreatment Control Module / Motor Control Module / Common Powertrain Controller been
recently reprogrammed?
1.a Yes; clear the faults codes. If they do not become active, then release the vehicle.
2. Turn the ignition OFF (key OFF, engine OFF) and disconnect DiagnosticLink . Wait five minutes for all
modules to power-down.
4. Reconnect DiagnosticLink. Are any fault codes active?
4.a Yes; follow the entire SPN 625/FMI 9 procedure for further PT Controller Area Network (CAN)
troubleshooting.
1
225.1 SPN 3238/FMI 2 - GHG17

Selective Catalyst Reduction Outlet NOx Sensor Failure to Activate
2. Is SPN 5357 FMI 16 or 18 also present?
3. Monitor (chart) the following parameters.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
1

4.b No; replace the SCR outlet NOx sensor.
2
226.1 SPN 3242/FMI 3 - GHG17

Diesel Oxidation Catalyst Inlet Temperature Sensor Circuit Failed High
1. Disconnect the Diesel Oxidation Catalyst (DOC) inlet temperature sensor connector.
2.a If the pins are bent, spread, or corroded, repair as necessary. Verify Repairs
3. DOC inlet temperature test: measure the resistance between pin 1 and 2 of the DOC inlet temperature
sensor connector.
Temp - °C Temp -°F Range

Min Resistance () Max Resistance ()
0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
3.a If the resistances are out of range, replace the DOC inlet temperature sensor.
For 1-Box™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
For 2-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
3.b If the resistances are in range, Go to step 4.
5. Measure the voltage between pin 2 on the harness side of the DOC inlet temperature sensor connector and
ground.
5.a If the voltage is greater than 3 volts, repair the short to power between pin 2 on the harness side of the
DOC inlet temperature sensor connector and pin 107 of the Aftertreatment Control Module (ACM) 120-
pin connector.
5.b If the voltage is between 2.75 and 3 volts, Go to step 6.
5.c If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the DOC inlet
temperature sensor connector and pin 107 of the ACM 120-pin connector.
1
6. Measure the voltage between pin 1 on the harness side of the DOC inlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the DOC inlet
6.b If no voltage is present, repair the open between pin 1 on the harness side of the DOC inlet
2
226.2 SPN 3242/FMI 4 - GHG17

Diesel Oxidation Catalyst Inlet Temperature Sensor Failed Low
2. Disconnect the Diesel Oxidation Catalyst (DOC) inlet temperature sensor harness connector.
3. Inspect the DOC inlet temperature sensor harness connector for bent, pushed out, spread, or corroded
pins.
3.a If the pins are bent, pushed out, spread, or corroded, repair as necessary. Verify repairs.
3.b If the DOC inlet temperature sensor harness connector shows no signs of damage, Go to step 4.
4. Disconnect the Aftertreatment Control Module (ACM) 120-pin connector.
5. Inspect ACM 120-pin connector and harness connector for bent, pushed out, spread, or corroded pins.
5.a If there are signs of bent, pushed out, spread, or corroded, repair as necessary. Verify repairs.
5.b If Motor Control Module (MCM) 120-pin connector and harness show no signs of damage, Go to step 6.
6. Measure the resistance between pin 2 on the harness side of the DOC inlet temperature sensor connector
and ground - (Battery Ground).
6.a If the resistance is less than 1K ohms, repair the short to ground in the wire between pin 2 of the DOC
inlet temperature sensor connector and pin 107 of the ACM 120-pin connector. Verify repairs.
7. Inspect Aftertreatment harness connectors (14-way or 47-way depending on application) and intermediate
chassis wiring (OEM dependent) for bent, pushed out, spread, or corroded pins or signs of damage to the
wiring.
7.a If there are signs of bent, pushed out, spread, or corroded pins or harness damage, repair as
necessary. Verify repairs.
7.b If connectors and harness show no signs of damage, Go to step 8.
8. If problem is still unresolved, review previous steps. If issue is still not resolved, replace the DOC inlet
temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
For 2- BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
3
226.3 SPN 3242/FMI 8 - GHG17

Diesel Oxidation Catalyst Inlet Temperature – Signal Spike
Note : This fault indicates the Aftertreatment Control Module (ACM) has detected a sudden temperature shift on
the Diesel Oxidation Catalyst (DOC) inlet temperature sensor. The most likely cause is an intermittent wiring
concern (poor terminal fit, corrosion, chaffing etc.).
3. Check fault codes:
3.a If SPN 3242/FMI 3 or 4 are active, repair those faults first.
3.b If SPN 3242/FMI 3 or 4 are inactive or not present, Go to step 4.
4. Using the Selective Catalyst Reduction (SCR) and Diesel Particulate Filter (DPF) voltages service routine
tab, monitor parameter DOC inlet temp (pin 107).
5. While wiggle-testing the harness, look for abnormal voltage spikes on the DOC inlet temperature signal.
Once a spike is detected, isolate that section of harness and inspect for wire chaffing, corrosion, improper
connections or physical damage and repair as necessary. If no voltage spikes are detected, Go to step 6.
6. DOC inlet temperature sensor test – Disconnect the DOC inlet temperature sensor, measure the resistance
between pins 1 and 2 of the DOC inlet temperature sensor connector (refer to chart for resistance values).

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
6.a If the resistances are out of range, replace the DOC inlet temperature sensor.
7. Using appropriate test probes from J-48476 connector test kit and terminal repair kit J-47410, drag test and
inspect all harness connector terminals between the DOC inlet temperature sensor and the ACM including
the chassis extension harness and Aftertreatment Device (ATD) sensor box. Repair as necessary.
4
226.4 SPN 3242/FMI 17 - GHG17

Diesel Oxidation Catalyst Inlet Temperature Out Of Range Low Preventing HC Dosing
Diagnose as follows:
2. Disconnect the Diesel Oxidation Catalyst (DOC) inlet temperature sensor harness connector.
3. Inspect the DOC inlet temperature sensor harness for bent, spread, or corroded pins.
3.a If the pins are bent, spread, or corroded, repair as necessary. Verify repairs.
3.b If the DOC inlet temperature connector shows no signs of damage, Go to step 4.
5. Measure the resistance between pin 2 on the harness side of the DOC inlet temperature sensor connector
and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the DOC inlet temperature
sensor connector and pin 107 of the ACM 120-pin connector. Verify repairs.
5.b If the resistance is greater than 1K ohms, replace the DOC inlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .
5
226.5 SPN 3242/FMI 20 - GHG17

Diesel Oxidation Catalyst Temperature Drift - Inlet High or Outlet Low
SPN 3242/FMI 20
Description 70°C (126°F) Difference During Non-regeneration Mode
Monitored Parameter Diesel Oxidation Catalyst (DOC) Inlet Temperature vs. DOC
Outlet Temperature
Typical Enabling Conditions Coolant Temperature Greater than 60°C (140°F); Regen not
Active in Last Five Minutes
Typical Duration One Minute
Dash Lamps MIL, CEL
Engine Reaction Regen Inhibit and 10% Engine Derate
Verification Low Temperature Regen
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
1. Check for multiple fault codes. Are SPN 3242/FMI 3, 4, 8 or SPN 3250/FMI 3, 4, and 8 present?
WARNING
PERSONAL INJURY
6
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

3. Run service routine Perform Performance Check - Low Temp ATD; allow the routine to run for 20 to 25
minutes.
4. Compare the Diesel Oxidation Catalyst (DOC) inlet temperature with DOC outlet temperature and Diesel
Particulate Filter (DPF) outlet temperature. Are all three temperature sensors within 25°C (45°F) of each
other?
4.a Yes; DOC inlet and DOC outlet temperature sensors test good. Clear the code and release the vehicle.
5. Is the DOC outlet temperature sensor reading within 25°C (45°F) of the DPF outlet temperature sensor?
6. Shut OFF the engine.
7. Replace the DOC inlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" . Verify repair.
For Two-BOX option, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" . Verify repair.
8. Shut OFF the engine.
9. Replace the DOC outlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
For Two-BOX option, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
7
227.1 SPN 3246/FMI 0 - GHG17

SPN 3246/FMI 0
Description This Code Sets When The Diesel Particulate Filter (DPF)
Outlet Temperature is Greater Than 790°C (1454°F) for More
Than Two Seconds
Monitored Parameter DPF Outlet Temperature Sensor
Dash Lamps CEL, MIL, SEL
Engine Reaction 25% Derate, Engine Shutdown
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
Possible causes:
• Faulty DPF outlet temperature sensor
• Fluid intrusion into the exhaust
• Biased input for fuel mapping
• Incorrect or over-contributing fuel injectors
• Restricted air filter
• Incorrect camshaft timing
1

3. Check for any fuel system fault codes. Are there fuel system fault codes present?
3.a Yes; diagnose the fuel system codes first.
4. Check for multiple DPF outlet temperature sensor fault codes. Is code SPN 3246/FMI 8 present?
4.a Yes; diagnose code SPN 3246/FMI 8 first. Verify repair.
5. Does this vehicle have a DD15 engine?
6. Verify the MCM software level, is the MCM software level 6.5.0.2?
6.b No; update the MCM to software version 6.5.0.2 (or higher) with fuel map ZGS 003 and the ACM to
software 7.57.2.0 (or higher).
7. Check for multiple high exhaust temperature fault codes. Are fault codes SPN 3250/FMI 0, SPN 4360/FMI
15 or SPN 4363/FMI 0 present?
8. Remove and inspect the turbocharger exhaust outlet pipe. Are there signs of fluid in the exhaust?
8.a Yes; determine the cause of fluid in the exhaust. Repair as necessary. Inspect the Diesel Oxidation
Catalyst (DOC) and DPF.
Refer to section "Inspection of the Diesel Oxidation Catalyst" . Verify repair.
9. Remove and inspect the Exhaust Gas Recirculation (EGR) outlet pipe. Refer to section "Removal of the Exhaust
Gas Recirculation Hot Pipe" . Is there fuel present in the EGR outlet pipe?
9.a Yes; Refer to section "Test-E - Two-Filter Fuel System" . Verify repair.
10. Check for any air management system fault codes. Are there any air management system fault codes
present?
10.a Yes; diagnose the air management system fault codes first. Verify repair.
11. Remove and inspect the air filter; refer to OEM literature for removal and inspection procedures. Is the air
filter restricted?
11.a Yes; replace the air filter. Verify repair.
Note : A cold soak may take up to eight hours.
12. Allow the engine to cold soak so the temperature of the exhaust stabilizes with the ambient air temperature.
Go to step 13.
14. Monitor the DPF outlet temperature sensor reading. Is the DPF outlet temperature sensor within 25°C
(45°F) of the other exhaust temperature sensors?
14.b No; replace the DPF outlet temperature sensor.
For 1-Box™; Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
For Two-Box; Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
2
16. Disconnect the intake temperature sensor connector, shown above.

17. Inspect the intake temperature connector and the harness connector for signs of damage, bent, spread,
broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any damage
found?
17.a Yes; replace the intake temperature sensor and the harness pig tail.
17.b No; reconnect the sensor and Go to step 18.
19. Compare the barometric sensor reading to the intake manifold pressure sensor reading. Are the readings
within 8.27 kPa (1.2 psi) of each other?
20. Compare the intake manifold temperature sensor reading to the charge air cooler temperature sensor
reading. Are the readings within 5°C (9°F) of each other?
WARNING
ENGINE EXHAUST
3
WARNING
PERSONAL INJURY
21. Start the engine. Go to step 22.

22. Perform the Idle Speed Balance (ISB) test. Refer to section "Checking Idle Speed Balance" . Do all of the injectors
pass the ISB test?
22.b No; replace the faulty injector. Verify repair.
23. Turn the engine OFF. Go to step 24.
24. Remove and inspect the EGR cooler outlet pipe. Is there fuel present in the EGR cooler outlet pipe?

25. Perform an Automatic Fuel System Integrity Check (FSIC) routine and monitor Actual Fuel Mass at 600
rpm. Does Actual Fuel Mass exceed 50 mg/st at 600 rpm?
25.a Yes; stop FSIC routine and inspect for stuck engine brakes. Refer to section "Checking for Poor Engine Brake
Performance" . Verify repair.

26. Verify the fuel injector(s) part number is correct for engine application.
Refer to section "Removal of the Fuel Injector - Two-Filter System" . Is the fuel injector(s) part number correct for the
application?
4
26.a Yes; verify the camshaft timing. Refer to section "Camshaft Timing Verification" . Repair as necessary. Verify
repair.
26.b No; install the correct injectors.
Refer to section "Test-E - Two-Filter Fuel System" . Verify repair.
5
227.2 SPN 3246/FMI 2 - GHG17

DPF Outlet Temperature Not Plausible
SPN 3246/FMI 2
Description This fault sets if the Diesel Particulate Filter (DPF) outlet
temperature is 70°C (126°F) higher compared to all other
aftertreatment temperature sensors after 8 hours cold soak.
Monitored Parameter DPF Outlet Temperature versus all other ATS temperature
sensors
Typical Enabling Conditions Engine off for more than 8 hours, Battery Voltage greater than
10.98 V, Ignition on longer than 60 seconds
Monitor Sequence Key on; engine off for more than 60 seconds
Dash Lamps MIL
Verification Ignition off/ 8 hours cold soak
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 3246/ FMI 3/4 also present?
4. Disconnect and inspect the DPF outlet temperature sensor electrical connector, harness side.
5. Are there any spread pins, damaged pins, corrosion or signs of fretting present?
For 1-BOX™, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor"
For 2-BOX, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .Verify repair.
6
227.3 SPN 3246/FMI 3 - GHG17

Diesel Particulate Filter Outlet Temperature Sensor Circuit Failed High
1. Disconnect the Diesel Particulate Filter (DPF) outlet temperature sensor connector.
2. Inspect the DPF outlet temperature sensor harness for bent, spread, or corroded pins.
3. DPF outlet temperature test - measure the resistance between pin 1 and 2 of the DPF outlet temperature
sensor connector (refer to chart for resistance values).

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
3.a If the resistances are out of range, replace the DPF outlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
For 2-BOX, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
5. Measure the voltage between pin 2 on the harness side of the DPF outlet temperature sensor connector
and ground.
DPF Outlet Temperature sensor connector and pin 97 of the Aftertreatment Control Module (ACM)
120-pin connector.
5.c If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the DPF
outlet temperature sensor connector and pin 97 of the ACM 120-pin connector.
6. Measure the voltage between pin 1 on the harness side of the DPF outlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the DPF outlet
7
6.b If no voltage is present, repair the open between pin 1 on the harness side of the DPF outlet
8
227.4 SPN 3246/FMI 4 - GHG17

Diesel Particulate Filter Outlet Temperature Sensor Circuit Failed Low
2. Disconnect the Diesel Particulate Filter (DPF) outlet temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DPF Outlet Temperature sensor
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the DPF outlet temperature
sensor connector and pin 97 of the ACM 120-pin connector.
5.b If the resistance is greater than 1K ohms, replace the DPF outlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor"
For 2-BOX, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor"
9
227.5 SPN 3246/FMI 8 - GHG17

Diesel Particulate Filter Outlet Temperature - Signal Spike
the Diesel Particulate Filter (DPF) outlet temperature sensor. The most likely cause is an intermittent wiring
concern (poor terminal fit, corrosion, chaffing etc.).
3. Check fault codes:
3.a If SPN 3246/FMI 3 or 4 are active, repair those faults first.
3.b If SPN 3246/FMI 3 or 4 are inactive or not present, Go to step 4.
4. Using the Selective Catalyst Reduction (SCR) and DPF voltages service routine tab, monitor parameter
DPF outlet temp (pin 97).
5. While wiggle-testing the harness, look for abnormal voltage spikes on the DPF outlet temperature signal.
Once a spike is detected, isolate that section of harness and inspect for wire chaffing, corrosion, improper
connections or physical damage and repair as necessary. If no voltage spikes are detected, Go to step 6.
6. DPF outlet temperature sensor test – Disconnect the DPF outlet temperature sensor, measure the
resistance between pins 1 and 2 of the DPF outlet temperature sensor connector (refer to chart for
resistance values).

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
6.a If the resistances are out of range, replace the DPF outlet temperature sensor.
inspect all harness connector terminals between the DPF outlet temperature sensor and the ACM including
the chassis extension harness and ATD sensor box. Repair as necessary.
10
227.6 SPN 3246/FMI 15 - GHG17

Diesel Particulate Filter Outlet Temperature - High
SPN 3246/FMI 15
Description This Code Sets When The Diesel Particulate Filter (DPF)
Outlet Temperature is Greater Than 730°C (1346°F) for More
Than Two Seconds
Monitored Parameter DPF Outlet Temperature Sensor
Dash Lamps CEL, MIL
Check as follows:
Possible causes:
• Faulty DPF outlet temperature sensor
• Incorrect camshaft timing
1. Connect DiagnosticLink®. Go to step 2.
4. Check for multiple DPF outlet temperature sensor fault codes. Is code SPN 3246/FMI 8 present?
5. Check for any SPN 190/FMI engine over-speed fault codes. Are any SPN 190/FMI fault codes active or
previously active?
5.a Yes; Check DDEC reports for an engine over-speed and inspect camshafts for spun cam lobes. Go to
step 6.

7.a Yes; determine the cause of fluid in the exhaust. Repair as necessary. Inspect the Diesel Oxidation
Catalyst (DOC) and Diesel Particulate Filter (DPF).
Refer to section " Diesel Oxidation Catalyst (DOC) Inspection - All Years " .
Refer to section " Diesel Particulate Filter (DPF) Inspection - All Years ". Verify repair.
11

8.a Yes; Refer to section "Test-E - Two-Filter Fuel System" .Verify repair.
present?
10. Remove and inspect the air filter; refer to OEM literature for removal and inspection procedures. Is the air
filter restricted?
Note : A cold soak may take up to eight hours.
Go to step 12.
13. Monitor the DPF outlet temperature sensor reading. Is the DPF outlet temperature sensor within 25°C
For 1-BOX™, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
For 2-BOX, Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
14. Compare the barometric sensor reading to the intake manifold pressure sensor reading. Are the readings
15. Compare the intake manifold temperature sensor reading to the charge air cooler temperature sensor
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
12
pass the ISB test?
20. Perform an Automatic Fuel System Integrity Check (FSIC) routine and monitor Actual Fuel Mass at 600

application?
repair.
21.b No; install the correct injectors.
Refer to section "Test-E - Two-Filter Fuel System" . Verify repair.
13
227.7 SPN 3246/FMI 20 - GHG17

Diesel Particulate Filter Outlet Temperature Sensor Stuck
1. Check for multiple fault codes.
1.a If SPN 3246/FMI 3/4/8 or SPN 3250/FMI 3/4/8 is also present, repair those faults first.
1.b If the above faults are not present, Go to step 2.
3. Compare the Diesel Oxidation Catalyst (DOC) outlet temperature and Diesel Particulate Filter (DPF) outlet
temperature; is the DOC outlet temperature within 7°C (45°F) of the DPF outlet temperature?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Start the engine (key ON, engine ON).

5. Compare the DOC outlet temperature and DPF outlet temperature; are the DOC outlet temperature and
DPF outlet temperature within 7°C (45°F) of each other?
6. Continue idling the engine for 10 minutes. Are the DOC outlet temperature and DPF outlet temperatures
within 7°C (45°F) of each other?
7. Turn engine OFF.
8. Disconnect the DOC outlet temperature sensor harness.
9. Inspect the DOC outlet temperature sensor and harness connector for signs of damage, bent, spread,
connector.
10. Measure the resistance across the DOC outlet temperature sensor at the pigtail connector (refer to chart).
Is the resistance within range?
14

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98

10.b No; replace the DOC outlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
11. Disconnect the DPF outlet temperature sensor harness.
12. Inspect the DPF outlet temperature sensor and harness connector for signs of damage, bent, spread,
connector.
13. Measure the resistance across the DPF outlet temperature sensor at pigtail connector (refer to chart
above). Is the resistance within range?
15
227.8 SPN 3246/FMI 21 - GHG17

Diesel Particulate Filter Outlet Temperature Sensor - Not Plausible
1.a If SPN 3246 FMI 3/4/8 or SPN 3250 FMI 3/4/8 is also present, repair those faults first. Verify repairs.
3. Compare Diesel Oxidation Catalyst (DOC) outlet temperature and Diesel Particulate Filter (DPF) outlet
temperature. Is the DOC outlet temperature within 7°C (45°F) of the DPF outlet temperature?
WARNING
ENGINE EXHAUST
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

5. Compare DOC outlet temperature with the DPF outlet temperature. Is the DOC outlet temperature within
7°C (45°F) of the DPF outlet temperature?
6. Continue idling engine for ten minutes. Is the DOC outlet temperature within 7°C (45°F) of the DPF outlet
temperature?
7. Turn engine OFF (key OFF, engine OFF).
8. Disconnect the DOC outlet temperature sensor harness. Inspect harness for bent, spread or corroded pins.
8.a If pin damage is found, repair as necessary. Verify repairs.
8.b If no pin damage is found, Go to step 9.
16

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
9. Measure the resistance across the DOC Out temperature sensor at pigtail connector (refer to chart). Is the
resistance within range?
9.b No, replace the DOC outlet temperature sensor.
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
10. Disconnect the DPF outlet temperature sensor harness. Inspect harness for bent, spread or corroded pins.
10.a If pin damage is found, repair as necessary. Verify repairs.
11. Measure the resistance across the DPF outlet temperature sensor at pigtail connector (refer to chart). Is the
resistance within range?
11.b No, replace the DPF outlet temperature sensor.
17
228.1 SPN 3250/FMI 0 - GHG17

SPN 3250/FMI 0
Description This Code Sets When the Diesel Oxidation Catalyst (DOC)
Outlet Temperature is Greater Than 760°C (1400°F) For More
Than Two Seconds
Monitored Parameter Diesel Oxidation Catalyst Temperature Sensor
Dash Lamps MIL, CEL
Possible causes:
• Faulty DOC outlet temperature sensor
• Incorrect cam timing
Check as follows:
1. Connect Diagnostic Link . Go to step 2.
4. Check for multiple DOC outlet temperature sensor fault codes. Is code SPN 3250/FMI 8 present?
6.a Yes; determine and repair the cause of fluid in the exhaust. Repair as necessary. Inspect the DOC and
DPF.. Refer to section "Inspection of the Diesel Oxidation Catalyst" . Verify repair.
1

present?
9. Remove and inspect the air filter; refer to Original Equipment Manufacturer (OEM) literature for removal
and inspection procedures. Is the air filter restricted?
Note : A cold soak may take up to 8 hours.
Go to step 11.
12. Monitor the DOC outlet temperature sensor reading. Is the DOC outlet temperature sensor within 25°C
For 1-Box™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
13. Compare the Barometric sensor reading to the Intake Manifold Pressure sensor reading. Are the readings
14. Compare the Intake Manifold Temperature sensor reading to the Charge Air Cooler Temperature sensor
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

pass the Idle Speed Balance test?
2

18.a Yes;
For two filter fuel systems, Refer to section "Test-E - Two-Filter Fuel System" .Verify repair.
19. Perform an automatic Fuel System Integrity Check (FSIC) routine and monitor Actual Fuel Mass at 600

application?
repair.
20.b No; install the correct injectors. Refer to section "Test-E - Two-Filter Fuel System" . Verify repair.
3
228.2 SPN 3250/FMI 2 - GHG17

DOC Outlet Temperature Not Plausible
SPN 3250/FMI 2
Description This fault sets if the DOC outlet temperature is 70°C (126°F)
higher compared to all other aftertreatment temperature
sensors after 8 hours cold soak.
Monitored Parameter Diesel Oxidation Catalyst (DOC) Outlet Temperature versus
all other ATS temperature sensors
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 3250/ FMI 3/4/8 also present?
4. Disconnect and inspect the DOC outlet temperature sensor electrical connector, harness side.
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
4
228.3 SPN 3250/FMI 3 - GHG17

Diesel Oxidation Catalyst Outlet Temperature Sensor Circuit Failed High
1. Disconnect the Diesel Oxidation Catalyst (DOC) outlet temperature sensor connector.
3. DOC outlet temperature test – measure the resistance between pin 1 and 2 of the DOC outlet temperature
sensor connector and refer to chart for resistance values.
Resistance Values
Temp C° (F°) Min. Resistance () Max. Resistance () Min. Voltage Max. Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 498.84 0.970 1.007
3.a If the resistances are out of range, replace the DOC outlet temperature sensor.
For 1-Box™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
For 2-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
5. Measure the voltage between pin 2 on the harness side of the DOC outlet temperature sensor connector
and ground.
DOC outlet temperature sensor connector and pin 27 of the ACM 120-pin connector. Verify repairs.
5.c If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the DOC
outlet temperature sensor connector and pin 27 of the ACM 120-pin connector. Verify repairs.
6. Measure the voltage between pin 1 on the harness side of the DOC outlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the DOC outlet
temperature sensor connector and pin 73 of the Aftertreatment Control Module (ACM) 120-pin
6.b If no voltage is present, repair the open between pin 1 on the harness side of the DOC outlet
temperature sensor connector and pin 73 of the ACM 120-pin connector. Verify repairs.
5
228.4 SPN 3250/FMI 4 - GHG17

Diesel Oxidation Catalyst Outlet Temperature Circuit Failed Low
2. Disconnect the Diesel Oxidation Catalyst (DOC) outlet temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DOC outlet temperature sensor connector
and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the DOC outlet temperature
5.b If the resistance is greater than 1K ohms, replace the DOC outlet temperature sensor.
6
228.5 SPN 3250/FMI 7 – GHG17

Diesel Oxidation Catalyst Outlet Temperature Response Error
This fault code sets when the difference between the Diesel Oxidation Catalyst (DOC) outlet temperature and
Ambient Air Temperature (in the ACM) is less than 35°C (95°F) after the engine has been running continuously for
40 minutes.
SPN 3250/FMI 7
Description DOC Outlet Temperature Response Error
Monitored Parameter DOC Outlet Temperature, Ambient Air Temperature (ACM)
Typical Enabling Conditions Engine Running for more than 40 minutes
Dash Lamps MIL, CEL
Verification Run the engine at idle for 40 minutes
Possible causes:
• No exhaust flow through the Aftertreatment System (ATS)
2. Turn the ignition ON (Key ON, Engine OFF). Go to step 3.
3. Check for other fault codes. Are fault codes SPN 3250/FMI 3/ 4/ or 20 present?
4. Visually inspect the DOC outlet temperature sensor. Is the DOC outlet temperature installed correctly?
4.b No; correctly install the DOC outlet temperature sensor.
For 2-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
5. Inspect the ATS. Is the ATS damaged or modified?
7
228.6 SPN 3250/FMI 8 – GHG17

Diesel Oxidation Catalyst Outlet Temperature - Signal Spike
SPN 3250/FMI 8
Description This Fault Indicates the Aftertreatment Control Module (ACM)
has Detected a Sudden Temperature Shift on the Diesel
Oxidation Catalyst (DOC) Outlet Temperature Sensor
Monitored Parameter DOC Outlet Temperature
Typical Enabling Conditions DOC Outlet Temperature Greater Than 150°C (302°F)
Dash Lamps CEL, MIL
Verification Low Temp ATD Check
Note : The most likely cause is an intermittent wiring concern (poor terminal fit, corrosion, chaffing etc.).
3. Check for other fault codes. Are SPN 3250/FMI 3 or 4 present?
3.a Yes; repair the other fault codes first.
5. Remove the DOC outlet temperature sensor.
6. Allow the DOC outlet temperature sensor to cold soak for several minutes until the sensor has reached
ambient temperature.
7. Measure the resistance between pins 1 and 2 of the DOC outlet temperature sensor connector. Does the
DOC outlet temperature sensor match the resistance specification in the chart below?
7.a Yes; Go to step 8. .
Temp °C (°F) Min Resistance () Max Resistance () Min Voltage Max Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 498.84 0.970 1.007
inspect all harness connector terminals between the DOC outlet temperature sensor and the ACM including
8
9
228.7 SPN 3250/FMI 15 - GHG17

Diesel Oxidation Catalyst Outlet Temperature High
SPN 3250/FMI 15
Description Exhaust Temperature High
Monitored Parameter Exhaust Temperature
Dash Lamps MIL
steps.
4. Check for multiple fault codes. Are SPN 3250 / FMI 2, 3, 4, 7, or 8 also present?
4.a Yes; troubleshoot those first.
WARNING
ENGINE EXHAUST
5. Monitor the Diesel Oxidation Catalyst (DOC) outlet temperature. Is the temperature greater than 760°C
(1400°F)?
6. With DiagnosticLink connected, run the engine at 1200 rpm for 10 minutes.
7. Monitor the DOC inlet temperature and the DOC outlet temperature. Are the temperatures within 25°C
(45°F) of each other?
9. Disconnect the DOC outlet temperature sensor and inspect the connector for damaged, bent, spread, or
corroded pins. If the temperature sensor connector is OK, check the connections upstream of the
Aftertreatment Control Module (ACM): pin 3 of the Aftertreatment Device (ATD) harness 14–pin connector ,
pin 7 of the VIH 47-pin connector , and pin 27 of the ACM 120-pin connector. Is damage present?
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
10. Perform an Idle Speed Balance test using DiagnosticLink. Retain the log file. Refer to section "Checking Idle Speed
Balance" .
10
11. Was a faulty fuel injector/cylinder identified?

11.a Yes; repair the faulty fuel injector/cylinder, and repeat the Idle Speed Balance (ISB) test to verify the
repair. Go to step 22.
13.a Yes, stop FSIC routine and inspect for stuck engine brakes. Refer to section "Checking for Poor Engine Brake

14. Remove the ATD.
Refer to section "Removal of the 1-BOX™ from the Vehicle" .
Refer to section "Removal of the 2-Box (2V2) from the Vehicle" .
15. Disassemble the ATD and inspect the inlet face of the Diesel Particulate Filter (DPF) substrate for
contamination. Note: an inlet flange washed clean indicates fuel contamination. Is contamination present?
16. Is coolant contamination found (white residue on inlet face of the DPF and a sweet smell from exhaust)?
17. Is oil contamination found (oil residue or paste on DPF Inlet face or an oil lacquer on the inlet flange)?
18. Inspect the ATD components for fuel contamination. If fuel contamination is found (inlet flange washed
clean), repair the cause of fuel contamination and Go to step 26.
11
19. Question the operator about coolant usage.

20. Visually inspect the coolant reservoir for low level.
21. Repair the cause of coolant entry as necessary and Go to step 26.
22. Question the operator about excessive oil consumption.
23. Repair the cause of oil contamination and Go to step 26.
24. Inspect the ATD components for fuel contamination.
25. Repair the cause of fuel contamination and Go to step 26.
WARNING
HOT EXHAUST
26. Install the ATD.

Refer to section "Installation of the 1-BOX™ to the Vehicle" .
Refer to section "Installation of the 2-Box (2V2) to the Vehicle" .
WARNING
HOT EXHAUST
Note : The parked regeneration is successful if the DOC outlet temperature is within 100°C (212°F) of the DOC
Model Delay.
27. Perform a parked regeneration, reset ash accumulators, and e-mail a log file of the successful regeneration
to Detroit™ Customer Support Center. Verify repairs.
Refer to section "Performing a Parked Regeneration - GHG17" .
Refer to section "Resetting the Diesel Particulate Filter Ash Accumulators" . Was regeneration successful?
28. Verify the fuel injector(s) part number is correct for engine application. Refer to section "Removal of the Fuel Injector
- Two-Filter System" . Is the fuel injector(s) part number correct for the application?
12
repair.
13
228.8 SPN 3250/FMI 20 - GHG17

Diesel Oxidation Catalyst Temperature Drift - Inlet Low or Outlet High
SPN 3250/FMI 20
Description 70°C (158°F ) Difference During Non-regeneration Mode
Outlet Temperature
Typical Enabling Conditions Coolant Temperature Greater than 60°C (140°F), Regen not
active in last five minutes
Dash Lamps CEL, MIL
Check as follows:
1.a If SPN 3242/FMI 3/4/8 or SPN3250/FMI 3/4/8 is also present, repair those faults first.
Refer to section "SPN 3250/FMI 8 – GHG17" .
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

3. Run service routine "Perform Performance Check - Low Temp ATD" found under the Diesel Particulate
Filter (DPF) System tab. Let the test run completely to stabilize the aftertreatment temperatures.
4. Compare DOC inlet temperature and DOC outlet temperature to DPF outlet temperature.
5. Replace the DOC temperature sensor that is drifted more than 25°C (45°F) compared to the DPF outlet
temperature sensor.
14
228.9 SPN 3250/FMI 31 - GHG17

SPN 3250/FMI 31
Description Abnormal Diesel Oxidation Catalyst (DOC) Temperature Rise
Monitored Parameter DOC Temperature
Dash Lamps MIL, CEL
concern (poor terminal fit, corrosion, chaffing, etc.).
WARNING
PERSONAL INJURY
3. Check for multiple fault codes. Are other faults codes active?
6. Perform a DOC Outlet Temperature Sensor Test. Measure the resistance between pins 1 and 2 of the DOC
outlet temperature sensor connector. Does the DOC outlet temperature sensor match the resistance
specification in the chart below?
Temp ºC (ºF) Min Resistance () Max Resistance () Min Voltage Max Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 489.84 0.970 1.007
15
7. Using appropriate test probes from J-48476 connector test kit and J-47410 terminal repair kit , drag test
and inspect all harness connector terminals between the DOC outlet temperature sensor and the ACM,
including the chassis extension harness and Aftertreatment Device (ATD) sensor box. Repair as necessary
to ensure a snug fit between the test probes and the female terminals.
16
17
228.1 SPN 3250/FMI 0 - GHG17

SPN 3250/FMI 0
Description This Code Sets When the Diesel Oxidation Catalyst (DOC)
Outlet Temperature is Greater Than 760°C (1400°F) For More
Than Two Seconds
Monitored Parameter Diesel Oxidation Catalyst Temperature Sensor
Dash Lamps MIL, CEL
Possible causes:
• Incorrect cam timing
Check as follows:
4. Check for multiple DOC outlet temperature sensor fault codes. Is code SPN 3250/FMI 8 present?
6.a Yes; determine and repair the cause of fluid in the exhaust. Repair as necessary. Inspect the DOC and
DPF.. Refer to section "Inspection of the Diesel Oxidation Catalyst" . Verify repair.

present?
18
9. Remove and inspect the air filter; refer to Original Equipment Manufacturer (OEM) literature for removal
and inspection procedures. Is the air filter restricted?
Note : A cold soak may take up to 8 hours.
Go to step 11.
12. Monitor the DOC outlet temperature sensor reading. Is the DOC outlet temperature sensor within 25°C
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
13. Compare the Barometric sensor reading to the Intake Manifold Pressure sensor reading. Are the readings
14. Compare the Intake Manifold Temperature sensor reading to the Charge Air Cooler Temperature sensor
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

pass the Idle Speed Balance test?
18.a Yes;
19
For two filter fuel systems, Refer to section "Test-E - Two-Filter Fuel System" .Verify repair.

application?
repair.
20
228.2 SPN 3250/FMI 2 - GHG17

DOC Outlet Temperature Not Plausible
SPN 3250/FMI 2
Description This fault sets if the DOC outlet temperature is 70°C (126°F)
sensors after 8 hours cold soak.
Monitored Parameter Diesel Oxidation Catalyst (DOC) Outlet Temperature versus
all other ATS temperature sensors
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 3250/ FMI 3/4/8 also present?
4. Disconnect and inspect the DOC outlet temperature sensor electrical connector, harness side.
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" . Verify repair.
21
228.3 SPN 3250/FMI 3 - GHG17

Diesel Oxidation Catalyst Outlet Temperature Sensor Circuit Failed High
1. Disconnect the Diesel Oxidation Catalyst (DOC) outlet temperature sensor connector.
3. DOC outlet temperature test – measure the resistance between pin 1 and 2 of the DOC outlet temperature
sensor connector and refer to chart for resistance values.
Resistance Values
Temp C° (F°) Min. Resistance () Max. Resistance () Min. Voltage Max. Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 498.84 0.970 1.007
3.a If the resistances are out of range, replace the DOC outlet temperature sensor.
5. Measure the voltage between pin 2 on the harness side of the DOC outlet temperature sensor connector
and ground.
DOC outlet temperature sensor connector and pin 27 of the ACM 120-pin connector. Verify repairs.
5.c If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the DOC
outlet temperature sensor connector and pin 27 of the ACM 120-pin connector. Verify repairs.
6. Measure the voltage between pin 1 on the harness side of the DOC outlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the DOC outlet
temperature sensor connector and pin 73 of the Aftertreatment Control Module (ACM) 120-pin
6.b If no voltage is present, repair the open between pin 1 on the harness side of the DOC outlet
temperature sensor connector and pin 73 of the ACM 120-pin connector. Verify repairs.
22
228.4 SPN 3250/FMI 4 - GHG17

Diesel Oxidation Catalyst Outlet Temperature Circuit Failed Low
2. Disconnect the Diesel Oxidation Catalyst (DOC) outlet temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DOC outlet temperature sensor connector
and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the DOC outlet temperature
5.b If the resistance is greater than 1K ohms, replace the DOC outlet temperature sensor.
23
228.5 SPN 3250/FMI 7 – GHG17

Diesel Oxidation Catalyst Outlet Temperature Response Error
This fault code sets when the difference between the Diesel Oxidation Catalyst (DOC) outlet temperature and
Ambient Air Temperature (in the ACM) is less than 35°C (95°F) after the engine has been running continuously for
40 minutes.
SPN 3250/FMI 7
Description DOC Outlet Temperature Response Error
Monitored Parameter DOC Outlet Temperature, Ambient Air Temperature (ACM)
Typical Enabling Conditions Engine Running for more than 40 minutes
Dash Lamps MIL, CEL
Verification Run the engine at idle for 40 minutes
Possible causes:
• No exhaust flow through the Aftertreatment System (ATS)
3. Check for other fault codes. Are fault codes SPN 3250/FMI 3/ 4/ or 20 present?
4. Visually inspect the DOC outlet temperature sensor. Is the DOC outlet temperature installed correctly?
4.b No; correctly install the DOC outlet temperature sensor.
5. Inspect the ATS. Is the ATS damaged or modified?
24
228.6 SPN 3250/FMI 8 – GHG17

Diesel Oxidation Catalyst Outlet Temperature - Signal Spike
SPN 3250/FMI 8
Description This Fault Indicates the Aftertreatment Control Module (ACM)
has Detected a Sudden Temperature Shift on the Diesel
Oxidation Catalyst (DOC) Outlet Temperature Sensor
Monitored Parameter DOC Outlet Temperature
Typical Enabling Conditions DOC Outlet Temperature Greater Than 150°C (302°F)
Dash Lamps CEL, MIL
Verification Low Temp ATD Check
Note : The most likely cause is an intermittent wiring concern (poor terminal fit, corrosion, chaffing etc.).
3. Check for other fault codes. Are SPN 3250/FMI 3 or 4 present?
3.a Yes; repair the other fault codes first.
7. Measure the resistance between pins 1 and 2 of the DOC outlet temperature sensor connector. Does the
DOC outlet temperature sensor match the resistance specification in the chart below?
7.a Yes; Go to step 8. .
Temp °C (°F) Min Resistance () Max Resistance () Min Voltage Max Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 498.84 0.970 1.007
inspect all harness connector terminals between the DOC outlet temperature sensor and the ACM including
25
26
228.7 SPN 3250/FMI 15 - GHG17

Diesel Oxidation Catalyst Outlet Temperature High
SPN 3250/FMI 15
Dash Lamps MIL
steps.
4. Check for multiple fault codes. Are SPN 3250 / FMI 2, 3, 4, 7, or 8 also present?
WARNING
ENGINE EXHAUST
(1400°F)?
corroded pins. If the temperature sensor connector is OK, check the connections upstream of the
Aftertreatment Control Module (ACM): pin 3 of the Aftertreatment Device (ATD) harness 14–pin connector ,
pin 7 of the VIH 47-pin connector , and pin 27 of the ACM 120-pin connector. Is damage present?
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .
Balance" .
27

11.a Yes; repair the faulty fuel injector/cylinder, and repeat the Idle Speed Balance (ISB) test to verify the
repair. Go to step 22.
13.a Yes, stop FSIC routine and inspect for stuck engine brakes. Refer to section "Checking for Poor Engine Brake

14. Remove the ATD.
Refer to section "Removal of the 1-BOX™ from the Vehicle" .
Refer to section "Removal of the 2-Box (2V2) from the Vehicle" .
15. Disassemble the ATD and inspect the inlet face of the Diesel Particulate Filter (DPF) substrate for
contamination. Note: an inlet flange washed clean indicates fuel contamination. Is contamination present?
16. Is coolant contamination found (white residue on inlet face of the DPF and a sweet smell from exhaust)?
17. Is oil contamination found (oil residue or paste on DPF Inlet face or an oil lacquer on the inlet flange)?
18. Inspect the ATD components for fuel contamination. If fuel contamination is found (inlet flange washed
clean), repair the cause of fuel contamination and Go to step 26.
28

22. Question the operator about excessive oil consumption.
24. Inspect the ATD components for fuel contamination.
WARNING
HOT EXHAUST
26. Install the ATD.

Refer to section "Installation of the 1-BOX™ to the Vehicle" .
Refer to section "Installation of the 2-Box (2V2) to the Vehicle" .
WARNING
HOT EXHAUST
Note : The parked regeneration is successful if the DOC outlet temperature is within 100°C (212°F) of the DOC
Model Delay.
27. Perform a parked regeneration, reset ash accumulators, and e-mail a log file of the successful regeneration
to Detroit™ Customer Support Center. Verify repairs.
Refer to section "Performing a Parked Regeneration - GHG17" .
Refer to section "Resetting the Diesel Particulate Filter Ash Accumulators" . Was regeneration successful?
28. Verify the fuel injector(s) part number is correct for engine application. Refer to section "Removal of the Fuel Injector
- Two-Filter System" . Is the fuel injector(s) part number correct for the application?
29
repair.
30
228.8 SPN 3250/FMI 20 - GHG17

Diesel Oxidation Catalyst Temperature Drift - Inlet Low or Outlet High
SPN 3250/FMI 20
Description 70°C (158°F ) Difference During Non-regeneration Mode
Outlet Temperature
Typical Enabling Conditions Coolant Temperature Greater than 60°C (140°F), Regen not
active in last five minutes
Dash Lamps CEL, MIL
Check as follows:
1.a If SPN 3242/FMI 3/4/8 or SPN3250/FMI 3/4/8 is also present, repair those faults first.
Refer to section "SPN 3250/FMI 8 – GHG17" .
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Compare DOC inlet temperature and DOC outlet temperature to DPF outlet temperature.
5. Replace the DOC temperature sensor that is drifted more than 25°C (45°F) compared to the DPF outlet
temperature sensor.
31
228.9 SPN 3250/FMI 31 - GHG17

SPN 3250/FMI 31
Description Abnormal Diesel Oxidation Catalyst (DOC) Temperature Rise
Monitored Parameter DOC Temperature
Engine Reaction 25% Derate, Engine Shutdown
concern (poor terminal fit, corrosion, chaffing, etc.).
WARNING
PERSONAL INJURY
3. Check for multiple fault codes. Are other faults codes active?
6. Perform a DOC Outlet Temperature Sensor Test. Measure the resistance between pins 1 and 2 of the DOC
outlet temperature sensor connector. Does the DOC outlet temperature sensor match the resistance
specification in the chart below?
Temp ºC (ºF) Min Resistance () Max Resistance () Min Voltage Max Voltage
0 (32) 197.67 207.62 0.491 0.520
10 (50) 205.33 215.24 0.506 0.536
25 (77) 216.77 226.64 0.530 0.559
50 (122) 235.72 245.52 0.567 0.597
100 (212) 273.19 282.83 0.638 0.667
150 (302) 310.07 319.56 0.704 0.733
200 (392) 346.36 355.70 0.765 0.794
300 (572) 416.47 429.09 0.874 0.909
400 (752) 484.17 489.84 0.970 1.007
32
7. Using appropriate test probes from J-48476 connector test kit and J-47410 terminal repair kit , drag test
and inspect all harness connector terminals between the DOC outlet temperature sensor and the ACM,
including the chassis extension harness and Aftertreatment Device (ATD) sensor box. Repair as necessary
to ensure a snug fit between the test probes and the female terminals.
33
34
230.1 SPN 3251/FMI 0 – GHG17

SPN 3251/FMI 0
Description This Fault Code Sets when the Diesel Oxidation Catalyst
(DOC) Inlet Pressure is 35 kPa (5 psi) Greater than the
Calculated Diesel Particulate Filter (DPF) Outlet Pressure for
More than 10 Seconds
Monitored Parameter DOC Inlet Pressure Sensor
Engine Reaction Derate 25%, Shutdown
Verification Run Engine Between 1200 to 1800 rpm With a Load Less
Than 10%
Check as follows:
3. Check for other fault codes. Are fault codes SPN 3609/FMI 3 or FMI 4 present?
4. Using DiagnosticLink, go to Service Routines > SCR and DPF voltages.
5. Monitor the DOC inlet pressure sensor voltage, pin 87. Is the voltage between 0.44 and 0.56 volts?
5.b No; replace the DOC inlet pressure sensor. Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure
6. What aftertreatment system does the vehicle have?

6.a For a One-Box aftertreatment system; Go to step 9.
6.b For a Two-Box aftertreatment system; Go to step 7.
7. Monitor the DPF outlet pressure sensor voltage, pin 72. Is the voltage between 0.44 and 0.56 volts?
7.b No; replace the DPF outlet pressure sensor. Verify repair.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1
WARNING
HOT EXHAUST
8. Start the engine and run a Low temperature ATD routine. Refer to section "GHG17 Perform Performance Check - Low
Temperature ATD" .
9. Monitor the DOC inlet temperature and the DOC outlet temperature readings. Does the DOC outlet
temperature sensor reading follow the DOC inlet temperature sensor reading during the Low Temperature
ATD routine? See Example 1.
1. Engine started
2. Low Temp Regen Started
3. DOC Inlet 116°C (241°F)
4. Engine coolant reaches (124°F) and Jake brake turned ON
5. DOC Inlet 378°C (714°F)
6. DOC Inlet 367°C (694°F)
7. As the DOC Inlet warms up, the DOC Outlet temp follows
8. DOC Outlet temp 112°C (234°F)
Fig 0.1, Example 1
9.a Yes; replace the DPF due to a restriction. Verify repair.

10. Stop the Perform Performance Check - Low Temperature ATD service routine.
2
11. Perform Parked Regeneration. Monitor DOC inlet pressure and engine speed during the regen. Compare
your DOC inlet pressure reading to the screen shots and descriptions below in (a and b) to determine what
step to go to next.
11.a If the DOC inlet pressure starts out high above 10 kPa (1.45 psi) and decreases during the parked
regen, this indicates the DPFs were plugged and the parked regen cleared them. Go to step 12.
11.b If the DOC inlet pressure starts above 6 kPa (0.8 psi), and stays high, the DOC is considered plugged.
Go to step 13.
3
12. The parked regen has reduced the DOC inlet pressure by reducing the soot accumulated in the DPF. Verify
the fault code is gone and fill out the "ATD Checklist". Refer to section "ATD Checklist - GHG17" .
13. Is the DOC inlet pressure above 20 KPa (2.9 psi) during the regen?
14. Using DiagnosticLink, perform the DOC face cleaning routine. Refer to section "GHG17 Diesel Oxidation Catalyst Face
Cleaning" . Verify repairs.
15. The DOCs are severely plugged. Perform the Diesel Oxidation Catalyst (DOC) air cleaning procedure. Refer
to section "Diesel Oxidation Catalyst Air Cleaning" . Verify repair.
4
230.2 SPN 3251/FMI 20 - GHG17

SPN 3251/FMI 20
Description Diesel Oxidation Catalyst (DOC) Inlet Pressure Sensor - Not
Plausible
Monitored Parameter Exhaust Pressure
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5
Check as follows:
3. Is the aftertreatment a 1-Box™ configuration?
4. Using the Selective Catalytic Reduction (SCR) voltage service routine, monitor the DOC inlet pressure
sensor (pin 87) voltage with key ON and engine OFF.
5. Is the DOC inlet pressure sensor voltage between 0.44 and 0.56 volts?
5.a Yes; inspect and repair the DOC and DPF pressure sensor tubes and elbows for leaks, kinks, or
restrictions.
6. Disconnect the DOC inlet pressure sensor connector.
7. Inspect the DOC inlet pressure sensor connector for damaged pins, spread pins, or corrosion. Is there any
damage found?
7.b No; replace the sensor. Verify repairs.
sensor (pin 87) and Diesel Particulate Filter (DPF) outlet pressure sensor (pin 72) voltages with key ON and
engine OFF.
6

damage found?
12. Measure the voltage from pin 3 of the DOC inlet pressure sensor connector to ground. Is the voltage
12.a Yes; replace the sensor. Verify repairs. For Two-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst
Inlet Pressure Sensor" .
12.b No; repair the wire. Verify repairs.

13. Is the DPF outlet pressure sensor voltage between 0.44 and 0.56 volts?
restrictions. Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube" .
14. Disconnect the DPF outlet pressure sensor connector.
15. Inspect the DPF outlet pressure sensor connector for damaged pins, spread pins or corrosion. Is there any
damage found?
16. Measure the voltage between pin 3 of the DPF outlet pressure sensor connector and ground. Is the voltage
16.a Yes; replace the sensor. Verify repair. Refer to section "Removal of the Diesel Particulate Filter Outlet Pressure
Sensor" .
16.b No; repair the wire. Verify repair.
7
230.3 SPN 3251/FMI 21 - GHG17

SPN 3251/FMI 21
Description Diesel Oxidation Catalyst (DOC) Inlet/Outlet Pressure Not
Plausible
Monitored Parameter Exhaust Pressures
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
8
Check as follows:
1. Visually inspect the entire exhaust system for signs of leaks or damage. Is there any damage found?
3. Using the Selective Catalyst Reduction (SCR) Voltage Service routine, monitor the DOC inlet pressure
voltage (pin 87) with the key ON, engine OFF.
damage found?
7. Remove the DOC inlet pressure sensor tube. Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure
Sensor Tube" .
8. Inspect the DOC inlet pressure sensor tube for any restrictions. Were restrictions found?
8.a Yes; clear the restriction and reinstall the pressure sensor tube. Verify repair.
8.b No; reinstall the pressure sensor tube. Go to step 9.
9.a Yes; the failed component could not be identified. Go to step 10.
9
9.b No; repair the wire between pin 3 harness side and pin 117 of the ACM. Verify repair.
10. Reconnect the DOC inlet pressure sensor.
11. Run a Parked Regen to verify the fault code is no longer active.
10
230.1 SPN 3251/FMI 0 – GHG17

SPN 3251/FMI 0
(DOC) Inlet Pressure is 35 kPa (5 psi) Greater than the
Calculated Diesel Particulate Filter (DPF) Outlet Pressure for
More than 10 Seconds
Engine Reaction Derate 25%, Shutdown
Than 10%
Check as follows:
3. Check for other fault codes. Are fault codes SPN 3609/FMI 3 or FMI 4 present?
4. Using DiagnosticLink, go to Service Routines > SCR and DPF voltages.
5. Monitor the DOC inlet pressure sensor voltage, pin 87. Is the voltage between 0.44 and 0.56 volts?
6. What aftertreatment system does the vehicle have?

6.a For a One-Box aftertreatment system; Go to step 9.
6.b For a Two-Box aftertreatment system; Go to step 7.
7. Monitor the DPF outlet pressure sensor voltage, pin 72. Is the voltage between 0.44 and 0.56 volts?
7.b No; replace the DPF outlet pressure sensor. Verify repair.
WARNING
PERSONAL INJURY
11
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
8. Start the engine and run a Low temperature ATD routine. Refer to section "GHG17 Perform Performance Check - Low
Temperature ATD" .
9. Monitor the DOC inlet temperature and the DOC outlet temperature readings. Does the DOC outlet
temperature sensor reading follow the DOC inlet temperature sensor reading during the Low Temperature
ATD routine? See Example 1.
12
1. Engine started
2. Low Temp Regen Started
3. DOC Inlet 116°C (241°F)
4. Engine coolant reaches (124°F) and Jake brake turned ON
5. DOC Inlet 378°C (714°F)
6. DOC Inlet 367°C (694°F)
7. As the DOC Inlet warms up, the DOC Outlet temp follows
8. DOC Outlet temp 112°C (234°F)
Fig 230.2, Example 1
9.a Yes; replace the DPF due to a restriction. Verify repair.

10. Stop the Perform Performance Check - Low Temperature ATD service routine.
11. Perform Parked Regeneration. Monitor DOC inlet pressure and engine speed during the regen. Compare
your DOC inlet pressure reading to the screen shots and descriptions below in (a and b) to determine what
step to go to next.
11.a If the DOC inlet pressure starts out high above 10 kPa (1.45 psi) and decreases during the parked
regen, this indicates the DPFs were plugged and the parked regen cleared them. Go to step 12.
13
11.b If the DOC inlet pressure starts above 6 kPa (0.8 psi), and stays high, the DOC is considered plugged.
Go to step 13.
12. The parked regen has reduced the DOC inlet pressure by reducing the soot accumulated in the DPF. Verify
the fault code is gone and fill out the "ATD Checklist". Refer to section "ATD Checklist - GHG17" .
13. Is the DOC inlet pressure above 20 KPa (2.9 psi) during the regen?
14

14. Using DiagnosticLink, perform the DOC face cleaning routine. Refer to section "GHG17 Diesel Oxidation Catalyst Face
Cleaning" . Verify repairs.
15. The DOCs are severely plugged. Perform the Diesel Oxidation Catalyst (DOC) air cleaning procedure. Refer
to section "Diesel Oxidation Catalyst Air Cleaning" . Verify repair.
15
230.2 SPN 3251/FMI 20 - GHG17

SPN 3251/FMI 20
Description Diesel Oxidation Catalyst (DOC) Inlet Pressure Sensor - Not
Plausible
Monitored Parameter Exhaust Pressure
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
16
Check as follows:
3. Is the aftertreatment a 1-Box™ configuration?
sensor (pin 87) voltage with key ON and engine OFF.
restrictions.
damage found?
7.b No; replace the sensor. Verify repairs.
sensor (pin 87) and Diesel Particulate Filter (DPF) outlet pressure sensor (pin 72) voltages with key ON and
engine OFF.
17

damage found?
12.a Yes; replace the sensor. Verify repairs. For Two-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst
Inlet Pressure Sensor" .
12.b No; repair the wire. Verify repairs.

13. Is the DPF outlet pressure sensor voltage between 0.44 and 0.56 volts?
restrictions. Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube" .
14. Disconnect the DPF outlet pressure sensor connector.
15. Inspect the DPF outlet pressure sensor connector for damaged pins, spread pins or corrosion. Is there any
damage found?
16. Measure the voltage between pin 3 of the DPF outlet pressure sensor connector and ground. Is the voltage
16.a Yes; replace the sensor. Verify repair. Refer to section "Removal of the Diesel Particulate Filter Outlet Pressure
Sensor" .
18
230.3 SPN 3251/FMI 21 - GHG17

SPN 3251/FMI 21
Description Diesel Oxidation Catalyst (DOC) Inlet/Outlet Pressure Not
Plausible
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
19
Check as follows:
1. Visually inspect the entire exhaust system for signs of leaks or damage. Is there any damage found?
3. Using the Selective Catalyst Reduction (SCR) Voltage Service routine, monitor the DOC inlet pressure
voltage (pin 87) with the key ON, engine OFF.
damage found?
7. Remove the DOC inlet pressure sensor tube. Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure
Sensor Tube" .
8. Inspect the DOC inlet pressure sensor tube for any restrictions. Were restrictions found?
8.a Yes; clear the restriction and reinstall the pressure sensor tube. Verify repair.
8.b No; reinstall the pressure sensor tube. Go to step 9.
9.a Yes; the failed component could not be identified. Go to step 10.
20
9.b No; repair the wire between pin 3 harness side and pin 117 of the ACM. Verify repair.
10. Reconnect the DOC inlet pressure sensor.
11. Run a Parked Regen to verify the fault code is no longer active.
21
230.1 SPN 3353/FMI 2 - GHG17

Generator (Charging System) D+ Terminal Failure
SPN 3353/FMI 2
Description J1939 Charging System D+ Terminal Failure
Monitored Parameter Battery Voltage
Dash Lamps CEL
Check as follows:
2.b No; reprogram the CPC with the correct information as necessary. To verify repair. Go to step 3.
1
232.1 SPN 3361/FMI 3 - GHG17
SPN 3361/FMI 3
Description Diesel Exhaust Fluid (DEF) System Circuit Voltage Above
Normal, Or Shorted To High Source
Monitored Parameter DEF Dosing Unit Voltage
Typical Enabling Conditions DEF Dosing enabled
Dash Lamps None
Verification Key OFF five minutes after repair
Check as follows:
2. Disconnect the DEF dosing unit harness connector.
3. Inspect the Dosing Unit connector and the Dosing Unit harness connector for signs of damage, bent,
spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any
damage found?
1
3.a Yes; repair as needed. Verify repairs.

Note : Fault will remain active until key cycle with five-minute Aftertreatment Control Module (ACM) power down.
6. Clear fault codes. Does the fault code change from SPN 3361/FMI 3 to SPN 3361/FMI 5?
6.a Yes; replace the DEF Dosing Unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify
repairs.
7. Measure the voltage between the DEF dosing unit connector pin 1, harness side and ground. Is the voltage
greater than 10 volts?
7.a Yes; repair the short to voltage between pin 1 of the DEF dosing unit connector and pin 28 of the ACM
connector.
9. Check intermediate connections in chassis wiring; refer to Original Equipment Manufacturer wiring
diagrams for exact routing. Inspect for signs of damage, bent, spread, broken, pushed out (unseated) or
corroded pins or wire damage near the connector. Was any damage found?
11. Inspect the ACM 120-pin connector and 120-pin harness connector for signs of damage, bent, spread,
found?
11.b No; replace ACM.
Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repairs.
Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
2
232.2 SPN 3361/FMI 4 - GHG17
SPN 3361/FMI 4
Description Diesel Exhaust Fluid (DEF) System Circuit low voltage signal
or short to ground
Typical Enabling Conditions DEF Dosing enabled then disabled
Typical Duration 50 seconds (max)
Dash Lamps MIL, CEL
Verification Key Cycle OFF five minutes after repair
Check as follows:
3. Inspect the Dosing Unit connector and the Dosing Unit harness connector for signs of damage, bent,
spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector. Was any
damage found?
3

Note : Fault will remain active until key cycle with five-minute Aftertreatment Control Module (ACM) power down.
repairs.
8-Pin Circuit ACM - Pin Connector

1 Dosing Unit Low Side 28
2 Dosing Unit High Side 33
3 Heating Low Side 22
4 Heating Supply 3
5 Sensor Supply 5V 84
6 Not Used Not Used
7 Sensor Ground 99
8 DEF Pressure Signal 100
8. Measure the resistance between the DEF dosing unit connector pin 1, harness side and ground. Is the
8.b No; repair the short to ground between pin 1 of the DEF dosing unit connector and pin 28 of the ACM
9. Check intermediate connections in chassis wiring; refer to Original Equipment Manufacturer wiring
diagrams for exact routing. Inspect for signs of damage, bent, spread, broken, pushed out (unseated) or
corroded pins or wire damage near the connector. Was any damage found?
found?
12. Measure the resistance between pins 1 and 2 on the DEF dosing unit harness connector. Is the resistance
12.a Yes; replace ACM.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repairs.
For Two-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
12.b No; repair the shorted wires between pins 1 and 2 of the DEF dosing unit harness and pins 28 and 33
of the ACM harness connector. Verify repairs.
4
232.3 SPN 3361/FMI 5 - GHG17

SPN 3361/FMI 5
Description This Fault Code Sets When the Aftertreatment Control Module
(ACM) Detects an Open in the Diesel Exhaust Fluid DEF
Doser Valve Electrical Circuit
Typical Enabling Conditions DEF Dosing Enabled Then Disabled
Typical Duration 50 Seconds (max)
Dash Lamps MIL, CEL
Verification Key OFF Five Minutes After Repair
Check as follows:
2. Disconnect and inspect the DEF dosing unit electrical connector harness side. Is there corrosion present?
2.a Yes; replace the DEF dosing unit and the aftertreatment harness. Refer to section "Removal of the Diesel
Exhaust Fluid Dosing Unit" . Verify repairs.

5
4. Inspect the DEF dosing unit electrical connector component side. Are any of the pins or the connector
damaged?
4.a Yes; replace the DEF dosing unit and the aftertreatment harness.
Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit"
Refer to section "Removal of the 1-BOX™ Aftertreatment Harness"
Verify repairs.
4.b No; replace the aftertreatment harness. Refer to section "Removal of the 1-BOX™ Aftertreatment Harness" . Verify
repairs.
5. Use the appropriate flex probe and check pins 1 and 2 in the DEF dosing unit electrical connector harness
side. Is either of the pins spread?
5.a Yes; replace the aftertreatment harness. Refer to section "Removal of the 1-BOX™ Aftertreatment Harness" . Verify
repairs.
6. Jump pin 1 to pin 2 on the DEF dosing unit electrical connector harness side.
9. Check the fault codes. Is fault code SPN 3361/FMI 5 now inactive and fault code SPN 3361/FMI 3 now
active?
9.a Yes; replace the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify
repairs.
9.b No; replace the aftertreatment harness.
6
232.4 SPN 3361/FMI 31 - GHG17
SPN 3361/FMI 31
Description The fault indicates that the Diesel Exhaust Fluid (DEF) Dosing
Unit was switched off before completing a cycle
Monitored Parameter DEF Pressure
Typical Enabling Conditions When service routine is enabled and during infrequent in-use
checks under non DEF dosing conditions
Execution Frequency Service tool and infrequent in-use checks during DEF dosing
conditions
Dash Lamps MIL, CEL
Verification Selective Catalyst Reduction (SCR) Airless Dosing System
(ADS) Self-Check Routine
3. Check for multiple DEF system circuit failed faults; SPN (any) FMIs 3, 4, or 5; may also set SPN 3361/FMI
31. Are any other DEF system circuit-related faults also present?
4. Perform SCR ADS Self-Check Routine. Did the SCR ADS test pass with DEF pump speed and DEF
pressure values in normal range?
• Acceptable DEF Pump Speed: greater than 750 rpm and less than 1800 rpm.
• Acceptable DEF Pressure: greater than 9000 mbar and less than 11000 mbar (130-160 psi).
4.b No; replace the DEF Dosing Unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify repairs
by running SCR ADS Self-Check Routine.
7. Inspect the DEF dosing unit harness wiring and connector for damage, wire chafing, bent, spread or
corroded pins. Is any damage found?
7.a Yes; repair as necessary. Verify repairs by running SCR ADS Self-Check Routine.
8. Check all intermediate connections in chassis wiring, including Aftertreatment Control Module (ACM), for
damage, wire chafing, bent, spread or corroded pins. Refer to OEM wiring diagrams for exact routing. Is
any damage found?
8.a Yes; repair as necessary. Verify repairs by running SCR ADS Self-Check Routine.
9. Restore all connections except the DEF dosing unit harness connector. Leave the DEF dosing unit harness
connector disconnected.
Note : Fault will remain active until key cycle with five-minute ACM power down.
repairs by running SCR ADS Self-Check Routine.
7

Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .Verify repairs by running SCR ADS Self-
Check Routine.
Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .Verify repairs by running SCR ADS
Self-Check Routine.
8
233.1 SPN 3363/FMI 0 - GHG17

Diesel Exhaust Fluid Tank Temperature - High
Check as follows:
SPN 3363/FMI 0
Description Diesel Exhaust Fluid (DEF) Tank Temperature - High
Monitored Parameter DEF Tank Temperature
Typical Enabling Conditions Coolant Valve Closed greater than 1.5 hrs, Coolant
Temperature greater than 158F
Dash Lamps MIL
Engine Reaction
3. Perform output component test service routine. Does fault SPN 3363/FMI 3, 4, or 5 become active during
the routine?
3.a Yes; repair those faults first; clear codes and release vehicle.
4. Using DiagnosticLink, monitor parameter AS021 DEF tank temperature.
5. Remove the DEF tank filler cap. Using an external thermometer (ex. infrared temperature gun), compare
the actual DEF temperature (liquid) to the DiagnosticLink reported tank temperature. Is the AS021 DEF
tank temperature 49°C (120°F) higher than the externally measured temperature?
6. Inspect coolant line routing from engine to DEF pump.
7. Are coolant lines routed correctly?
7.a Yes; replace the DEF tank header assembly on the 13/23 gallon DEF tank or the coolant valve on 6-
gallon DEF tanks and coach applications. Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid
Tank Header Unit" .
7.b No; correct coolant line routing.

8. Disconnect the DEF tank header harness connector. Inspect harness connector for bent, spread or
corroded pins.
8.b If no pin damage is found, replace the DEF tank header assembly. Refer to section "Removal of the 13- and 23-
Gallon Diesel Exhaust Fluid Tank Header Unit" .
1
233.2 SPN 3363/FMI 1 - GHG17

Diesel Exhaust Fluid Tank Temperature - Low
This code sets when the Diesel Exhaust Fluid (DEF) tank temperature does not increase 0.5°C (0.9°F) within 300
seconds after the DEF tank coolant valve has been commanded on.
SPN 3363/FMI 1
Description DEF Tank Temperature - Low
Monitored Parameter DEF Tank Temperature
Typical Enabling Conditions Coolant Valve Commanded Open, Coolant Temperature
Greater Than 70°C (158°F), Ambient Temperature Less Than
-1°C (30°F) as measured by the ACM
Dash Lamps MIL
Engine Reaction
Possible causes:
• Coolant valve stuck closed
• Lack of coolant flow to the coolant valve
• Faulty DEF tank temperature sensor
1. Are there any cooling system issues or complaints?
1.a Yes; service cooling system issues or complaints.
2. Inspect the DEF tank coolant valve supply lines for a restriction or closed shut off valves plumbed into the
cooling system. Are there any restrictions present?
5. Command the DEF coolant valve on. (Service Routines > Activate Outputs > Coolant Valve Open: Start
Coolant Valve Open Status). Does SPN 3363/FMI 3, 4 or 5 become active?
5.a Yes; diagnose and repair the other SPN 3363 codes. Verify repair.
6. Remove the DEF tank fill cap, then use an external thermometer or infrared heat gun to measure the
temperature of the DEF as close to the DEF tank temperature sensor as possible. Go to step 7.
7. Compare the externally measured DEF temperature reading to the DEF tank temperature reading in
DiagnosticLink. Is the AS022 DEF tank temperature within 1 degree Celsius (2 degrees Fahrenheit) of the
externally measured temperature?
7.b No; replace the DEF tank header assembly due to a faulty DEF tank temperature sensor. Refer to section
"Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" or OEM literature for the 6-gallon DEF
tank header unit. Verify repair.
8. Is the vehicle equipped with a 6-gallon DEF tank?
8.a No; replace the DEF tank header assembly due to the coolant valve being stuck closed. Refer to section
"Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit" .
2
8.b Yes; replace the DEF coolant valve. Refer to OEM literature for the 6-gallon DEF tank header unit.
Verify repair.
3
233.3 SPN 3363/FMI 3 - GHG17

Diesel Exhaust Fluid Coolant Valve Circuit Failed High
SPN 3363/FMI 3
Description Diesel Exhaust Fluid (DEF) Coolant Valve Circuit Failed High
Monitored Parameter DEF Coolant Valve
Typical Enabling Conditions DEF Tank Temperature less than 36F and Engine coolant
Dash Lamps MIL, CEL
Verification Output Component Test
3. Perform Output Component Test.
4. Does the fault become active?
5. Repeat Output Component Test three times. The ignition must be cycled between each test. Does the fault
become active?
5.b No; clear the fault and release the vehicle.
6. Disconnect the DEF coolant valve harness connector.
7.b If connector shows no signs of damage, repair the short to battery (12 volts) between pin 1 of the DEF
coolant valve harness connector and pin 34 of the Aftertreatment Control Module (ACM) 120-pin
connector.
4
233.4 SPN 3363/FMI 4 - GHG17

Diesel Exhaust Fluid Valve Circuit Failed Low
SPN 3363/FMI 4
Description Diesel Exhaust Fluid (DEF) Valve Circuit Failed Low
Monitored Parameter DEF Valve
Typical Enabling Conditions DEF Tank Temperature less than 36F and Engine valve
Dash Lamps MIL, CEL
1. Ensure the ignition is OFF (key OFF, engine OFF).

2. Disconnect the DEF valve connector.
5. Measure the resistance between pin 1 on the harness side of the DEF valve connector and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 1 of the DEF valve connector and
pin 8 and 34 of the ACM 120-pin connector.
5.b If the resistance is greater than 1K ohms, replace the DEF valve.
5
233.5 SPN 3363/FMI 5 - GHG17

Diesel Exhaust Fluid Coolant Valve Circuit Failed Open
SPN 3363/FMI 5
Description Diesel Exhaust Fluid (DEF) Coolant Valve Circuit Failed Open
Monitored Parameter DEF Coolant Valve
Dash Lamps MIL, CEL
1. Disconnect the DEF coolant valve connector.

2.b If connector shows no signs of damage, Go to step 3. .
4. Using the appropriate table below based on DEF tank size, measure for proper voltage as listed.
4.a If voltage is within range, Go to step 5.
4.b If voltage is not within range, repair wire between DEF coolant valve harness connector and the
Aftertreatment Control Module (ACM).
13/23 Gallon DEF Tank

DEF Coolant Valve Harness Connector Voltage
Pin 4 and ground greater than 11.5 volts
Pin 1 and ground Approx 2.50 +/- 0.25
6 Gallon DEF Tank
DEF Coolant Valve Harness Connector Voltage
Pin 3 and ground greater than 11.5 volts
Pin 1 and ground Approx 2.50 +/- 0.25

7. Using the appropriate table below based on DEF tank size, measure the resistance between the DEF
coolant valve harness connector and the ACM.
7.a If resistance is within range, replace the DEF coolant valve.
7.b If resistance is not within range, repair wire between DEF coolant valve harness connector and the
ACM.
6
13/23 Gallon DEF Tank

DEF Coolant Valve Harness ACM 120-Pin Connector Acceptable Resistance
Connector
Pin 4 Pin 19 less than 3 ohms
6 Gallon DEF Tank
DEF Coolant Valve Harness ACM 120-Pin Connector Acceptable Resistance
Connector
7
234.1 SPN 3461/FMI 2 - GHG17

SPN 3461/FMI 2
Description This Code Sets When the Power Take Off (PTO) Input Has
Been Grounded when the PTO is not Engaged.
Monitored Parameter PGR13 PTO1 Switch Source
Dash Lamps CEL
Verification Clear fault codes. Turn ignition OFF and disconnect
DiagnosticLink . Wait five minutes for all modules to power
down.
Check as follows:
1. Is the vehicle equipped with a PTO?

See the Electronic Controls Application and Installation Manual section Throttle Controls/Governors for
specific parameter programming information. Does the CPC have the proper configuration?
1
2.b No; reprogram the CPC with the correct information as necessary. To verify repair.
3. Disconnect the PTO switch and measure the resistance between the PTO signal wire (B) and ground. Is
the resistance less than 1000 ohms?
3.a Yes; repair a short to ground between the PTO signal wire (B) and ground.
4. With the PTO switch still disconnected and the switch in the OFF position, measure the resistance across
the PTO signal (B) and the sensor return (A). Is the resistance less than five ohms?
4.a Yes; the PTO switch is internally shorted and should be replaced.
4.b No; the PTO is stuck in the engaged position. Repair or replace the PTO.
2
234.2 SPN 3461/FMI 7

SPN 3461/FMI 7
Description This Code Sets When the Power Take Off (PTO) Drive
Installation Does Not Match Up with the Programmed
Parameters for that PTO, Causing a Mismatch Between the
PTO Switch and Having No PTO Feedback
Monitored Parameter PGR13 PTO1 Switch Source
Dash Lamps CEL
See the Electronic Controls Application and Installation Manual section Throttle Controls/Governors for
specific parameter programming information. Does the CPC have the proper configuration?
3
235.1 SPN 3464/FMI 3 - GHG17

H Bridge 1 Circuit Shorted to Battery
SPN 3464/FMI 3
Description H Bridge 1 Circuit Shorted to Battery
Typical Enabling Conditions Key On & Engine Off
Dash Lamps MIL, CEL
Verification Engine OFF, then 1 minute idle
WARNING
ENGINE EXHAUST
Check as follows:
1
3. Disconnect and inspect the Intake Throttle Valve (ITV) electrical connector. Is there damage or corrosion
present?
5.b No; replace the ITV.
6. Reconnect the ITV electrical connector.
9. Once the ITV completes its cycle, disconnect the ITV electrical connector.
10. Measure the voltage between pin 4 of the ITV electrical connector harness side and ground. Is there any
voltage present?
10.a Yes; repair the short to voltage on the circuit between pin 4 of the ITV electrical connector and pin 100
of the 120-pin Motor Control Module (MCM) electrical connector.
11. Measure the voltage between pin 5 of the ITV electrical connector harness side and Ground. Is there any
voltage present?
of the 120-pin MCM electrical connector.
2
235.2 SPN 3464/FMI 4 - GHG17

H Bridge 1 Circuit Shorted to Ground
SPN 3464/FMI 4
Description H Bridge 1 Circuit Shorted to Ground
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
3
present?
7. Measure the resistance between pin 4 of the ITV electrical connector harness side and ground. Is the
9.b No; repair the short to ground on the circuit between pin 4 of the ITV electrical connector and pin 100 of
the 120-pin MCM electrical connector.
4
235.3 SPN 3464/FMI 5 - GHG17

H Bridge 1 Circuit Open Load
SPN 3464/FMI 5
Description H Bridge 1 Circuit Open Load
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
2. Disconnect and inspect the ITV electrical connector. Is there any damage or corrosion present?
5

3. Measure the resistance across pins 4 and 5 of the ITV connector components side. Is the resistance less
than 3 ohms?
4. Disconnect and inspect the 120-pin MCM electrical connector. Is there any damage or corrosion present?
5. Measure the resistance between pin 4 of the ITV electrical connector harness side and pin 100 of the 120-
pin MCM electrical connector harness side. Is the resistance less than 5 ohms?
5.b No; repair the circuit between pin 4 of the ITV electrical connector and pin 100 of the 120-pin MCM
electrical connector.
6
235.4 SPN 3464/FMI 16 – GHG17

Intake Manifold Pressure Too High (Restricted Mode)
SPN 3464/FMI 16
Description Intake Manifold Pressure Over-boost Detected During a Regeneration
Monitored Parameter Intake Manifold Pressure
Typical Enabling Conditions General Enabling Condition: Engine is in normal mode (not regeneration), steady state
operation (highway cruise operation)
Specific Enabling Conditions: See table below
Engine Torque N·m (lb·ft) 1100 (811)
Intake Air Throttle Position (%) 5
Engine Coolant Outlet 65 (149)
Temperature °C (°F)
Ambient Temperature °C (°F) -8 (18)
Engine Speed Gradient -10 10
(rpm/s)
Fuel Mass Gradient -10 10
((mg/stroke)/s)
Dash Lamps MIL, CEL
Verification Once engine is at standard operating temperature, drive at highway speed with loaded trailer
above 1130 rpm continuously for five minutes.

2. Check for other codes. Are any other fault codes present?
3. Inspect the front grill for air blockage including winter fronts, plows, or large hose reels. Is any blockage
found?
4. Inspect hood seals. Are seals missing or damaged?
5. Using DiagnosticLink , measure barometric pressure. Is barometric pressure above 69 kPa (10 psi) and
below 110 kPa (16 psi)?
6. Measure the inlet manifold pressure and the barometric pressure. Is the inlet manifold pressure within 10.3
kPa (1.5 psi) of barometric pressure?
7
7. Disconnect the inlet manifold pressure sensor harness connector.

8. Inspect the inlet manifold pressure sensor and harness connector for signs of damaged, bent, spread,
connector. Is any damage present?
8.b No; replace the inlet manifold pressure sensor. Refer to section "Removal of the Intake Pressure/Temperature
Sensor" .
9. Check for engine type. Is engine equipped with an Asymmetrical Turbocharger (AT)?
11. Inspect the wastegate actuator and the plumbing to and from the actuator. Verify wastegate linkage. Is any
damage found?
12. Inspect the air line connection to the wastegate solenoid for leaks. Are any air leaks found?
12.a Yes; repair or replace as necessary. Verify repair.
Note : Wastegate will not remain open if DiagnosticLink slide control is set above 95%.
14. Using DiagnosticLink, activate turbo control (wastegate) from the I/O Control window. Run slide control up
to 95% - adjust Duration to 20 seconds- (Click Set). Wastegate will open with air psi available. Does
wastegate open when commanded?
15. Does wastegate close when the duration timer expires?
16. Drain air tanks. Refer to OEM literature for details.
17. Install a suitable air pressure gauge in the inlet air pressure line to the waste gate solenoid from the vehicle.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8
WARNING
HOT EXHAUST
18. Start engine to stabilize the vehicle air pressure.

19. With a suitable air pressure gauge installed, measure the inlet air pressure to the waste gate solenoid from
the vehicle. Is the pressure at least 599 kPa (87 psi)?
19.a Yes; restore air hose connection. Go to step 20.
19.b No; refer to OEM troubleshooting for air pressure issues.
21. With the vehicle air pressure stabilized, use a suitable air pressure gauge to measure the outlet air
pressure from the solenoid to the turbocharger wastegate.
23. Is the pressure out of the wastegate solenoid less than one psi?
24. Using DiagnosticLink, activate turbo control (wastegate) from I/O Control window. Run slide control up to
50% - adjust Duration to 20 seconds- (Click Set). Is the pressure out of the wastegate solenoid between
117 and 158 kPa (17 and 23 psi)?
241 and 275 kPa (35 and 40 psi)?
28. Inspect the wastegate solenoid and harness connector for signs of damaged, bent, spread, corroded or
any damage found?
31. Inspect the MCM 120-pin connector and the 120-pin harness connector for signs of corrosion, spread,
of wire damage. Is any damage found?
32. Install a test MCM and retest with verification cycle. Does fault code return?
32.b No; replace MCM. Refer to section "Removal of the Motor Control Module" . Verify repairs.
33. Install original MCM. Bring to operating temperature of 71°C (160°F). Road test the vehicle. Drive at
highway speed with loaded trailer above 1130 rpm continuously for five minutes. Does fault become active?
9
33.a Yes; replace turbocharger.

Refer to section "Removal of the DD13 and DD15 Turbocharger" .
Refer to section "Removal of the DD16 Turbocharger" .
10
235.5 SPN 3464/FMI 18 - GHG17

Intake Manifold Pressure Too Low (Restricted Mode)
SPN 3464/FMI 18 - GHG17

Description Intake Manifold Pressure Lower than Expected During a Regeneration
(rpm/s)
((mg/stroke)/s)
Dash Lamps MIL, CEL
Check as follows:
3. Check the Motor Control Module (MCM) software level. Compare the current MCM software level to the
server. Is the MCM software at the latest level?
3.b No; update the MCM software level and perform the verification procedure in the table above. If the
fault code does not return, release the vehicle. If the fault code returns, Go to step 4.
found?
6. Inspect the entire air intake system, including the Charge Air Cooler (CAC), for leaks and/or restrictions.
Are any air intake system leaks or restrictions found?
11
6.a Yes; repair as necessary. Verify repairs. Retest with verification cycle; once engine is at standard
operating temperature, drive at highway speed with loaded trailer above 1130 rpm continuously for five
minutes.
8. Using DiagnosticLink, compare inlet manifold pressure to barometric pressure. Is the inlet manifold
pressure within 10.3 kPa (1.5 psi) of barometric pressure?
Sensor" . Verify repairs.
11. Visually inspect exhaust system for leaks or damage, including manifold, gaskets, turbine housing, EGR
valve, and Aftertreatment Device (ATD). Are any leaks found?
minutes. If fault code returns, Go to step 12.
12. Check for engine type. Is engine equipped with an asymmetrical turbocharger?
damage found?
15.a Yes; repair or replace as necessary. Verify repairs.
95% - adjust Duration to 20 seconds- (Click Set). Wastegate will open with air psi available. Does
12
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
21. Start engine to stabilize vehicle air pressure.

22. With a suitable air pressure gauge installed, measure the inlet air pressure to the wastegate solenoid from
the vehicle. Is the pressure at least 599 kPa (87psi)?
25. Turn the ignition ON (key ON, engine OFF). Is the pressure out of the wastegate solenoid less than one
psi?
50% - adjust Duration to 20 seconds- (Click Set). Is the pressure out of the wastegate solenoidbetween 117
and 158 kPa (17-23 psi)?
241 and 275 kPa (35-40 psi)?
any damage found?
13

31. Inspect the turbocharger for damage. Is any damage present?
If fault returns, for AT engines, Go to step 33.
If fault returns, for Turbo-Compound (TC) engines, Go to step 32.
31.b No; for AT engines, Go to step 33.
For TC engines, Go to step 32.
32. Inspect the axial power turbine for damage. Is any damage present?
32.a Yes; repair as necessary. Clear codes and verify repairs. Retest with verification cycle; once engine is
at standard operating temperature, drive at highway speed with loaded trailer above 1130 rpm
continuously for five minutes.
If fault returns, Go to step 33.
34. Inspect the Diesel Oxidation Catalyst (DOC) pressure sensor tube and elbow and the Diesel Particulate
Filter (DPF) pressure sensor tube and elbow for leaks, kinks, or blockages. Are any leaks, kinks, or
blockages found?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
35. Start engine, allow to warm up so coolant temperature is greater than 65°C (149°F).
Note : Normal DOC pressure is less than 10 kPa (1.5 psi) for a 1-box ATS and 13 kPa (1.9 psi) for a 2-box ATS.
36. Using DiagnosticLink, monitor DOC Inlet Pressure while performing a parked regeneration. Refer to section
"Performing a Parked Regeneration - GHG17" . Does the DOC Inlet Pressure start out high and stay high?
36.a Yes; the DOC(s) are plugged. Refer to 13TS-15 for DOC inspection, cleaning, and replacement
procedures.
36.b No; if DOC Inlet Pressure starts out high and then decreases, the DOCs were plugged and the parked
regen cleared them. Clear any fault codes. Verify repairs. If DOC pressure reading is low or fault code
14

of wire damage. Are any signs of damage found?
41.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" Verify repairs.
15
235.6 SPN 3464/FMI 31 - GHG17

Intake air throttle control electrical fault
SPN 3464/FMI 31
Description Intake Air Throttle Control Electrical Fault
Dash Lamps MIL, CEL
1. Is fault code active?

2. Cycle the ignition switch OFF, wait 15 seconds, turn ignition back ON and repeat Key ON/OFF sequence
three times. Does the fault become active?
2.b No; testing complete. Clear all faults and release vehicle.
4. Disconnect the Intake Throttle Valve (ITV) harness connector.
6. Measure the resistance between pin 4 of the ITV harness connector and ground.
6.a If the resistance is less than 1k ohms, repair wire between pin 4 of the ITV harness connector and
ground.
6.b If the resistance is greater than 1k ohms, Go to step 7.
ground.
8. Measure the resistance between pin 4 of the ITV harness connector and pin 100 of the MCM 120-pin
connector.
8.b If the resistance is greater than 3 ohms, repair wire between pin 4 of the ITV harness connector and
connector.
9.a If the resistance is less than 3 ohms, replace the Intake Throttle Valve. Refer to section "Removal of the Intake
Throttle Valve and Adaptor"
9.b If the resistance is greater than 3 ohms, repair wire between pin 5 of the Intake Throttle Valve harness
connector and pin 101 of the MCM 120-pin connector.
16
235.1 SPN 3464/FMI 3 - GHG17

H Bridge 1 Circuit Shorted to Battery
SPN 3464/FMI 3
Description H Bridge 1 Circuit Shorted to Battery
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
17
present?
6. Reconnect the ITV electrical connector.
9. Once the ITV completes its cycle, disconnect the ITV electrical connector.
10. Measure the voltage between pin 4 of the ITV electrical connector harness side and ground. Is there any
voltage present?
of the 120-pin Motor Control Module (MCM) electrical connector.
11. Measure the voltage between pin 5 of the ITV electrical connector harness side and Ground. Is there any
voltage present?
of the 120-pin MCM electrical connector.
18
235.2 SPN 3464/FMI 4 - GHG17

H Bridge 1 Circuit Shorted to Ground
SPN 3464/FMI 4
Description H Bridge 1 Circuit Shorted to Ground
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
19
present?
20
235.3 SPN 3464/FMI 5 - GHG17

H Bridge 1 Circuit Open Load
SPN 3464/FMI 5
Description H Bridge 1 Circuit Open Load
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
Check as follows:
2. Disconnect and inspect the ITV electrical connector. Is there any damage or corrosion present?
21

3. Measure the resistance across pins 4 and 5 of the ITV connector components side. Is the resistance less
than 3 ohms?
4. Disconnect and inspect the 120-pin MCM electrical connector. Is there any damage or corrosion present?
22
235.4 SPN 3464/FMI 16 – GHG17

Intake Manifold Pressure Too High (Restricted Mode)
SPN 3464/FMI 16
Description Intake Manifold Pressure Over-boost Detected During a Regeneration
(rpm/s)
((mg/stroke)/s)
Dash Lamps MIL, CEL

found?
6. Measure the inlet manifold pressure and the barometric pressure. Is the inlet manifold pressure within 10.3
kPa (1.5 psi) of barometric pressure?
23

connector. Is any damage present?
Sensor" .
9. Check for engine type. Is engine equipped with an Asymmetrical Turbocharger (AT)?
damage found?
12.a Yes; repair or replace as necessary. Verify repair.
14. Using DiagnosticLink, activate turbo control (wastegate) from the I/O Control window. Run slide control up
to 95% - adjust Duration to 20 seconds- (Click Set). Wastegate will open with air psi available. Does
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
24
WARNING
HOT EXHAUST
18. Start engine to stabilize the vehicle air pressure.

19. With a suitable air pressure gauge installed, measure the inlet air pressure to the waste gate solenoid from
the vehicle. Is the pressure at least 599 kPa (87 psi)?
23. Is the pressure out of the wastegate solenoid less than one psi?
117 and 158 kPa (17 and 23 psi)?
241 and 275 kPa (35 and 40 psi)?
any damage found?
25

26
235.5 SPN 3464/FMI 18 - GHG17

Intake Manifold Pressure Too Low (Restricted Mode)
SPN 3464/FMI 18 - GHG17

Description Intake Manifold Pressure Lower than Expected During a Regeneration
(rpm/s)
((mg/stroke)/s)
Dash Lamps MIL, CEL
Check as follows:
3. Check the Motor Control Module (MCM) software level. Compare the current MCM software level to the
server. Is the MCM software at the latest level?
3.b No; update the MCM software level and perform the verification procedure in the table above. If the
fault code does not return, release the vehicle. If the fault code returns, Go to step 4.
found?
27
minutes.
11. Visually inspect exhaust system for leaks or damage, including manifold, gaskets, turbine housing, EGR
valve, and Aftertreatment Device (ATD). Are any leaks found?
minutes. If fault code returns, Go to step 12.
damage found?
95% - adjust Duration to 20 seconds- (Click Set). Wastegate will open with air psi available. Does
28
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
21. Start engine to stabilize vehicle air pressure.

22. With a suitable air pressure gauge installed, measure the inlet air pressure to the wastegate solenoid from
the vehicle. Is the pressure at least 599 kPa (87psi)?
25. Turn the ignition ON (key ON, engine OFF). Is the pressure out of the wastegate solenoid less than one
psi?
50% - adjust Duration to 20 seconds- (Click Set). Is the pressure out of the wastegate solenoidbetween 117
and 158 kPa (17-23 psi)?
241 and 275 kPa (35-40 psi)?
any damage found?
29

32.a Yes; repair as necessary. Clear codes and verify repairs. Retest with verification cycle; once engine is
at standard operating temperature, drive at highway speed with loaded trailer above 1130 rpm
continuously for five minutes.
If fault returns, Go to step 33.
blockages found?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
35. Start engine, allow to warm up so coolant temperature is greater than 65°C (149°F).
Note : Normal DOC pressure is less than 10 kPa (1.5 psi) for a 1-box ATS and 13 kPa (1.9 psi) for a 2-box ATS.
36. Using DiagnosticLink, monitor DOC Inlet Pressure while performing a parked regeneration. Refer to section
"Performing a Parked Regeneration - GHG17" . Does the DOC Inlet Pressure start out high and stay high?
36.a Yes; the DOC(s) are plugged. Refer to 13TS-15 for DOC inspection, cleaning, and replacement
procedures.
36.b No; if DOC Inlet Pressure starts out high and then decreases, the DOCs were plugged and the parked
regen cleared them. Clear any fault codes. Verify repairs. If DOC pressure reading is low or fault code
30

41.b No; replace the MCM. Refer to section "Removal of the Motor Control Module" Verify repairs.
31
235.6 SPN 3464/FMI 31 - GHG17

Intake air throttle control electrical fault
SPN 3464/FMI 31
Description Intake Air Throttle Control Electrical Fault
Dash Lamps MIL, CEL
1. Is fault code active?

2. Cycle the ignition switch OFF, wait 15 seconds, turn ignition back ON and repeat Key ON/OFF sequence
three times. Does the fault become active?
2.b No; testing complete. Clear all faults and release vehicle.
4. Disconnect the Intake Throttle Valve (ITV) harness connector.
ground.
ground.
connector.
8.b If the resistance is greater than 3 ohms, repair wire between pin 4 of the ITV harness connector and
connector.
9.a If the resistance is less than 3 ohms, replace the Intake Throttle Valve. Refer to section "Removal of the Intake
Throttle Valve and Adaptor"
9.b If the resistance is greater than 3 ohms, repair wire between pin 5 of the Intake Throttle Valve harness
32
1
236.2 SPN 3471/FMI 3 - GHG17

SPN 3471/FMI 3
Description Electronic Dosing Valve (EDV) Circuit Failed High
Monitored Parameter Electronic Dosing Valve (EDV) Circuit
Typical Enabling Conditions Doser Enabled
Execution Frequency Doser Enabled
Dash Lamps MIL, CEL
1. Disconnect the EDV connector.

3. Measure the voltage between pin 1 of the EDV connector and ground (battery ground lug by starter).
3.a If the voltage is greater than 4.5 volts, repair the short to power between pin 1 of the EDV connector
and pin 65 of the Motor Control Module (MCM) 120-pin connector.
3.b If the voltage is less than 4.5 volts, Go to step 4.
4. Turn the ignition switch to the OFF position.
6. Measure the resistance between pin 1 and pin 2 of the EDV connector.
6.a If the resistance is less than 10K ohms, repair short between pins 1 and 2 of the EDV connector and
pins 64 and 65 of the MCM 120-pin connector.
6.b If the resistance is greater than 10K ohms, replace the Metering Unit.
7. Using DiagnosticLink , perform “Purge Hydrocarbon Doser” service routine to verify repairs.
2
236.3 SPN 3471/FMI 4 - GHG17

Hydrocarbon Doser Circuit Failed Low.
SPN 3471/FMI 4
Description Hydrocarbon (HC) Doser Circuit Failed Low
Monitored Parameter HC Doser Circuit
Dash Lamps MIL, CEL
1. Disconnect the Electronic Dosing Valve (EDV) sensor.

3. Measure the resistance between pin 1 of the EDV sensor harness connector and ground (battery ground
lug by starter).
3.a If resistance is less than 5 ohms, repair the short circuit between pin 1 of the EDV sensor harness
3.b If resistance is greater than 5 ohms, Go to step 4. .
4. Measure the resistance between pin 2 of the EDV sensor harness connector and ground (battery ground
lug by starter).
4.a If resistance is less than 5 ohms, repair the short circuit between pin 2 of the EDV sensor harness
4.b If resistance is greater than 5 ohms, replace the EDV.
3
236.4 SPN 3471/FMI 5 - GHG17

Hydrocarbon Doser Circuit Failed Open
SPN 3471/FMI 5
Description Hydrocarbon (HC) Doser Circuit Failed Open
Monitored Parameter HC Doser Circuit
Dash Lamps MIL, CEL
4
Fig 236.1, EDV Harness Connector
5

2. Turn the ignition key ON (key ON, engine OFF). Go to step 3.
3. Check for multiple codes. Is SPN 3482/FMI 5 also present?
3.a Yes; repair the wire between pin 64 of the 120-pin Motor Control Module (MCM) connector and pin 2 of
the Electronic Dosing Valve (EDV) / pin 2 of the Fuel Cut-Off Valve. Verify repair.
5. Disconnect the EDV connector. Go to step 6.
7. Measure the voltage between pin 1 of the EDV connector, harness side and ground. Is the voltage within
1.5 volts of battery voltage?
8. Measure the voltage between pin 2 of the EDV connector, harness side and ground. Is the voltage between
2 and 4.5 volts?
8.a Yes; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify repair.
10. Disconnect the 120-pin MCM connector. Go to step 11.
11. Measure the resistance between pin 1 of the EDV connector, harness side and pin 65 of the 120-pin MCM
connector, harness side. Is the resistance less than 5 ohms?
11.b No; repair the wire between pin 1 of the EDV connector and pin 65 of the 120-pin MCM connector.
Verify repair.
6
12. Measure the resistance between pin 2 of the EDV connector, harness side and pin 64 of the 120-pin MCM
connector, harness side. Is the resistance less than 5 ohms?
12.a Yes; replace the MCM, Refer to section "Removal of the Motor Control Module" . Verify repair.
12.b No; repair the wire between pin 2 of the EDV connector and pin 64 of the 120-pin MCM connector.
Verify repair.
7
237.1 SPN 3480/FMI 0 - GHG17

Fuel Compensation Pressure High
SPN 3480/FMI 0
Description This Fault Will Become Active Once The Fuel Compensation
Pressure Reaches and Stays Above 799 kPa (116 psi), for
Longer Than 600 Seconds During a Driving Regen or 60
Seconds During a Parked Regeneration with all Conditions
Met
Monitored Parameter Doser Fuel Line Pressure
Typical Enabling Conditions Dosing Enabled
Dash Lamps MIL, CEL
Engine Reaction Derate 10%, DPF Inhibit Regeneration

J-48876 Priming Port Fuel Pressure Test Gauge
Check as follows:
steps.
4. Are any fuel system faults present?
• SPN 3480/FMI 3, or 4
• SPN 3480/FMI 14
• SPN 94/FMI 3, or 4
• SPN 94/FMI 2
4.a Yes; repair fault with the highest priority listed above. Verify repairs.
PLV return line.
5. Connect tool J-48876 Priming Port Fuel Pressure Test Gauge to the priming port valve. Go to step 6.
1
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

7. Monitor the fuel pressure at 600 rpm and at 1800 rpm. Is the fuel pressure above 90 psi at 600 rpm or 140
psi at 1800 rpm?
7.a Yes; inspect the two- stage valve.
7.b Yes; replace the hydrocarbon doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify
repairs.
2
237.2 SPN 3480/FMI 1 - GHG17

Doser Fuel Supply Pressure Abnormal
SPN 3480/FMI 1
Description This code sets when the Motor Control Module (MCM) detects
that the fuel compensation pressure is lower than 358 kPa (52
psi) for 10 minutes when dosing is enabled.
Monitored Parameter Doser Fuel Line Pressure Sensor
Typical Duration 10 minutes for parked regeneration, one minute during driving
regeneration
Dash Lamps MIL, CEL
Checks as Follows:
3. Are any of the following fuel system faults present?
• 3480/3, or 4
• 3480/14
• 94/3, or 4
• 94/2
3.a Yes; repair fault with the highest priority listed above. Verify repair.
Note : When inspecting for fuel leaks, as little as one drop of fuel can cause a fuel related concern.
WARNING
FIRE
To avoid injury from fire, contain and eliminate leaks of flammable fluids as they occur.
Failure to eliminate leaks could result in fire.
4. Visually inspect the HC doser block for external fuel leaks. Are any external fuel leaks present?
4.a Yes; repair the external fuel leaks as necessary. Verify repair.
WARNING
ENGINE EXHAUST
3
WARNING
PERSONAL INJURY

6. Using DiagnosticLink, monitor the Low Pressure Pump Outlet (LPPO) fuel pressure at 600 rpm and at 1800
rpm. Is the LPPO fuel pressure between 482 kPa (70 psi) to 620 kPa (90 psi) at 600 rpm and between 689
kPa (100 psi) to 965 kPa (140 psi) at 1800 rpm?
7. Inspect the pressure relief valve. Refer to section "Inspection of the Pressure Relief Valve - Two-Filter System" . Was
damage found with the pressure relief valve?
7.a Yes; replace the pressure relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" .
Verify repairs.
7.b No; check for a restriction in the fuel supply. Verify repair.
4
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

9. WIth the engine at 49°C (120°F) or higher, use DiagnosticLink to perform the "Purge Hydrocarbon Doser"
service routine. Go to step 10.
10. Review the log file for the "Purge Hydrocarbon Doser" service routine. Go to step 11.
11. Monitor the fuel compensation pressure when the fuel cut-off valve is commanded to 100 percent. Is the
fuel compensation pressure greater than 68 kPa (10 psi)?
11.a Yes; replace the high pressure fuel flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter
11.b No; replace the hydrocarbon doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify
repair.
12. With the engine at 49°C (120°F) or higher, use DiagnosticLink to perform the "Purge Hydrocarbon Doser"
service routine again. Go to step 13.
fuel pressure greater than 448 kPa (65 psi)?
14.a Yes; perform a parked regeneration. Verify repair.
repair.
5
237.3 SPN 3480/FMI 2 - GHG17

Hydrocarbon Doser Fuel Line Pressure Low
SPN 3480/FMI 2
Description Hydrocarbon (HC) Doser Fuel Line Pressure Low
Monitored Parameter HC Doser Fuel Line Pressure
Dash Lamps MIL, CEL
Check as follows:
3. Check the MCM software level. Is the MCM software level 6.5.0.3 or greater?
4. Are there any fuel system faults present?
4.a Yes; repair fault with the highest priority listed below. Verify repair.
3480/3, or 4
4077/3, or 4
3480/1
4077/14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

6. Using DiagnosticLink, perform two back-to-back "Purge Hydrocarbon Doser" service routines to help
improve the chances of identifying a leak.
6
8. Visually inspect the fuel line between the HC doser block assembly and fuel doser injector valve for any
sign of external fuel leaks. Are any external leaks present?
8.a Yes; replace the HC doser injector valve fuel supply line. Go to step 10.
8.b No; replace the HC fuel doser injector valve and fuel supply line. Go to step 9.
9. Was the truck built after 8-1-2017?
9.a Yes; replace the HC fuel doser injector valve. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector
Valve" . Go to step 10.
9.b No; replace the HC doser injector valve and fuel supply line. Refer to section "Removal of the Hydrocarbon Fuel
Doser Injector Valve" . Go to step 10.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
10. Turn the ignition ON and start the engine.
7
11. Clear fault codes.
WARNING
HOT EXHAUST
12. Perform a parked regeneration to verify the repair. Refer to section "Performing a Parked Regeneration - GHG17" . Did
SPN 3480/FMI 2 become active during regeneration?
12.a Yes; replace doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify repair
8
237.4 SPN 3480/FMI 3 - GHG17

SPN 3480/FMI 3
Description Fuel Compensation Pressure (FCP) Sensor Circuit Failed
High
Monitored Parameter Fuel Compensation Pressure Sensor
Dash Lamps MIL, CEL
Check as follows:
3.a If SPN 100/FMI 3, SPN 4077/FMI 3, and SPN 3480/FMI 3 are present, repair short to power between
pin 82 of the Motor Control Module (MCM) 120-pin connector and the engine oil pressure, fuel line, and
FCP sensors.
3.b If SPN 4077/FMI 3 and SPN 3480/FMI 3 are present, repair short to power between pin 104 of the
MCM 120-pin connector and the fuel line psi sensors.
4. Disconnect the FCP sensor connector.
5. Inspect the FCP sensor connector for bent, spread or corroded pins. Is damage found?
6. Using DiagnosticLink or newer, does the code go inactive with the FCP sensor disconnected?
6.a Yes; replace the Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
9. Inspect the MCM sensor connector for bent, spread, water, or corroded pins. Is damage found?
10. Measure the resistance across pins 1 and 2 of the FCP sensor connector. Is resistance less than 10K
ohms?
11. Measure the resistance between pin 4 of the FCP sensor harness connector and pin 104 of the MCM 120-
11.b No; repair the open wire between pin 4 of the FCP sensor harness connector and pin 104 of the MCM
120-pin connector.
12. Measure the resistance between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor
9

12.b No; repair the open circuit between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor
connector.
13. Reinstall MCM 120-pin connector. Do not reconnect FCP sensor.
16. Monitor voltage for FCP sensor. Is voltage reading greater than 4.5 volts?
16.a Yes; inspect harness for short to power due to abrasion or wire damage. Typical points of wear are
sharp bends.
16.b Yes; replace the Hydrocarbon Fuel Doser Block Assembly. Refer to section "Removal of the Hydrocarbon Fuel
Doser Block " . Verify repair.
10
237.5 SPN 3480/FMI 4 - GHG17

SPN 3480/FMI 4
Description Fuel Compensation Pressure (FCP) Sensor Circuit Failed Low
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
11
Check as follows:
3. Check for multiple codes; is 4077/FMI 4 present, but not SPN 100/FMI 4?
the fuel line pressure sensors. Clear codes. Verify repairs.
4. Are SPN 100/FMI 4 and SPN 4077/FMI 4 present?
6. Disconnect the FCP sensor.
7. Inspect the FCP sensor connector for bent, spread or corroded pins. Is any pin damage found?
9. Measure the resistance between 5V supply (pin 82 of the MCM 120-pin connector) and ground. Is
9.a Yes; repair short to ground between pin 82 of the MCM 120-pin connector and the engine oil, fuel line,
and FCP sensors.
9.b No; repair open circuit between pin 82 of the MCM 120-pin connector and the engine oil, fuel line, and
FCP sensors.
12
11. Disconnect the FCP sensor. Inspect the FCP sensor connector for bent, spread, or corroded pins. Is any
pin damage found?
13. Inspect the MCM sensor connector for bent, spread, water, or corroded pins. Is any pin damage found?
14. Measure the resistance between signal circuit (pin 84 of the MCM 120-pin connector) and ground. Is
14.a Yes; repair short to ground between pin 84 of the MCM 120-pin connector and the FCP sensor
connector.
15. Measure the resistance between pin 104 of the MCM 120-pin connector and pin 84 of the MCM 120-pin
connector. Is the resistance less than 10K ohms?
15.a Yes; repair the short between the ground circuit pin 104 of the MCM 120-pin connector and the signal
circuit pin 84 of the MCM 120-pin connector.
15.b No; replace the FCP sensor. Verify repairs.
13
237.6 SPN 3480/FMI 14 - GHG17

Doser FLP Sensors Failed Self Test
SPN 3480/FMI 14
Description This fault code runs a system check that closes the fuel cutoff
valve and opens the doser valve in the doser block, then
compares the fuel compensation sensor to the doser line
pressure sensor. If both pressure sensors are not within 48
kPa (7 psi) for a count of 4 seconds, the code becomes
active.
Typical Duration 1 min
Dash Lamps MIL, CEL, DPF Inhibit Regeneration
1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety
steps.
2. Replace the Hydrocarbon Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Go to step 3.
Note : It may take three purge attempts to purge all air from the lines. Do not exceed three purge attempts.
3. Using DiagnosticLink , perform Purge Hydrocarbon Doser service routine. Go to step 4.
WARNING
HOT EXHAUST
5. Perform parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17" . Did SPN 3480/ FMI 14
become active during regeneration?
5.a Yes; replace the Fuel Doser Injection Valve. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector Valve"
.
5.b No; clear active codes and release vehicle.
14
237.7 SPN 3480/FMI 21 - GHG17

SPN 3480/FMI 21
Description Fuel Cut-off Valve Pressure Not Plausible
Monitored Parameter Hydrocarbon (HC) Doser Fuel Compensation Pressure
Dash Lamps MIL, CEL
steps.
4. Are there any fuel system faults or SPN 3480/FMI 0, 3, 4, or 5 present?
4.a Yes; repair these faults first.
WARNING
FIRE
6. Visually inspect HC D oser B lock assembly and Fuel Doser Injector Valve fuel lines for external leaks. Are
there external leaks?
6.b No; replace the Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
15
237.1 SPN 3480/FMI 0 - GHG17

Fuel Compensation Pressure High
SPN 3480/FMI 0
Description This Fault Will Become Active Once The Fuel Compensation
Pressure Reaches and Stays Above 799 kPa (116 psi), for
Longer Than 600 Seconds During a Driving Regen or 60
Seconds During a Parked Regeneration with all Conditions
Met
Dash Lamps MIL, CEL
Engine Reaction Derate 10%, DPF Inhibit Regeneration

J-48876 Priming Port Fuel Pressure Test Gauge
Check as follows:
steps.
4. Are any fuel system faults present?
• SPN 3480/FMI 3, or 4
• SPN 3480/FMI 14
• SPN 94/FMI 3, or 4
• SPN 94/FMI 2
4.a Yes; repair fault with the highest priority listed above. Verify repairs.
PLV return line.
5. Connect tool J-48876 Priming Port Fuel Pressure Test Gauge to the priming port valve. Go to step 6.
16
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

7. Monitor the fuel pressure at 600 rpm and at 1800 rpm. Is the fuel pressure above 90 psi at 600 rpm or 140
psi at 1800 rpm?
7.a Yes; inspect the two- stage valve.
7.b Yes; replace the hydrocarbon doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify
repairs.
17
237.2 SPN 3480/FMI 1 - GHG17

Doser Fuel Supply Pressure Abnormal
SPN 3480/FMI 1
Description This code sets when the Motor Control Module (MCM) detects
that the fuel compensation pressure is lower than 358 kPa (52
psi) for 10 minutes when dosing is enabled.
Monitored Parameter Doser Fuel Line Pressure Sensor
Typical Duration 10 minutes for parked regeneration, one minute during driving
regeneration
Dash Lamps MIL, CEL
Checks as Follows:
3. Are any of the following fuel system faults present?
• 3480/3, or 4
• 3480/14
• 94/3, or 4
• 94/2
3.a Yes; repair fault with the highest priority listed above. Verify repair.
Note : When inspecting for fuel leaks, as little as one drop of fuel can cause a fuel related concern.
WARNING
FIRE
WARNING
ENGINE EXHAUST
18
WARNING
PERSONAL INJURY

6. Using DiagnosticLink, monitor the Low Pressure Pump Outlet (LPPO) fuel pressure at 600 rpm and at 1800
rpm. Is the LPPO fuel pressure between 482 kPa (70 psi) to 620 kPa (90 psi) at 600 rpm and between 689
kPa (100 psi) to 965 kPa (140 psi) at 1800 rpm?
7. Inspect the pressure relief valve. Refer to section "Inspection of the Pressure Relief Valve - Two-Filter System" . Was
damage found with the pressure relief valve?
7.a Yes; replace the pressure relief valve. Refer to section "Removal of the Pressure Relief Valve - Two-Filter System" .
Verify repairs.
7.b No; check for a restriction in the fuel supply. Verify repair.
19
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

9. WIth the engine at 49°C (120°F) or higher, use DiagnosticLink to perform the "Purge Hydrocarbon Doser"
service routine. Go to step 10.
fuel compensation pressure greater than 68 kPa (10 psi)?
11.a Yes; replace the high pressure fuel flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter
repair.
12. With the engine at 49°C (120°F) or higher, use DiagnosticLink to perform the "Purge Hydrocarbon Doser"
service routine again. Go to step 13.
fuel pressure greater than 448 kPa (65 psi)?
14.a Yes; perform a parked regeneration. Verify repair.
repair.
20
237.3 SPN 3480/FMI 2 - GHG17

SPN 3480/FMI 2
Description Hydrocarbon (HC) Doser Fuel Line Pressure Low
Monitored Parameter HC Doser Fuel Line Pressure
Dash Lamps MIL, CEL
Check as follows:
3. Check the MCM software level. Is the MCM software level 6.5.0.3 or greater?
Note :
4.a Yes; repair fault with the highest priority listed below. Verify repair.
3480/3, or 4
4077/3, or 4
3480/1
4077/14
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

6. Using DiagnosticLink, perform two back-to-back "Purge Hydrocarbon Doser" service routines to help
improve the chances of identifying a leak.
21
8. Visually inspect the fuel line between the HC doser block assembly and fuel doser injector valve for any
sign of external fuel leaks. Are any external leaks present?
8.a Yes; replace the HC doser injector valve fuel supply line. Go to step 10.
9. Was the truck built after 8-1-2017?
9.a Yes; replace the HC fuel doser injector valve. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector
9.b No; replace the HC doser injector valve and fuel supply line. Refer to section "Removal of the Hydrocarbon Fuel
Doser Injector Valve" . Go to step 10.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
10. Turn the ignition ON and start the engine.

22
WARNING
HOT EXHAUST
12. Perform a parked regeneration to verify the repair. Refer to section "Performing a Parked Regeneration - GHG17" . Did
SPN 3480/FMI 2 become active during regeneration?
12.a Yes; replace doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify repair
23
237.4 SPN 3480/FMI 3 - GHG17

SPN 3480/FMI 3
Description Fuel Compensation Pressure (FCP) Sensor Circuit Failed
High
Dash Lamps MIL, CEL
Check as follows:
3.a If SPN 100/FMI 3, SPN 4077/FMI 3, and SPN 3480/FMI 3 are present, repair short to power between
pin 82 of the Motor Control Module (MCM) 120-pin connector and the engine oil pressure, fuel line, and
FCP sensors.
3.b If SPN 4077/FMI 3 and SPN 3480/FMI 3 are present, repair short to power between pin 104 of the
MCM 120-pin connector and the fuel line psi sensors.
4. Disconnect the FCP sensor connector.
5. Inspect the FCP sensor connector for bent, spread or corroded pins. Is damage found?
6. Using DiagnosticLink or newer, does the code go inactive with the FCP sensor disconnected?
6.a Yes; replace the Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
9. Inspect the MCM sensor connector for bent, spread, water, or corroded pins. Is damage found?
10. Measure the resistance across pins 1 and 2 of the FCP sensor connector. Is resistance less than 10K
ohms?
11. Measure the resistance between pin 4 of the FCP sensor harness connector and pin 104 of the MCM 120-
11.b No; repair the open wire between pin 4 of the FCP sensor harness connector and pin 104 of the MCM
120-pin connector.
12. Measure the resistance between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor
24

12.b No; repair the open circuit between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor
connector.
13. Reinstall MCM 120-pin connector. Do not reconnect FCP sensor.
16. Monitor voltage for FCP sensor. Is voltage reading greater than 4.5 volts?
16.a Yes; inspect harness for short to power due to abrasion or wire damage. Typical points of wear are
sharp bends.
16.b Yes; replace the Hydrocarbon Fuel Doser Block Assembly. Refer to section "Removal of the Hydrocarbon Fuel
Doser Block " . Verify repair.
25
237.5 SPN 3480/FMI 4 - GHG17

SPN 3480/FMI 4
Description Fuel Compensation Pressure (FCP) Sensor Circuit Failed Low
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
26
Check as follows:
3. Check for multiple codes; is 4077/FMI 4 present, but not SPN 100/FMI 4?
the fuel line pressure sensors. Clear codes. Verify repairs.
4. Are SPN 100/FMI 4 and SPN 4077/FMI 4 present?
6. Disconnect the FCP sensor.
7. Inspect the FCP sensor connector for bent, spread or corroded pins. Is any pin damage found?
9. Measure the resistance between 5V supply (pin 82 of the MCM 120-pin connector) and ground. Is
9.a Yes; repair short to ground between pin 82 of the MCM 120-pin connector and the engine oil, fuel line,
and FCP sensors.
9.b No; repair open circuit between pin 82 of the MCM 120-pin connector and the engine oil, fuel line, and
FCP sensors.
27
11. Disconnect the FCP sensor. Inspect the FCP sensor connector for bent, spread, or corroded pins. Is any
pin damage found?
13. Inspect the MCM sensor connector for bent, spread, water, or corroded pins. Is any pin damage found?
14. Measure the resistance between signal circuit (pin 84 of the MCM 120-pin connector) and ground. Is
14.a Yes; repair short to ground between pin 84 of the MCM 120-pin connector and the FCP sensor
connector.
15. Measure the resistance between pin 104 of the MCM 120-pin connector and pin 84 of the MCM 120-pin
connector. Is the resistance less than 10K ohms?
15.a Yes; repair the short between the ground circuit pin 104 of the MCM 120-pin connector and the signal
circuit pin 84 of the MCM 120-pin connector.
15.b No; replace the FCP sensor. Verify repairs.
28
237.6 SPN 3480/FMI 14 - GHG17

Doser FLP Sensors Failed Self Test
SPN 3480/FMI 14
Description This fault code runs a system check that closes the fuel cutoff
valve and opens the doser valve in the doser block, then
compares the fuel compensation sensor to the doser line
pressure sensor. If both pressure sensors are not within 48
kPa (7 psi) for a count of 4 seconds, the code becomes
active.
Typical Duration 1 min
Dash Lamps MIL, CEL, DPF Inhibit Regeneration
1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety
steps.
2. Replace the Hydrocarbon Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Go to step 3.
Note : It may take three purge attempts to purge all air from the lines. Do not exceed three purge attempts.
3. Using DiagnosticLink , perform Purge Hydrocarbon Doser service routine. Go to step 4.
WARNING
HOT EXHAUST
5. Perform parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17" . Did SPN 3480/ FMI 14
become active during regeneration?
5.a Yes; replace the Fuel Doser Injection Valve. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector Valve"
.
5.b No; clear active codes and release vehicle.
29
237.7 SPN 3480/FMI 21 - GHG17

SPN 3480/FMI 21
Description Fuel Cut-off Valve Pressure Not Plausible
Monitored Parameter Hydrocarbon (HC) Doser Fuel Compensation Pressure
Dash Lamps MIL, CEL
steps.
4. Are there any fuel system faults or SPN 3480/FMI 0, 3, 4, or 5 present?
WARNING
FIRE
6. Visually inspect HC D oser B lock assembly and Fuel Doser Injector Valve fuel lines for external leaks. Are
there external leaks?
6.b No; replace the Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
30
238.1 SPN 3482/FMI 3 - GHG17

Fuel Cut-off Valve circuit failed high
SPN 3482/FMI 3
Description Fuel Cut Off Valve (FCV) Circuit Failed High
Monitored Parameter Fuel Cut Off Valve
Dash Lamps MIL, CEL
1. Disconnect the FCV connector.

3. Measure the voltage between pin 1 of the FCV connector and ground (battery ground lug by starter).
3.a If the voltage is greater than 4.5 volts, repair short to power between pin 1 of the FCV connector and
3.b If voltage is less than 4.5 volts, Go to step 4. .
4. Turn the ignition switch to the OFF position.
6. Measure the resistance between pin 1 and pin 2 of the FCV connector.
6.a If the resistance is less than 5 ohms, repair short between FCV connector and pins 1 and 2 and MCM
120-pin connector pins 64 and 69.
6.b If the resistance is greater than 5 ohms, replace the Hydrocarbon (HC) doser block assembly. Refer to
section "Removal of the Hydrocarbon Fuel Doser Block " .
1
238.2 SPN 3482/FMI 4 - GHG17

Fuel Cut-off Valve circuit failed low
SPN 3482/FMI 4
Description Short to ground
Monitored Parameter Fuel Cut off Valve
Execution Frequency Once per drive cycle
Typical Duration 20 Milliseconds
Dash Lamps MIL, CEL
Verification Key On Engine Off
1. Disconnect the Fuel Cutoff Valve (FCV) sensor.

3. Measure the resistance between pin 1 of the FCV sensor harness connector and ground (battery ground
lug by starter). Is the resistance less than 10k ohms?
3.a Yes; repair the short circuit between pin 1 of the FCV sensor harness connector and ground.
3.b No; replace Hydrocarbon Doser Block., Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
2
238.3 SPN 3482/FMI 5 - GHG17

Fuel Cut-off Valve circuit failed open.
SPN 3482/FMI 5
Description Fuel Cut Off Valve (FCV) Circuit Failed Open
Monitored Parameter Fuel Cut Off Valve
Dash Lamps MIL, CEL
1. Turn vehicle ignition switch ON.

2. Read multiple codes.
2.a If fault code SPN 3471/FMI 5 is active in addition to SPN 3482/FMI 5, repair open circuit between pin
64 of the Motor Control Module (MCM) 120-pin connector and the Electronic Dosing Valve (EDV), pin 2
and Fuel Cut-off Valve (FCV), pin 2 sensors.
2.b If only fault code SPN 3482/FMI 5 is active, Go to step 4. .
3. Disconnect the FCV sensor.
4. Measure the resistance across pin 1 and pin 2 of the FCV sensor.
4.a If resistance is greater than 20 ohms, replace the Hydrocarbon (HC) doser block assembly. Refer to
section "Removal of the Hydrocarbon Fuel Doser Block " .
4.b If resistance is less than 20 ohms, Go to step 6. .

6. Measure the voltage between pin 2 of the FCV sensor harness connector and ground (battery ground lug
by starter).
6.a If the voltage is between 11.5 and 12.5 volts, repair the open between pin 1 of the FCV sensor harness
6.b If the voltage is less 11.5 volts, repair open circuit between pin 2 of the FCV sensor harness connector
3
239.1 SPN 3490/FMI 3 - GHG17

Post Run Indicator Lamp - Indicates an open circuit on Pin 14 circuit of the Aftertreatment Control Module 120-pin
connector.
Repair the open circuit on pin 14 circuit of the Aftertreatment Control Module (ACM) 120-pin connector. For wiring
Note : ACM Post Run Process Lamp only applies to negative battery disconnect system.
1
239.2 SPN 3490/FMI 4 - GHG17

Post Run Indicator Lamp - Indicated a Short to Ground on Pin 14 circuit of the Aftertreatment Control Module 120-
pin connector
Repair the short to ground on pin 14 circuit of the Aftertreatment Control Module (ACM) 120-pin connector. For
2
239.3 SPN 3490/FMI 5 - GHG17

Post Run Indicator Lamp - Indicates a short circuit on Pin 14 circuit of the Aftertreatment Control Module 120-pin
connector
Repair the short circuit on pin 14 circuit of the Aftertreatment Control Module (ACM) 120-pin connector. For wiring
3
240.1 SPN 3509/FMI 3 - GHG17

The 5V Sensor Supply Bank 1 Circuit Failed High
SPN 3509/FMI 3
Description 5V Sensor Supply Bank 1 Circuit Failed High
Monitored Parameter Aftertreatment Control Module (ACM) 5V Internal Power
Supply
Dash Lamps MIL, CEL
Engine Reaction
Note : Additional faults SPN 3610/ FMI 3 Diesel Particulate Filter (DPF) Outlet Pressure Circuit Failed High and
SPN 3609/FMI 3 DPF Inlet Pressure Circuit Failed High may also be present.
Check as follows:
2. Disconnect the Diesel Oxidation Catalyst (DOC) inlet pressure sensor connector.
3. Inspect the sensor harness for bent, spread, or corroded pins. Is any damage present?
1

4. Measure the voltage between pin 3 on the harness side of the DOC inlet pressure sensor connector and
ground. Is voltage greater than 5.5 volts?
4.a Yes; repair the short to battery between pin 3 of the DOC inlet pressure sensor connector and pin 117
of the ACM 120-pin connector.
4.b No; repair the short to battery between pin 1 of the DOC inlet pressure sensor connector and pin 88 of
the ACM 120-pin connector.
2
240.2 SPN 3509/FMI 4 - GHG17

The 5V Sensor Supply Bank 1 Circuit Failed Low
SPN 3509/FMI 4
Description 5V Sensor Supply Bank 1 Circuit Failed Low
Supply
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
2. Disconnect the Diesel Oxidation Catalyst (DOC) inlet pressure sensor connector.
3. Inspect the sensor harness for bent, spread, or corroded pins. Is any damage present?
5. Measure the resistance between pin 3 on the harness side of the DOC inlet pressure sensor connector and
3
5.a Yes; repair the wire between pin 3 of the DOC inlet pressure sensor connector and pin 117 of the ACM
120-pin connector. Verify repairs.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" . Verify repair.
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" . Verify repair.
4
SPN 3509 (CPC3) (GHG17)
242.1 SPN 3509/FMI 3 - GHG17

SPN 3509/FMI 3
Description Coolant Level Circuit Signal Failed High
Dash Lamps CEL
Check as follows:
2. Inspect the coolant level sensor harness connector for bent, spread, or corroded terminals. Is pin damage
present?
4. Measure the voltage between pin 1 and ground. Is the voltage greater than 5.5 volts?
4.a Yes; repair the short to battery power between pin 1 of the coolant level sensor harness connector and
pin 22 of the CPC3 connector #2.
5.a Yes; repair the short to battery power between pin 2 of the coolant level sensor harness connector and
pin 11 of the CPC3 connector #2.
5.b No; replace the coolant level sensor.
1
242.2 SPN 3509/FMI 4 - GHG17

SPN 3509/FMI 4
(CPC3) Detects a Short to Ground on the Coolant Level
Circuit
Dash Lamps CEL
Check as follows:
2. Inspect the coolant level sensor harness connector for bent, spread, or corroded terminals. Is pin damage
present?
4. Measure the voltage between pins 1 and 2 of the coolant level sensor harness connector. Is the voltage
5.a Yes; repair wire between pin 2 of the coolant level sensor harness connector and pin 11 of the CPC3
connector #2.
5.b No; repair wire between pin 1 of the coolant level sensor harness connector and pin 22 of the CPC3
connector #2.
2
241.1 SPN 3509/FMI 3 - GHG17

SPN 3509/FMI 3
Detects a Short to Voltage on Pins 58 or 117
Monitored Parameter 5V Internal Power Supply
Dash Lamps MIL, CEL
Check as follows:
2. Is the vehicle equipped with a DD16 engine?
3. Disconnect and inspect the Intake Throttle Valve (ITV) electrical connector. Is damage or corrosion
present?
1

8. Is code SPN 3509/FMI 3 still present?
8.b No; repair the short to power on the circuits for pins 58 and/or 117 of the MCM 120-pin connector.
Verify repair.
2
241.2 SPN 3509/FMI 4 - GHG17

SPN 3509/FMI 4
Detects a Short to Ground on Pins 58 or 117
Monitored Parameter 5V Internal Power Supply
Dash Lamps MIL, CEL
Check as follows:
3. Disconnect each one of the sensors or components listed below, one at a time, while monitoring
DiagnosticLink for fault code SPN 3509/FMI 4 to go inactive. Go to step 4.
• Oil Separator Speed Sensor
• Intake Manifold Pressure Sensor/Charge Air Cooler Outlet Temperature Sensor
• EGR Delta P Sensor
3
• Intake Throttle Valve (DD16 only)

• LPPO Fuel Pressure Sensor
4. Does the fault code go inactive when the sensors have been disconnected?
4.a Yes; replace the last sensor that was disconnected that caused the fault code SPN 3509/FMI 4 to go
inactive. Verify repair.
8.b No; repair the short to ground on the circuits for pins 58 and/or 117 of the MCM 120-pin connector.
Verify repair.
4
244.1 SPN 3510/FMI 3 - GHG17

Aftertreatment Control Module 2 Sensor Supply 2 Short to Battery
SPN 3510/FMI 3
Monitored Parameter Motor Control Module (MCM) 5V Internal Power Supply
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
2. Disconnect the Diesel Exhaust Fluid (DEF) dosing unit electrical connector.
3. Inspect the DEF dosing unit harness for bent, spread, or corroded pins. Is any damage present?
1
4. Measure the voltage between pin 5 on the harness side of the DEF dosing unit connector and ground. Is
the voltage greater than 5.5 volts?
4.a Yes; repair the short to battery between pin 5 of the DEF dosing unit connector and pin 84 of the
Aftertreatment Control Module (ACM) 120-pin connector. Verify repairs.
4.b No; repair the short between pin 7 of the DEF dosing unit connector and pin 99 of the ACM 120-pin
2
244.2 SPN 3510/FMI 4 - GHG17

Aftertreatment Control Module 2 Sensor Supply Bank 2 Short to Ground
SPN 3510/FMI 4
Dash Lamps MIL, CEL
Engine Reaction
Check as follows:
2. Disconnect the Diesel Exhaust Fluid (DEF) dosing unit electrical connector.
3. Inspect the DEF dosing unit harness for bent, spread, or corroded pins. Is any damage present?
5. Measure the resistance between pin 5 on the harness side of the DEF dosing unit connector and ground. Is
the resistance less than 1K ohms?
3
5.a Yes; repair the wire between pin 5 of the DEF dosing unit connector and pin 84 of the ACM 120-pin
5.b No; replace the DEF doser unit.
4
243.1 SPN 3510/FMI 4 - GHG17

SPN 3510/FMI 4
Description Accelerator Pedal Sensor Failed Low
Monitored Parameter Pedal Supply Voltage
Dash Lamps CEL
Analog Pedal Type
Williams Dual-Channel Analog Pedal
1

Function CPC Pinout Connector Pinout Comments Harness
Connector
Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
GND2 3/2 E APS2 GND
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
Check as follows:
2. Disconnect the Accelerator Pedal (AP) connector.
damage found?
2
5. Clear codes and cycle ignition.

6. Using DiagnosticLink , monitor fault code SPN 3510/FMI 4 with the AP disconnected. Does the fault code
change or go inactive?
6.a Yes; replace the AP, clear codes and verify repair. Refer to Original Equipment Manufacturer (OEM)
7.a Yes; repair a short to voltage between pin B of the AP harness connector and pin 4 of the CPC#1
connector.
8. Measure the resistance between pins B and C of the AP harness connector. Is the resistance less than 10K
ohms?
8.a Yes; repair the short between pins B and C of the AP harness connector. Verify repair.
9. Measure the resistance between pin C of the AP harness connector and ground. Is the resistance less than
10K ohms?
9.a Yes; repair the short circuit between pin C of the AP harness connector and ground. Verify repair.
11. Measure the resistance between pins D and E of the AP harness connector. Is the resistance less than 10K
ohms?
11.a Yes; repair the short between pins D and E of the AP harness connector. Verify repair.
12. Measure the resistance between pin D of the AP harness connector and ground. Is the resistance less than
10K ohms?
12.a Yes; repair the short circuit between pin D of the AP harness connector and ground. Verify repair.
13.a Yes; repair a short to voltage between pin E of the Accelerator Pedal (AP) harness connector and pin 2
of the CPC #3 connector. Verify repair.
14.a Yes; repair a short to voltage between pin F of the AP harness connector and pin 2 of the CPC #2
17. Disconnect the CPC. Inspect the CPC and the harness connectors for signs of damaged, bent, spread,
17.b No; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature.
3
243.2 SPN 3510/FMI 7 - GHG17

SPN 3510/FMI 7
Description Accelerator Pedal Sensor Failed High
Dash Lamps CEL
Analog Pedal Type
Williams Dual-Channel Analog Pedal
4

Connector
Body
APS1 1/7 A SENSOR 1
GND1 1/4 B APS1 GND
GND2 3/2 E APS2 GND
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
Check as follows:
damage found?
4. Measure the voltage between pin C of the AP harness connector and ground. Is the voltage above 5.5
volts?
5
4.a Yes; repair short to battery power between pin C of the AP harness connector and pin 8 of the CPC #1
5.a Yes; repair short to power between pin B of the AP harness connector and pin 4 of the CPC #1
6.a Yes; repair short to power between pin A of the AP harness connector and pin 7 of the CPC #1
8. Measure the voltage between pin D of the AP harness connector and ground. Is the voltage above 5.5
volts?
8.a Yes; repair short to battery power between pin D of the AP harness connector and pin 3 of the CPC #3
6
243.3 SPN 3510/FMI 8 - GHG17

SPN 3510/FMI 8
Description Accelerator Pedal Sensor Signal Failed
Dash Lamps CEL

Connector
Body
APS1 1/7 A SENSOR 1
GND2 3/2 E APS2 GND
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
7
Check as follows:
2. Inspect the AP and harness side connector for signs of damaged, bent, spread, corroded or unseated
damage found?
4. Measure the voltage between pins B and C of the AP harness side connector. Is the voltage above 5.5
volts?
4.a Yes; repair short to battery power between pin C of the AP harness side connector and pin 8 of the
5. Measure the resistance between pins C and B of the AP harness side connector. Is the resistance greater
than 10K ohms?
5.b No; repair the short between pins C and B of the AP harness side connector and pins 8 and 4 of the
6. Measure the resistance between pin C of the AP harness side connector and ground. Is the resistance
6.b No; repair the short to ground between pin C of the AP harness side connector and pin 8 of the CPC#1
7. Measure the resistance between pin C of the AP harness side connector and pin 8 of the CPC #1
8

7.b No; repair the open circuit between pin C of the AP harness side connector and pin 8 of the CPC #1
connector.
9. Measure the voltage between pins D of the AP harness side connector and ground. Is the voltage above
5.5 volts?
9.a Yes; repair short to battery power between pin D of the AP harness side connector and pin 3 of the
10. Measure the resistance between pin D of the AP harness side connector and ground. Is the resistance
10.b No; repair the short circuit between pin D of the AP harness side connector and ground. Verify repair.
11. Measure the resistance between pin D of the AP harness side connector and pin 3 of the CPC #3
connector. Is the resistance greater than five ohms?
11.a Yes; repair the open circuit between pin D of the AP harness side connector and pin 3 of the CPC #3
harness side connector.
9
245.1 SPN 3510/FMI 3 - GHG17

5V Sensor Supply Bank 2 Circuit Failed High
SPN 3510/FMI 3
Description 5V Sensor Supply Bank 2 Circuit Short to Power
Dash Lamps CEL
Verification Key ON
This fault indicates the Motor Control Module (MCM) detects a short to power (voltage greater than 5.3) on any of
the MCM pins, which are listed in the chart below. Inspect the harness and repair as necessary. Verify repairs.
MCM Pins for Short to Power Check

Component MCM Pin
Camshaft Position Sensor 82
Engine Oil Pressure Sensor 82
Fuel Compensation Pressure Sensor 82
HC Doser Fuel Pressure Sensor 82
Water Pump Speed Sensor (DD15AT / DD13 Optional) 82
Fan Speed Sensor (If equipped) 85
1
Check as follows:
3. Disconnect each component listed below (if equipped) one at a time, while monitoring fault code in
DiagnosticLink.
• Fuel Compensation Pressure Sensor
• HC Doser Fuel Pressure Sensor
• Camshaft Position Sensor
• Engine Oil Pressure Sensor
• Water Pump Sensor (DD15AT/DD13 Optional)
• Fan Speed Sensor (if equipped)
4. Does the fault code go inactive when a component is disconnected?
5. For the component in question, inspect the harness connector for signs of damaged, bent, spread,
connector. Are any signs of damage present?
5.b No; replace that component. Verify repairs.
7. Disconnect the engine harness 10-pin connector on the left side of engine.
8. Inspect the harness connector for signs of damaged, bent, spread, corroded or unseated (pushed out) pins
and signs of moisture in the connector or wire damage near the connector. Are any signs of damage
present?
2

10. Does the fault code go inactive when the engine harness 10-pin connector is disconnected?
10.a Yes; repair wiring harness between 10-pin connector and the Fan Speed Sensor (if equipped). Refer to
Original Equipment Manufacturer (OEM) literature to identify chassis components wired to the 10-pin
connector.
of wire damage. Are any signs of damage present?
15. Does the fault code go inactive when the MCM is disconnected?
16. With the components still disconnected, measure the voltage between pin 82 of the MCM 120-pin
connector and ground. Is any voltage present?
16.a Yes; repair the wire short to power on pin 82 of the MCM 120-pin connector. Verify repairs.
16.b No; repair the wire short to power on pin 85 of the MCM 120-pin connector. Verify repairs.
3
245.2 SPN 3510/FMI 4 - GHG17

5V Sensor Supply Bank 2 Circuit Failed Low
SPN 3510/FMI 4
Dash Lamps MIL, CEL
Check as follows:
3. Disconnect each component listed below (if equipped) one at a time, while monitoring fault code in
DiagnosticLink .
• Fuel Compensation Pressure Sensor
• HC Doser Fuel Pressure Sensor
• Camshaft Position Sensor
• Engine Oil Pressure Sensor
4
• Water Pump Sensor (DD15AT / DD13 Optional)

• Fan Speed Sensor (If equipped)
4. Does the fault code go inactive when component is disconnected?
5. For the component in question,inspect the harness connector for signs of damaged, bent, spread, corroded
or unseated (pushed out) pins and signs of moisture in the connector or wire damage near the connector.
Are any signs of damage present?
5.b No; replace that component. Verify repairs.
7. Disconnect the engine harness 10-pin connector on the left side of engine.
and signs of moisture in the connector or wire damage near the connector. Are any signs of damage are
present?
10. Does the fault code go inactive when the engine harness 10-pin connector is disconnected?
10.a Yes; repair wiring harness between 10-pin connector and the Fan Speed Sensor (If equipped). Refer to
Original Equipment Manufacturer (OEM) literature to identify chassis components wired to the 10-pin
connector.
of wire damage. Are any signs of damage present?
15. Does the fault code go inactive when the MCM is disconnected?
17. With the components still disconnected, measure the resistance between pin 82 of the MCM 120-pin
connector and ground. Is the resistance greater than 10K ohms?
17.a Yes; repair the wire short to ground on pin 85 of the MCM 120-pin connector. Verify repairs.
17.b No; repair the wire short to ground on pin 82 of the MCM 120-pin connector. Verify repairs.
5
246.1 SPN 3511/FMI 3 - GHG17

SPN 3511/FMI 3
Supply
Dash Lamps MIL, CEL
This SPN indicates that the ACM detects a short to power (voltage is greater than 3.29) on any of the ACM pins
listed in the table.
Component ACM Pin

Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor 27
DOC Inlet Temperature Sensor 107
Diesel Particulate Filter (DPF) Outlet Temperature Sensor 97
Selective Catalyst Reduction (SRC) Outlet Temperature 78
Sensor
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
1. Inspect the harness and repair as necessary.
1
246.2 SPN 3511/FMI 4 - GHG17

SPN 3511/FMI 4
Monitored Parameter ACM 3V Internal Power Supply
Dash Lamps MIL, CEL
This code indicates an Aftertreatment Control Module (ACM) internal failure. Replace the ACM. Refer to section
"Removal of the 1-BOX™ Aftertreatment Control Module" Refer to section "Removal of the 1-BOX™
Aftertreatment Control Module" or Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control
Module" Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .
2
248.1 SPN 3511/FMI 3 - GHG17

Remote Accelerator Pedal Supply Voltage Circuit Failed High
This code sets when the Common Powertrain Controller (CPC) detects the voltage on the sensor supply circuits is
out of range.
SPN 3511/FMI 3
Description Remote Accelerator Pedal Supply Circuit Short to Voltage or
Open
Monitored Parameter Remote Accelerator Pedal Voltage
Monitor Sequence Key On
Typical Duration None
Dash Lamps CEL
Engine Reaction Idle Only
Verification Ignition Key Cycle ON
Check as follows:
configuration.
1

4. Measure the voltage between remote throttle sensor supply (from pin 3 of the CPC connector #3) and
present?
4.b No; repair the open circuit between pin 3 of the CPC connector #3 and the remote throttle switch.
5. Is the voltage measured in step 4 greater than 5.5 volts?
5.a Yes; repair a short to battery power between pin 3 of the CPC connector #3 and the remote throttle
switch.
7. Measure the resistance between remote throttle sensor supply and pin 3 of CPC connector #3. Refer to
Original Equipment Manufacturer (OEM) literature for schematic information. Is the resistance less than five
ohms?
7.a Yes; replace the remote throttle switch.
7.b No; repair the open circuit between pin 3 of the CPC connector #3 and the remote throttle switch.
2
248.2 SPN 3511/FMI 4 - GHG17

Remote Accelerator Pedal Supply Voltage Circuit Failed Low
This code sets when the Common Powertrain Controller (CPC) detects the voltage on the sensor supply circuits is
out of range.
SPN 3511/FMI 4
Description Remote Accelerator Pedal Supply Circuit Short to Ground
Monitored Parameter Remote Accelerator Pedal Voltage
Dash Lamps CEL
Verification Ignition Key Cycle ON
Check as follows:
1. Is the vehicle equipped with a remote accelerator pedal?
configuration.
3
4. Measure the resistance between remote throttle switch sensor supply and ground. Refer to Original
Equipment Manufacturer (OEM) literature for schematic information. Is the resistance greater than 10k
ohms?
4.a Yes; replace the remote throttle switch.
4.b No; repair the short to ground between pin 3 of the CPC connector #3 and the remote throttle switch.
4
SPN 3511 (CPC3) (GHG17)
249.1 SPN 3511/FMI 3 - GHG17
Check as follows:
damage present?
CPC3 connector #4.
the voltage greater than two volts?
6.a Yes; repair wire (short to power) between pin 1 of the ambient temperature sensor harness connector
and pin 17 of the CPC3 connector #4.
6.b No; replace the ambient temperature sensor.
1
249.2 SPN 3511/FMI 14 - GHG17

Ambient Air Temp Sensor Ground Wire Shorted to Chassis
Check as follows:
damage present?
CPC3 connector #4.
the voltage greater than two volts?
6.a Yes; repair wire (short to power) between pin 1 of the ambient temperature sensor harness connector
and pin 17 of the CPC3 connector 4.
6.b No; replace the ambient temperature sensor.
2
247.1 SPN 3511/FMI 3 - GHG17

3V Sensor Supply Bank 1 Circuit Failed High
SPN 3511/FMI 3
Description This Fault Code Sets When the Motor Control Module MCM)
Detects a Voltage Greater than 3.2 Volts on 3 Volts Supply
Bank
Typical Enabling Conditions Circuit Voltage Greater than 3.2 Volts
Dash Lamps MIL, CEL
Possible causes:
• Internally shorted Intake Manifold Pressure Sensor
• Short to power on the Fuel Temperature sensor signal circuit
• Short to power on the Coolant Inlet Temperature sensor signal circuit
• Short to power on the Intake Manifold Temperature sensor signal circuit
• Short to power on the Engine Oil Temperature sensor signal circuit
• Short to power on the Coolant Outlet Temperature sensor signal circuit
• Short to power on the Intake Manifold Pressure/ Temperature sensor signal circuit
• Short to power on the Turbocharger Compressor Inlet Temperature sensor circuit
• Internally shorted MCM
1
3. Check the fault codes. Are any of the fault codes below also present?
• SPN 4193/FMI 3
• SPN 174/FMI 3
• SPN 175/FMI 3
• SPN 1636/FMI 3
• SPN 2630/FMI 3
• SPN 110/FMI 3
• SPN 2629/FMI 3
4. Disconnect and inspect the Intake Manifold pressure/temperature sensor electrical connector harness side.
Is there corrosion, damage or spread pins?
4.a Yes; Refer to section "Electrical Connector Inspection" and repair as necessary. Verify repair.
2
5. Recheck the fault code. Is fault code SPN 3511/FMI 3 still active?
Pressure/Temperature Sensor" . Verify Repair.

7. Disconnect and inspect the MCM 120-pin electrical connector. Is there corrosion, damage or bent pins?
7.a Yes; Refer to section "Electrical Connector Inspection" and repair as necessary. Verify repair.
9. Recheck the fault code. Is fault code SPN 3511/FMI 3 still active?
9.b No; find and repair the short to power. Refer to the chart below.
Sensor Sensor pin MCM pin

Fuel Temperature Sensor 2 77
Coolant Inlet Temperature Sensor 2 80
Coolant Outlet Temperature Sensor 2 110
Intake Manifold Temperature Sensor 2 106
Engine Oil Temperature Sensor 2 108
Intake Manifold Pressure/ Temperature 3 119
Sensor
Turbocharger Compressor Inlet 2 86
Temperature Sensor
3
247.2 SPN 3511/FMI 4 - GHG17

3V sensor supply bank 1 circuit failed low
This code indicated an Motor Control Module (MCM) internal failure. Replace the MCM. Refer to section "Removal
of the Motor Control Module" Refer to section "Removal of the Motor Control Module"
SPN 3511/FMI 4
Monitored Parameter MCM 3V Internal Power Supply
Dash Lamps MIL, CEL
Engine Reaction
4
250.1 SPN 3512/FMI 3 - GHG17

SPN 3512/FMI 3
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
This fault indicates that the Aftertreatment Control Module (ACM) detects a short to power (voltage greater than
3.2V) on any of the ACM pins in the table below.
1
ACM Pins for Short to Power Check

Component ACM Pin
DEF Tank Temperature Signal 103
DEF Tank Level Signal 109
Not Used By OEM 76
Not Used By OEM 78
Not Used By OEM 63
Not Used By OEM 83
Not Used By OEM 85
Inspect the harness and repair as necessary.
2
250.2 SPN 3512/FMI 4 - GHG17

SPN 3512/FMI 4
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
This code indicates an Aftertreatment Control Module (ACM) internal failure. Replace the ACM. Refer to section
"Removal of the 1-BOX™ Aftertreatment Control Module" Refer to section "Removal of the 1-BOX™
Aftertreatment Control Module" .
3
251.1 SPN 3512/FMI 3 - GHG17

3 V Sensor Supply Bank 2 Circuit Failed High
This fault indicates that the Motor Control Module (MCM) detects a short to power (voltage greater than 3.2) on
any of the MCM pins in the table below.
MCM Pins for Short to Power Check

Component MCM Pin
Fuel Temperature Sensor, Engine Coolant Temperature 55
Sensor
Fuel Temperature Sensor 77
Charge Air Cooler Outlet Pressure Sensor 102
Engine Oil Temperature/Pressure Sensor 108
Engine Coolant Temperature Sensor 110
Inspect the harness and repair as necessary.
1
251.2 SPN 3512/FMI 4 - GHG17

3V Sensor Supply Bank 2 Circuit Failed Low
This code indicates a Motor Control Module (MCM) internal failure. Replace the MCM. Refer to section "Removal
of the Motor Control Module" Refer to section "Removal of the Motor Control Module" .
SPN 3512/FMI 4
Monitored Parameter MCM 3V Internal Power Supply
Dash Lamps MIL, CEL
Engine Reaction
2
252.1 SPN 3556/FMI 0 - GHG17

Regeneration Temperature - Out of Range High
SPN 3556/FMI 0
Description This code sets when the ACM detects that the DOC outlet
temperature sensor is greater than the modeled threshold.
Monitored Parameter Diesel Oxidation Catalyst (DOC) Temperature Outlet
temperature sensor.
Typical Enabling Conditions Aftertreatment 1 Hydrocarbon Doser Data Valid But Above
Normal Operational Range - Most Severe Level
Dash Lamps MIL, CEL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 3246 FMI,3, 4 or 8 and SPN 3250 FMI 3, 4, or 8 also
present?
3.a Yes; diagnose and repair those fault codes first. Verify repair.
4. Are there any Hydrocarbon (HC) doser low pressure fault codes present?
4.a Yes; diagnose HC doser low pressure fault codes first. Verify repair.
5. Perform a low temp Aftertreatment Device (ATD) regeneration; Refer to section "GHG17 Perform Performance Check
- Low Temperature ATD" . Go to step 6.
6. After the low temperature regeneration has run for at least 20 minutes, monitor the DOC outlet temperature
sensor reading. Is the reading within 25°C (45°F) of the other exhaust temperature sensor readings?
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .Verify repair.
For 2-BOX , Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .Verify repair.
7. Visually inspect the exhaust system for leaks. Are there exhaust leaks present?
WARNING
ENGINE EXHAUST
1
WARNING
PERSONAL INJURY
7.b No; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Verify repair.
2
252.2 SPN 3556/FMI 1 - GHG17

SPN 3556/FMI 1
Description This Code Sets when the Exhaust Temperature Does Not
Increase Above the Modeled Threshold when Regeneration is
Enabled
Monitored Parameter Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor
Typical Enabling Conditions Regeneration Enabled, 1100 to 2050 rpm, 50% to 100%
Engine Load
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
3. Check for multiple codes. Are there DOC outlet temperature sensor drift codes, DOC outlet temperature
sensor stuck fault codes, or DOC outlet temperature sensor circuit fault codes present?
4. Is there any Hydrocarbon (HC) doser low pressure fault codes present?
4.a Yes; diagnose HC doser low pressure fault codes first.
5. Visually inspect the exhaust system for leaks; look for signs of soot trails indicating a system leak. Are there
exhaust leaks present?
3

6. Remove and inspect the Hydrocarbon (HC) fuel doser injection valve. Refer to section "Removal of the Hydrocarbon
Fuel Doser Injector Valve" . Is the HC fuel doser injection valve plugged?
6.a Yes; replace the Hydrocarbon (HC) doser injection valve and clean the port. Refer to section "Installation of
the Hydrocarbon Fuel Doser Injector Valve" . Verify repair.

7. Reinstall the HC doser injection valve. Refer to section "Installation of the Hydrocarbon Fuel Doser Injector Valve" .
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

9. Perform a GHG17 Perform Performance Check - Low Temperature ATD. Run the service routine for 20
minutes allowing for the aftertreatment temperatures to stabilize.
10. Is the DOC outlet temperature sensor reading within 25°C (45°F) of the DOC inlet temperature sensor?
10.a Yes; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Go to step 11.
10.b No; replace the DOC outlet temperature sensor. Refer to section "Removal of the Diesel Oxidation Catalyst Outlet
Temperature Sensor" . Go to step 11.

12. Run service routine "DOC Lightoff Temperature Reset" under the Actions, Aftertreatment drop-down menu.
Verify repair.
4
252.1 SPN 3556/FMI 0 - GHG17

Before starting this troubleshooting procedure, please verify if an Advanced Diagnostic (AD) version is available,
and continue with that version if available. ADs provide enhanced functionality that increase the accuracy of the
troubleshooting process and are preferred over traditional troubleshooting. The ADs are identified in
DiagnosticLink by the magic wand icon next to the fault, and the word "Advanced" label in the "Troubleshooting
Type" field.
Regeneration Temperature - Out of Range High
SPN 3556/FMI 0
Description This code sets when the ACM detects that the DOC outlet
temperature sensor is greater than the modeled threshold.
Monitored Parameter Diesel Oxidation Catalyst (DOC) Temperature Outlet
temperature sensor.
Typical Enabling Conditions Aftertreatment 1 Hydrocarbon Doser Data Valid But Above
Normal Operational Range - Most Severe Level
Dash Lamps MIL, CEL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 3246 FMI,3, 4 or 8 and SPN 3250 FMI 3, 4, or 8 also
present?
3.a Yes; diagnose and repair those fault codes first. Verify repair.
4. Are there any Hydrocarbon (HC) doser low pressure fault codes present?
4.a Yes; diagnose HC doser low pressure fault codes first. Verify repair.
5. Perform a low temp Aftertreatment Device (ATD) regeneration; Refer to section "GHG17 Perform Performance Check
- Low Temperature ATD" . Go to step 6.
6. After the low temperature regeneration has run for at least 20 minutes, monitor the DOC outlet temperature
sensor reading. Is the reading within 25°C (45°F) of the other exhaust temperature sensor readings?
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .Verify repair.
For 2-BOX , Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor" .Verify repair.
7. Visually inspect the exhaust system for leaks. Are there exhaust leaks present?
WARNING
ENGINE EXHAUST
5
WARNING
PERSONAL INJURY
6
252.2 SPN 3556/FMI 1 - GHG17

Type" field.
SPN 3556/FMI 1
Description This Code Sets when the Exhaust Temperature Does Not
Increase Above the Modeled Threshold when Regeneration is
Enabled
Monitored Parameter Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor
Typical Enabling Conditions Regeneration Enabled, 1100 to 2050 rpm, 50% to 100%
Engine Load
Dash Lamps MIL, CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
3. Check for multiple codes. Are there DOC outlet temperature sensor drift codes, DOC outlet temperature
sensor stuck fault codes, or DOC outlet temperature sensor circuit fault codes present?
4. Is there any Hydrocarbon (HC) doser low pressure fault codes present?
7
4.a Yes; diagnose HC doser low pressure fault codes first.

5. Visually inspect the exhaust system for leaks; look for signs of soot trails indicating a system leak. Are there
exhaust leaks present?
6. Remove and inspect the Hydrocarbon (HC) fuel doser injection valve. Refer to section "Removal of the Hydrocarbon
Fuel Doser Injector Valve" . Is the HC fuel doser injection valve plugged?
6.a Yes; replace the Hydrocarbon (HC) doser injection valve and clean the port. Refer to section "Installation of
the Hydrocarbon Fuel Doser Injector Valve" . Verify repair.

7. Reinstall the HC doser injection valve. Refer to section "Installation of the Hydrocarbon Fuel Doser Injector Valve" .
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

9. Perform a GHG17 Perform Performance Check - Low Temperature ATD. Run the service routine for 20
minutes allowing for the aftertreatment temperatures to stabilize.
10. Is the DOC outlet temperature sensor reading within 25°C (45°F) of the DOC inlet temperature sensor?
10.a Yes; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " . Go to step 11.
Temperature Sensor" . Go to step 11.

12. Run service routine "DOC Lightoff Temperature Reset" under the Actions, Aftertreatment drop-down menu.
Verify repair.
8
253.1 SPN 3563/FMI 3 - GHG17

Intake manifold pressure circuit failed high
1. Disconnect the intake manifold pressure/temperature sensor.
2. Inspect the intake manifold pressure/temperature sensor harness for bent, spread, or corroded pins.
4. Measure the voltage between pin 1 of the intake manifold pressure/temperature sensor harness connector
and ground.
4.a If the voltage is greater than 5 volts, repair the short to battery between pin 1 of the intake manifold
pressure/temperature sensor harness connector and pin 87 of the Motor Control Module (MCM) 120-
4.b If the voltage is less than 5 volts, Go to step 5.
5. Measure the voltage between pin 2 and 4 of the intake manifold pressure/temperature sensor harness
connector.
5.a If voltage is present, replace the intake manifold pressure/temperature sensor .
Refer to section "Removal of the Intake Pressure/Temperature Sensor" .
5.b If no voltage is present, repair the open between pin 4 of the intake manifold pressure/temperature
sensor harness connector and pin 102 of the MCM 120-pin connector. Verify repairs.
1
253.2 SPN 3563/FMI 4 - GHG17

Intake Manifold Pressure Circuit Failed Low
SPN 3563/FMI 4
Description Intake Manifold Pressure Circuit Failed Low
Monitored Parameter Intake Manifold Pressure Circuit
Dash Lamps MIL, CEL
1. Disconnect the intake manifold pressure/temperature sensor harness connector.

2. Inspect the intake manifold pressure/temperature sensor harness connector for bent, spread or corroded
pins.
2.a If the pins are bent, spread or corroded, repair as necessary. Verify repairs.
4. Measure the voltage between pins 2 and 4 of the intake manifold pressure/temperature sensor harness
connector.
4.a If 4.5-5.5 volts are present, Go to step 5.
4.b If less than 4.5 are volts present, repair the open between pin 2 of the intake manifold
pressure/temperature sensor connector and pin 58 of the Motor Control Module (MCM) 120-pin
7. Measure the resistance between pin 1 on the harness side of the intake manifold pressure/temperature
sensor harness connector and pin 87 of the MCM 120-pin connector.
7.a If the resistance is greater than 5 ohms, repair the open between pin 1 on the harness side of the
intake manifold pressure/temperature sensor harness connector and pin 87 of the MCM 120-pin
connector.
8. Measure the resistance between pin 1 on the harness side of the intake manifold pressure/temperature
sensor harness connector and ground.
8.a If the resistance is less than 1K ohms, repair the short-to-ground between pin 1 of the intake manifold
pressure/temperature sensor harness connector and pin 87 of the MCM 120-pin connector.
8.b If the resistance is greater than 1K ohms, replace the intake manifold pressure/temperature sensor.
Refer to section "Removal of the Intake Pressure/Temperature Sensor" .
2
253.3 SPN 3563/FMI 10 - GHG17

SPN 3563/FMI 10
Description This Fault Code Sets When the Difference Between
Barometric Pressure and Intake Manifold Pressure Sensors is
Larger Than a Calibrated Threshold
Monitored Parameter Barometric Pressure and Intake Manifold Pressure
Typical Enabling Conditions Ignition OFF for a Minimum of 30 Minutes, Then Turn the
Ignition to the ON Position. Engine Speed less than 250 rpm
Typical Duration One Second
Dash Lamps MIL, CEL
Verification Ignition OFF for 30 minutes, then Turn Ignition ON with the
Engine Not Running
Check as follows:
3. Check for multiple fault codes. Are fault codes also present?
4. Compare the barometric pressure reading in the Motor Control Module (MCM) to the local barometric
pressure reading. Is the barometric pressure sensor reading in the MCM within 6.9 kPa (1 psi) of the local
barometric pressure reading?
6. Disconnect and inspect the intake manifold pressure sensor electrical connector harness side. Is there any
corrosion present?
6.a Yes; replace the intake manifold pressure sensor and the electrical connector on the harness. Refer to
section "Removal of the Intake Pressure/Temperature Sensor" . Verify repairs.

7.a Yes; replace the intake manifold pressure sensor and the electrical connector on the harness. Refer to
section "Removal of the Intake Pressure/Temperature Sensor" . Verify repairs.
3
253.4 SPN 3563/FMI 16 - GHG17

SPN 3563/FMI 16
Detects That the Difference between the Commanded Boost
Pressure and the Actual Boost Pressure Exceeds a Calibrated
Threshold
Typical Enabling Conditions Engine Speed Between 1130 and 1650 rpm, Engine Coolant
Temperature greater than 65°C (149°F)
Monitor Sequence When The Enabling Conditions Are Met
Dash Lamps MIL
Verification Once Engine Coolant Temperature is greater than 65°C
(149°F) Drive at Highway Speed with Loaded Trailer Above
1130 rpm Continuously for Five Minutes
Check as follows:
3. Check the MCM software level. Compare the MCM software and fuel map to the chart. Is the MCM
software equal or greater than specified in the chart below?
4
Engine MCM Software

DD13 380 - 410HP 1450 rpm Go to step 4.
DD13 525HP 1850 rpm 6.5.0.2 ZGS 001
DD13 - All Other 6.5.0.2 ZGS 002
DD15 6.5.0.2 ZGS 003
DD16 6.5.0.2 ZGS 002

3.b No; update the MCM software and perform the repair verification. If the fault returns, Go to step 5.
4. Update the MCM software level using the latest server information. Once the MCM software has been
updated, perform the repair verification. If the fault code returns, Go to step 5.
5. Compare the Barometric Pressure sensor reading in DiagnosticLink to the barometric pressure for your
area. Are the readings within 6.9 kPa (1 psi) of each other?
6. Compare intake manifold pressure to barometric pressure using the chart below. Tolerances will vary
depending on the intake air temperature. Is the intake manifold pressure within range of barometric
pressure?
Intake Air Temperature Tolerance

-40°C to 10°C (-40°F to 50°F) +/- 8.6 kPa (1.25 psi)
10°C to 110°C (50°F to 230°F) +/- 5.6 kPa (0.81 psi)
110°C to 130°C (230°F to 266°F) +/- 8.6 kPa (1.25 psi)

8. Disconnect and inspect the intake manifold pressure sensor (8) electrical connector harness side. Is there
any corrosion present?
5
8.a Yes; replace the intake manifold pressure sensor and electrical connector.
Sensor" .
10. Inspect the intake manifold electrical connector sensor side. Are any of the pins or the connector
damaged?
10.a Yes; replace the intake manifold pressure sensor and electrical connector. Refer to section "Removal of the
Intake Pressure/Temperature Sensor" . Verify repair.
10.b No; replace the intake manifold electrical connector.

11. Monitor the DOC inlet pressure sensor voltage. Is the DOC inlet pressure sensor voltage between 0.44 and
0.56 volts?
12. Monitor the DPF inlet pressure sensor voltage. Is the DPF inlet pressure sensor voltage between 0.44 and
0.56 volts?
6

12.b No; replace the DPF inlet pressure sensor.
13. Disconnect and inspect the turbocharger inlet elbow and outlet pipe. Are there signs of oil residue, fluid
contamination or debris?
13.a Yes; replace the turbocharger. If the oil has contaminated the ATD, replace the ATD.
Refer to section "Removal of the 1-BOX™ from the Vehicle"
Refer to section "Removal of the 2-Box (2V2) from the Vehicle"
For vehicles with a DD13 or DD15 engine, Refer to section "Removal of the DD13 and DD15 Turbocharger"
For vehicles equipped with a DD16 engine, Refer to section "Removal of the DD16 Turbocharger"
13.b No; reinstall the turbocharger inlet and outlet pipes, then Go to step 14.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
14. Start and run the engine until the engine coolant temperature is greater than 65°C (149°F).
15. Using DiagnosticLink, start a parked regeneration.
16. While the parked regeneration is running, monitor the DOC inlet pressure. Is the DOC inlet pressure greater
than 20 kPa (2.9 psi)?
16.a Yes; clean the face of the DOC. Refer to section "Diesel Oxidation Catalyst Air Cleaning" . Verify repair.
17. Does the DOC inlet pressure start high and stay high?
17.a Yes; the DOC face plugging is causing back pressure in the system. Perform the DOC face plugging
routine in DiagnosticLink or clean the face of the DOC.
Refer to section "GHG17 Diesel Oxidation Catalyst Face Cleaning" . Verify repair.
Refer to section "Diesel Oxidation Catalyst Air Cleaning" . Verify repair.
17.b No; replace the turbocharger. Verify repair.
For vehicles with a DD13 or DD15 engine, Refer to section "Removal of the DD13 and DD15 Turbocharger"
For vehicles equipped with a DD16 engine, Refer to section "Removal of the DD16 Turbocharger"
7
253.5 SPN 3563/FMI 18 - GHG17

Inlet Manifold Pressure Low
SPN 3563/FMI 18
Description Compare actual to desired boost pressure. When the
difference exceeds a calibrated threshold, the fault is set.
Engine speed between 1130 rpm and 1650 rpm
Torque greater than 1250 N·m (921 lb·ft)
Coolant Temperature greater than 65 °C (149 °F)
Barometric Pressure greater than 755 mbar (10.9 psi)
Ambient Temperature greater than -8 °C ( 17.6 °F)
Engine speed gradient between -10 rpm/sec and +10 rpm/sec
Fuel mass gradient between -10 mg/st and +10 mg/st
Monitor Sequence After enabling conditions are met, a 15 second stability time is
followed by a 10s calculation of the manifold pressure error
Execution Frequency Every 10 seconds after the stability time has been met
Dash Lamps MIL, CEL
Verification At operating temperature of 71 °C (160 °F). Drive at highway
speed with loaded trailer above 1130 rpm continuously for five
minutes
8
Check as follows:
found?
depending on the intake air temperature. Is the intake manifold pressure within range of barometric
pressure?

-40°C to 10°C (-40°F to 50°F) +/- 8.6 kPa (1.25 psi)
10°C to 110°C (50°F to 230°F) +/- 5.6 kPa (0.81 psi)
110°C to 130°C (230°F to 266°F) +/- 8.6 kPa (1.25 psi)

9
6. Inspect intake manifold pressure/temperature sensor connector for bent, spread or corroded pins. Is any
damage found?
6.a Yes; repair the intake manifold pressure/temperature sensor connector as necessary. Verify repairs.
10
253.6 SPN 3563/FMI 21 - GHG17

SPN 3563/FMI 21
Description This Fault Sets When Ambient and Inlet Manifold Pressure Difference is
Out of Range Under a Load
Monitored Parameter Inlet Manifold Pressure and Barometric Pressure
Typical Enabling Conditions Engine Parameter Min Max
Engine Torque (N·m) 1400 3000
Engine Coolant Outlet Temperature °C (°F) 65 (149)
Dash Lamps SEL, CEL, MIL
Engine Reaction 25% Derate + Engine Shutdown
Verification Once Engine is at Standard Operating Temperature, Drive at Highway
Speed with Loaded Trailer Between 1350 To 1800 rpm Continuously for
Five Minutes.
found?
4.b No; replace the Motor Control Module (MCM). Refer to section "Removal of the Motor Control Module" . Verify
repairs.
corroded, or unseated (pushed out) pins and signs of moisture in the connector or wire damage near the
11
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY

9. At idle, compare inlet manifold air pressure to barometric pressure.
10. Is the inlet manifold air pressure within 10.3 kPa (1.5 psi) of barometric pressure?
10.b No; replace the inlet manifold pressure/temperature sensor. Refer to section "Removal of the Intake

12. Visually inspect exhaust system for leaks or damage, including manifold, gaskets, turbine housing, Exhaust
Gas Recirculation (EGR) valve, and Aftertreatment Device (ATD). Are any leaks found?
12.a Yes; repair as necessary. Verify repairs. If fault code returns, Go to step 13.
closes. Is any binding or damage found?
12

control up to 95% - (Click Set). Wastegate will open with air psi available. Does wastegate open when
commanded?
Note : Wastegate activates at 0% or 95%. There is no response at 50%.
19. Move slide control down to 0. Does wastegate close when commanded?
any damage found?
Verify repairs. If fault code returns, Go to step 27.
23. Using DiagnosticLink, monitor EGR delta P voltage (pin 109).
25. Remove the EGR delta P sensor from the mounting pad; leave electrical harness connected.
26.b No; replace the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" . Verify repairs.
28. Inspect the EGR delivery pipe delta P pressure ports for blockage. Is any blockage found?
28.a Yes; clean the venturi pipe and reinstall the sensor. Verify repairs.
29. Remove the EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for excessive build-up
or blockage. Is any excessive build-up or blockage found?
Refer to section "Removal of the Exhaust Gas Recirculation Venturi" .
29.a Yes; clean piping and replace EGR cooler. Verify repairs.
30. Disconnect the EGR valve actuator pull rod. Inspect the ball sockets on the pull rod for free movement. Do
the sockets rotate or move freely?
30.b No; replace the EGR valve actuator pull rod. Verify repairs.
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Pull
Rod" .
For the DD16: Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve Actuator Pull Rod" .
Note : Some resistance is normal; however, the actuator should not bind in any particular spot.
13
31. Physically move the EGR butterfly from stop-to-stop to check for full travel (some drag is normal). Verify
EGR valve moves. Does the EGR butterfly move stop-to-stop?
31.a Yes; reconnect the EGR valve actuator pull rod to the EGR valve and EGR actuator. Clear codes and
verify repairs. If fault returns, Go to step 32.
31.b No; replace the EGR valve. Verify repairs.
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Manifold"
For the DD16: Refer to section "Removal of the DD16 Exhaust Manifold"
For the DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve"
For the DD16: Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve"
33.a Yes; repair as necessary. Clear codes and verify repairs. If fault returns, Go to step 34.
blockages found?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
36. Start engine, allow to warm-up until coolant temperature is greater than 65°C (149°F).
Note : Normal DOC pressure is less than 10 kPa (1.5 psi) for a 1-Box™ emissions package and 13 kPa (1.9 psi)
for a Two-Box option.
14
37. Using DiagnosticLink, monitor DOC inlet pressure while performing a parked regeneration. Refer to section
"Performing a Parked Regeneration - GHG17" . Does the DOC inlet pressure start out high and stay high?
37.a Yes; the DOC(s) are plugged. Perform DOC unplug routine. Refer to section "Diesel Oxidation Catalyst
Face Cleaning." Verify repairs.
37.b No; if DOC inlet pressure starts out high and then decreases, the DOC(s) were plugged and the
Parked Regeneration cleared them. Clear any fault codes. Verify repairs. If DOC pressure reading is
low or fault code returns, Go to step 38.
15
256.1 SPN 3597/FMI 3 - GHG17

High Side Digital Output 1 Circuit Failed High
SPN 3597/FMI 3
Description High Side Digital Output 1 Circuit Short to Power
Monitored Parameter High Side Digital Output 1 Circuit
Typical Duration 1 second
Dash Lamps MIL, CEL
Verification Ignition Key Cycle
Check as follows:
Note : This fault code sets when the Aftertreatment Control Module (ACM) detects a short to power on pin(s) 1, 3,
5, 62 or 66 of the ACM 120-pin connector.
2. Inspect wiring harness from ACM to the Aftertreatment Devices (ATD), including Diesel Exhaust Fluid
(DEF) pump, Diesel Exhaust Fluid (DEF) Dosing Unit, and DEF tank Controller Area Network (CAN) header
(if equipped) for damage, wear, or heat exposure. Is any damage found?
1
2.a Yes; repair as necessary. Verify repair with ignition key cycle.
4. Inspect the ACM 120-pin harness connector for damage, overheated or corroded pins. Was any damage
found?
6. Measure voltage between pin 1 of the 120-pin ACM connector, harness side, and battery ground. Is battery
voltage present?
6.a Yes; repair the short to power between pin 1 of the 120-pin ACM connector and pin 2 of the DEF pump
connector. Verify repair with ignition key cycle.
voltage present?
7.a Yes; repair the short to power between pin 3 of the 120-pin ACM connector and pin 4 of the DEF
Dosing Unit connector. Verify repair with ignition key cycle.
voltage present?
8.a Yes; repair the short to power on pin 5 of the 120-pin ACM connector. Verify repair with ignition key
cycle.
9. Measure voltage between pin 62 of the 120-pin ACM connector, harness side, and battery ground. Is
battery voltage present?
9.a Yes; repair the short to power between pin 62 of the 120-pin ACM connector and pin 3 of the CAN DEF
tank connector (if equipped). Verify repair with ignition key cycle.
10. Measure voltage between pin 66 of the 120-pin ACM connector, harness side, and battery ground. Is
battery voltage present?
10.a Yes; repair the short to power on pin 66 of the 120-pin ACM connector. Verify repair with ignition key
cycle.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .
For 2-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .
2
256.2 SPN 3597/FMI 4 - GHG17

SPN 3597/FMI 4
Description High Side Digital Output 1 Circuit Short to Ground
Dash Lamps MIL, CEL
4-Pin Circuit ACM Pin Conn

ector
Pin 1 Pump rpm Feedback 95
Pin 2 Pump Supply 1
Pin 3 Pump rpm Control 20
Pin 4 Pump GND 31
3
Dosing Unit
8-Pin Circuit ACM Pin Conn
ector
1 Dosing Unit Low Side 28
2 Dosing Unit High Side 33
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
Analog DEF Tank Circuit ACM Pin Conn

ector
1 DEF TANK LEVEL SIG 109
2 GROUND 102
3 DEF TANK TEMP SIG 103
4 GROUND 102
Check as follows:
Note : This fault code sets when the Aftertreatment Control Module (ACM) detects a short to ground on pin(s) 1 or
2. Inspect wiring harness from the ACM to the Aftertreatment Devices (ATD), including Diesel Exhaust Fluid
(DEF) pump, doser unit, and DEF tank Controller Area Network (CAN) header (if equipped) for damage,
wear, or chaffing. Is any damage found?
4. Inspect dosing unit harness connector for bent, spread, or corroded pins. Was any damage found?
4.b No; turn the ignition OFF. Go to step 5.
Note : Additional open circuit fault codes will set with the DEF doser disconnected. Disregard the new fault codes
at this time.
6. Does the SPN 3597/FMI 4 fault code change or go inactive?
6.a Yes; replace the DEF doser unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify repair
with ignition key cycle.
6.b No; turn ignition OFF. Go to step 7.
7. Disconnect the DEF pump harness connector.
8. Inspect DEF pump harness connector for bent, spread, or corroded pins. Was any damage found?
Note : Additional open circuit fault codes will set with the DEF pump disconnected. Disregard the new fault codes
at this time.
4

10.a Yes; replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" .
12. Inspect DEF tank header harness connector for bent, spread, or corroded pins. Was any damage found?
Note : Additional open circuit fault codes will set with the DEF tank header disconnected. Disregard the new fault
codes at this time.
14.a Yes; replace DEF tank header. Refer to section "Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header
Unit" .

16. Inspect the ACM 120-pin harness connector for damaged, loose, or corroded pins. Was any damage
found?
17. Measure resistance between pin 1 of the ACM 120-pin connector, harness side and battery ground. Is the
17.b No; repair the short to ground between pin 1 of the ACM 120-pin connector and pin 2 of the DEF pump
connector. Verify repair with ignition key cycle.
18. Measure the resistance between pin 3 of the ACM 120-pin connector, harness side and battery ground. Is
the resistance greater than 10k ohms?
18.a Yes; replace ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .
18.b No; repair the short to ground between pin 3 of the 120-pin ACM connector and pin 4 of the DEF
dosing unit. Verify repair with ignition key cycle.
5
SPN 3597 (CPC3) (GHG17)
254.1 SPN 3597/FMI 3 - GHG17

2 LIN 3/47 LIN COM
This fault indicates the CPC3 detects battery voltage on pin 21 of connector #3, with the ignition in the OFF
position. Repair short to battery power between pin 21 of the CPC3 connector #3, and pin 1 of the right shift stalk
lever connector.
1
255.1 SPN 3597/FMI 3 - GHG17

SPN 3597/FMI 3
Description Proportional valve bank 1 circuit failed high
Monitored Parameter Proportional valve bank 1 circuit
Dash Lamps MIL, CEL

3.a If the voltage is greater than 11.5 volts, repair short to power between pin 1 of the front Jake Brake®
solenoid and pin 66 of the MCM 120-pin connector.
3.b If no voltage is present, Go to step 4.
4. Measure the voltage between pin 91 of the MCM and ground.
4.a If the voltage is greater than 11.5 volts, repair short to power between pin 2 of the Jake Brake®
4.b If no voltage is present, replace the MCM. Refer to section "Removal of the Motor Control Module" .
1
255.2 SPN 3597/FMI 4 - GHG17

Proportional Valve Bank 1 Circuit Failed Low
Check as follows:
2. Disconnect the front valve cover fuel injector harness connector.
present?
5. Using DiagnosticLink , monitor fault code SPN 3597/ FMI 4. Does the fault code change or go inactive?
5.b No; Turn the ignition OFF. Go to step 9.
7. Remove the valve cover and disconnect the wires from the low engine brake solenoid.
8. Measure the resistance between pin 14 on the valve cover side of the fuel injector harness connector and
ground. Is the resistance less than 10K ohms?
8.a Yes; replace the front under valve cover fuel injector harness. Refer to section "Removal of the Two-Piece Fuel
Injector Wiring Harness - Two-Filter System" .
8.b No; replace the engine brake solenoid. Refer to section "Removal of the Engine Brake Solenoid" . Verify repairs.
2
9. Disconnect the engine Original Equipment Manufacturer (OEM) 10-pin connector.

present?
12. Using DiagnosticLink, monitor fault code SPN 3597/FMI 4. Does the fault code change or go inactive?
12.a Yes; inspect fan wiring and solenoid. For wiring schematic information, refer to OEM literature.
14. Inspect the MCM 120-pin and the 120-pin harness connector for signs of corrosion, spread, unseated
(pushed out) or damaged pins, connector seal for damage (signs of water or oil intrusion) or signs of wire
damage.
14.a If any signs of damage are found, repair as necessary.
14.b If no signs of damage, Go to step 15.
16. Using DiagnosticLink, monitor fault code SPN 3597/FMI 4. Does the fault code change or go inactive?
17. Measure resistance from pin 91 of the MCM 120-pin harness connector and ground. Is resistance greater
than 10K ohms?
17.a Yes; repair the short to ground on pin 93 of the MCM 120-pin harness connector. Verify repairs.
17.b No; repair the short to ground on pin 91 of the MCM 120-pin harness connector. Verify repairs.
3
257.1 SPN 3598/FMI 3 - GHG17

Proportional valve bank 2 circuit failed high
SPN 3598/FMI 3
Description Proportional Valve Bank 2 Circuit Failed High
Monitored Parameter Motor Control Module (MCM) Bank 2 Power
Dash Lamps MIL, CEL
Engine Reaction

3.a If the voltage is greater than 11.5 volts, repair short to power between pin 2 of the rear Jake Brake®
3.b If no voltage is present, Go to step 4. .
4. Measure the voltage between pin 64 of the MCM and ground.
4.a If the voltage is greater than 11.5 volts, repair short to power between pin 2 of the Electronic Dosing
Valve (EDV) and pin 64 of the MCM 120-pin connector.
4.b If no voltage is present, replace the MCM. Refer to section "Removal of the Motor Control Module" .
1
257.2 SPN 3598/FMI 4 - GHG17

Proportional Valve Bank 2 Circuit Failed Low.
SPN 3598/FMI 4
Description Proportional Valve Bank 2 Circuit Failed Low
Monitored Parameter Proportional Valve Bank 2 circuit
Dash Lamps MIL, CEL
Check as follows:
Note : Other circuit low fault codes may set as a result of SPN 3598/FMI 4.
2
A Engine Harness Side

B Valve Cover Side

connector seal for damage (signs of water or oil intrusion). Is there any damage found?
Note : Additional fault codes will be present as a result of turning the ignition ON while there are disconnected
components. Disregard these new fault codes at this time.
4. Using DiagnosticLink , does SPN 3598/FMI 4 fault code become inactive with the rear fuel injector harness
disconnected?
6. Disconnect the rear Jake Brake® electrical harness connector.
7. Measure resistance between either terminal on the Jake Brake® solenoid and ground. Is the resistance
greater than 10k ohms?
7.a Yes; install a new rear fuel injector valve cover harness.
7.b No; replace the Jake Brake® solenoid.
Refer to section "Removal of the Camshafts" .
Refer to section "Removal of the Exhaust Rocker Shaft Assembly" . Verify repairs.
8. Disconnect the fuel cutoff valve connector.
9. Inspect the harness connector and valve for bent or spread pins; inspect the connector seal for damage
(signs of water or oil intrusion). Is there any damage found?
3

10. Using DiagnosticLink, does SPN 3598/FMI 4 become inactive with the fuel cutoff valve disconnected?
10.a Yes; replace the HC doser block assembly. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
Verify repairs.
11. Disconnect the electronic dosing valve connector.
13. Using DiagnosticLink, does SPN 3598/FMI 4 become inactive with the electronic dosing valve
disconnected?
13.a Yes; replace the Hydrocarbon (HC) doser block assembly. Refer to section "Removal of the Hydrocarbon Fuel
Doser Block " . Verify repairs.

14. Disconnect the Exhaust Gas Recirculation (EGR) valve actuator connector.
(signs of water or oil intrusion). Is there any damage present?
16. Using DiagnosticLink, does SPN 3598/FMI 4 become inactive with the EGR valve disconnected?
16.a Yes; replace the EGR valve.
For DD13 and DD15: Refer to section "Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator" .
For DD16: Refer to section "Removal of the DD16 Exhaust Gas Recirculation Valve Actuator" . Verify repairs.
17. Is vehicle equipped with variable speed water pump?
18. Disconnect the variable speed water pump connector.
19. Inspect the harness connector and water pump for bent or spread pins; inspect the connector seal for
damage (signs of water or oil intrusion). Is there any damage found?
20. Using DiagnosticLink, does SPN 3598/FMI 4 become inactive with the variable speed water pump
disconnected?
20.a Yes; replace the variable speed water pump. Refer to section "Removal of the Variable Speed Water Pump" . Verify
repairs.
21. While monitoring fault code, wiggle-test the harness. Does SPN 3598/FMI 4 change or become inactive?
physical damage and repair as necessary. Verify repairs.
24. Inspect the 120-pin connector and MCM for bent or spread pins; inspect the connector seal for damage
4

25. Measure the resistance between pin 62 on the 120-pin MCM harness side connector and battery ground. Is
the resistance greater than 10K ohms?
25.b No; repair the short to ground on pin 62 of the MCM 120-pin connector. Verify repairs.
26. Measure the resistance between pin 64 of the 120-pin MCM harness side connector and battery ground. Is
26.b No; repair the short to ground on pin 64 of the MCM 120-pin connector. Verify repairs.
5
257.1 SPN 3599/FMI 3 - GHG17

High Side Digital Output 3 Circuit Failed High
SPN 3599/FMI 3
Description This Code Sets When the Aftertreatment Control Module
(ACM) Detects a Short to Power on Pins 9, 15, or 39 within
One Second After the Ignition has Been Turned On.
Execution Frequency One Second After the Ignition is Cycled On
Dash Lamps MIL, CEL
Verification Cycle the Ignition Key from the Off Position to the On Position.
Check as follows:
1. Disconnect the 120-pin ACM connector. Go to step 2.
4. Does code SPN 3599/FMI 3 still set?
1
4.a Yes; replace the ACM .

For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .Verify repair.
For Two-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .Verify repair.
4.b No; turn the ignition OFF. Refer to Original Equipment Manufacturer (OEM) literature and repair the
wire between the ACM and the line heaters. Verify repair.
2
257.2 SPN 3599/FMI 4 - GHG17

High Side Digital Output 3 Circuit Failed Low
SPN 3599/FMI 4
(ACM) Detects a Short to Ground on pins 9, 15, or 39.
Dash Lamps MIL, CEL
Verification Cycle the Ignition Key from the Off Position to the On Position.
Check as follows:
1. Disconnect the 120-pin ACM connector. Go to step 2.
4. Does code SPN 3599/ FMI 4 still set?
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" .Verify repair.
For Two-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .Verify repair.
3
4.b No; turn the ignition OFF. Refer to Original Equipment Manufacturer (OEM) literature and repair the
wire between the ACM and the line heaters. Verify repair.
4
259.1 SPN 3599/FMI 3 - GHG17

SPN 3599/FMI 3
Description Motor Control Module (MCM) Internal Injector Power Supply
Failed High
Monitored Parameter MCM Internal Injector Power Supply
Dash Lamps MIL, CEL
1. Replace the MCM.
1
259.2 SPN 3599/FMI 4 - GHG17

SPN 3599/FMI 4
Description Motor Control Module (MCM) Internal Fuel Injector Power
Supply Failed Low
Monitored Parameter MCM Internal Fuel Injector Power Supply
Dash Lamps MIL, CEL
1. Replace the MCM.
2
260.1 SPN 3606/FMI 9 - GHG17

J1939 ESS Message is Missing
1.a If CPC SPN 168/FMI 0 or SPN 168/FMI 14 (Battery Voltage) are present, troubleshoot these first.
Refer to section "SPN 168/FMI 0 - GHG17 " .
1.b If CPC SPN 625/FMI 9 is present, troubleshoot and repair the Controller Area Network (CAN) line.
1.c If only a 'J1939 Error' fault is present, Go to step 2.
1
261.1 SPN 3609/FMI 3 - GHG17

Diesel Oxidation Catalyst inlet pressure sensor circuit failed high
1.a If SPN 3609/FMI 3, SPN 3610/FMI 3 and SPN 3509/FMI 3 are present, repair short to power between
pin 1 of the Diesel Oxidation Catalyst (DOC) filter inlet pressure sensor and pin 88 of the Aftertreatment
Control Module (ACM).
1.b If SPN 3609/FMI 3 and SPN 3610/FMI 3 are present, repair open between pin 1 of the DOC inlet
pressure sensor and pin 88 of the ACM.
2. Disconnect the DOC inlet pressure sensor.
4. Measure the voltage between pin 2 of the DOC inlet pressure sensor and ground.
4.a If voltage is present, repair short to power between pin 2 of the DOC inlet pressure sensor and pin 87
of the ACM.
4.b If no voltage is present, Go to step 5.
7. Measure the resistance between pin 2 of the DOC inlet pressure sensor and pin 87 of the ACM.
7.a If the resistance is greater than 5 ohms repair the wire between pin 2 of the DOC inlet pressure sensor
and pin 87 of the ACM.
7.b If the resistance is less than 5 ohms, replace the DOC inlet pressure sensor.
1
261.2 SPN 3609/FMI 4 - GHG17

Diesel Oxidation Catalyst Inlet Pressure sensor circuit failed low
1.a If SPN 3609/FMI 4 and SPN 3610/FMI 4 are present, repair open between Aftertreatment Control
Module (ACM) pin 117 and Diesel Oxidation Catalyst (DOC)/Diesel Particulate Filter (DPF) pressure
sensors pin 3.
3. Disconnect the DOC inlet pressure sensor.
4. Inspect the DOC inlet pressure sensor harness for bent, spread, or corroded pins.
6. Measure the resistance between pin 2 of the DOC inlet pressure sensor and ground.
6.a If the resistance is less than 1k ohms, repair short to ground between pin 2 of the DOC inlet pressure
sensor and pin 87 of the ACM 120-pin connector.
7. Measure the resistance between pin 2 of the DOC inlet pressure sensor and pin 87 of the ACM 120-pin
connector.
7.a If the resistance is greater than 3 ohms repair wire between pin 2 of the DOC inlet pressure sensor and
7.b If the resistance is less than 3 ohms, replace the DOC inlet pressure sensor.
2
262.1 SPN 3610/FMI 2 - GHG17

Diesel Oxidation Catalyst Inlet Pressure - Not Plausible
SPN 3610/FMI 2
Description Diesel Oxidation Catalyst (DOC) Inlet Pressure Not Plausible
Dash Lamps MIL
WARNING
ENGINE EXHAUST
1
WARNING
PERSONAL INJURY
1. Start the engine and visually inspect the entire exhaust system for signs of leaks or damage. Are there any
leaks or damage present?
3. Using the Selective Catalyst Reduction (SCR) voltage service routine, monitor the Diesel Oxidation Catalyst
(DOC) filter inlet pressure (pin 87) and the DPF outlet pressure (pin 72) voltages with the ignition ON (key
ON, engine OFF). Is the DOC inlet pressure sensor voltage between 0.44 and 0.56 volts?
4. Disconnect the DOC inlet pressure sensor connector. Go to step 5.
5. Inspect the connectors for damaged pins, spread pins or corrosion. Is there any damage present?
6.a Yes; replace the sensor. Verify repair.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" .
For 2-BOX, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor" .
7. Measure the DPF outlet sensor voltage. Is the voltage between 0.44 and 0.56 volts?
7.a Yes; repair restricted/damaged DOC or DPF pressure sensor tubes. Refer to section "Removal of the Diesel
Oxidation Catalyst Inlet Pressure Sensor Tube" . Verify repair.

8. Disconnect the DOC inlet pressure sensor connector. Go to step 9.
9. Inspect the connectors for damaged pins, spread pins or corrosion. Is there any damage present?
10. Measure the voltage between pin 3 of the DOC inlet pressure sensor connector and ground. Is the voltage
10.a Yes; replace the sensor.
10.b No; repair the circuit. Verify repair.
2
262.2 SPN 3610/FMI 3 - GHG17

This is for DD13 2-Box only.
1.a If SPN 3610/FMI 3, SPN 3609/FMI 3 and SPN 3509/FMI 3 are present, repair short to power between
pin 1 of the Diesel Particulate Filter (DPF) outlet pressure sensor and pin 88 of the Aftertreatment
Control Module (ACM).
1.b If SPN 3610/FMI 3 and FMI 3609/FMI 3 are present, repair open between pin 1 of the DPF outlet
pressure sensor and pin 88 of the ACM.
2. Disconnect the DPF outlet pressure sensor.
4. Measure the voltage between pin 2 of the DPF outlet pressure sensor and ground. Is voltage present?
4.a Yes; repair short to power between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM.
7. Measure the resistance between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM. Is the
resistance greater than five ohms?
7.a Yes; repair the wire between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM.
7.b No; replace the DPF outlet pressure sensor . Refer to section "Removal of the GHG17 Diesel
Particulate Filter Outlet Pressure Sensor.
3
262.3 SPN 3610/FMI 4 - GHG17

Diesel Particulate Filter Outlet Pressure Sensor Circuit Failed Low
1.a If SPN 3610/FMI 4 and SPN 3609/FMI 4 are present, repair open between Aftertreatment Control
Module (ACM) pin 117 and Diesel Oxidation Catalyst (DOC)/Diesel Particulate Filter (DPF) pressure
sensors pin 3.
3. Disconnect the DPF outlet pressure sensor.
4. Inspect the DPF outlet pressure sensor harness for bent, spread, or corroded pins. Are any of the pins
damaged?
6. Measure the resistance between pin 2 of the DPF outlet pressure sensor and ground. Is the resistance less
than 1k ohm?
6.a Yes; repair short to ground between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM
120-pin connector.
7. Measure the resistance between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM 120-pin
connector. Is the resistance greater than three ohms?
7.a Yes; repair wire between pin 2 of the DPF outlet pressure sensor and pin 72 of the ACM 120-pin
connector.
7.b No; replace the DPF outlet pressure sensor. Refer to section "Removal of the GHG17 Diesel
Particulate Filter Outlet Pressure Sensor".
4
263.1 SPN 3645/FMI 9 - GHG17

J1939 TCI Message (Transfer Case Information) is Missing
SPN 3645/FMI 9
Description Transfer Case Information is Missing
Dash Lamps CEL
Verification Idle
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
configuration?
1
1
263.2 SPN 3659/FMI 3 - GHG17

Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MAX)
SPN 3659/FMI 3
Description Injector Cylinder #1 Amplifier Control Valve Abnormal
Operation (MAX)
Monitored Parameter Injector Cylinder #1 Amplifier Control Valve
Typical Enabling Conditions fis_nop_act greater than 1.85
Dash Lamps MIL, CEL
Verification Engine rpm 1400 - 1500 (One minute)
1. Check for multiple codes. Is SPN fault code 168 or 723 / FMI any present?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
connector seal for damage (signs of water or oil intrusion). Is any damage found?
2
Injector #1 Amplifier 0.5 – 2.0* greater than100k* greater than100k* greater than100k*
Are the values within range?
9.b No; replace the fuel injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector - Two-
Filter System" .
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Injector #1 Amplifier 2.0 or less* greater than100k* greater than100k* greater than100k*
3

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
Note : The use of extension harness J-49120 will ease installation of test MCM.
13. Reconnect all connections and start engine. Bring to operating temperature of 71°C (160°F). Did the fault
become active?
13.a Yes; replace injector listed in code description. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
4
263.3 SPN 3659/FMI 4 - GHG17

Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MIN)
SPN 3659/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
1. Check for multiple codes. Is SPN fault code 168 or 723/FMI any present?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
Filter System" .
6

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
WARNING
ENGINE EXHAUST
7
WARNING
PERSONAL INJURY
13. Reconnect all connections and start engine. Bring to operating temperature of 71°C (160°F). Does fault
become active?
13.a Yes; replace injector listed in code description. Refer to section "Removal of the Fuel Injector - Two-Filter System"
8
263.4 SPN 3659/FMI 5 - GHG17

Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (OPEN)
SPN 3659/FMI 5
Operation (OPEN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3. Turn the engine OFF (key OFF, engine OFF).
9
Filter System" .
10

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
WARNING
ENGINE EXHAUST
11
WARNING
PERSONAL INJURY
become active?
12
263.5 SPN 3659/FMI 6 - GHG17

Injector Cylinder #1 Amplifier Control Valve – Valve Shorted Circuit
SPN 3659/FMI 6
Description Injector Cylinder #1 Amplifier Control Valve, Valve Shorted
Circuit
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
seal for damage (signs of water or oil intrusion). Is any damage found?
13
8. Remove the front injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Note : Do NOT touch the metal ohmmeter leads with your hands when the measurements are taken.
9.a Yes; replace the front injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness -
System" .
14

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
13. Reconnect all connections and start engine, bring to operating temperature 71º C (160º F). Does fault
become active?
15
16
263.2 SPN 3659/FMI 3 - GHG17

SPN 3659/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
17
Filter System" .
18

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground

13. Inspect all injector terminals for loose of cross-threaded nuts. Refer to section "Installation of the Two-Piece Fuel
Injector Wiring Harness - Two-Filter System" . Are any injector nuts loose or cross-threaded?

19
263.3 SPN 3659/FMI 4 - GHG17

SPN 3659/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
20
Filter System" .
21

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


22
263.4 SPN 3659/FMI 5 - GHG17

SPN 3659/FMI 5
Operation (OPEN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3. Turn the engine OFF (key OFF, engine OFF).
23
Filter System" .
24

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


25
263.5 SPN 3659/FMI 6 - GHG17

SPN 3659/FMI 6
Circuit
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
26
System" .
27

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


28
1
265.2 SPN 3660/FMI 3 - GHG17

SPN 3660/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
Verification Engine rpm 1400 to 1500 (One Minute)
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
pins on the valve cover side of the front fuel injector harness listed below. Are the values within range?
2
greater than 100k greater than 100k greater than 100k
Injector #1 Amplifier 0.5 – 2.0 ohms* ohms* ohms* ohms*
ohms ohms ohms ohms
ohms ohms ohms ohms
ohms ohms ohms ohms
Test: Pins 1 and 2 Pins 2 and 3 Pin 1 and ground Pin 3 and ground
Specifications: 0.5 – 2.0 ohms* ohms* ohms* ohms*
Injector #1 Amplifier ohms ohms ohms ohms
Two-Filter System" . Repair complete. Verify repairs.
Filter System" . Repair complete. Verify repairs.
Test: Pins 1 and 2 Pins 2 and 3 Pin 1 and ground Pin 3 and ground
2.0 ohms or less* greater than 20k greater than 100k greater than 100k
Specification: ohms* ohms* ohms*
3
valve cover 14-pin connector and the MCM 120-pin connector. Are the values within range?

Front Engine Side Acceptable Front Engine Side Acceptable
MCM 120-Pin
Valve Cover 14-pin Harness Connector Resistance 1 ohms Valve Cover 14 pin Resistance 1K ohms
connector # or less connector # or greater
5 13 ohms 5 and ground ohms

12. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"

4
265.3 SPN 3660/FMI 4 - GHG17

SPN 3660/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
Two-Filter System" . Repair complete. Verify repairs.
Filter System" . Repair complete. Verify repairs.
6

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground

12. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"

7
265.4 SPN 3660/FMI 5 - GHG17

Injector Cylinder #2 Amplifier Control Valve Abnormal Operation OPEN
SPN 3660/FMI 5
Operation Open
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8

Filter System" .
9

Valve Cover 14-pin Valve Cover 14 pin Resistance 1K or
Harness Connector Resistance 1 or less
5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


10
265.5 SPN 3660/FMI 6 - GHG17

SPN 3660/FMI 6
Circuit
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect the front rocker cover 14-pin injector harness connector.
11
Front Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Front Injector Harness 14-Pin Connector Resistance Chart (Using J-48671-10 Injector Breakout Box)
System" .
12

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


13
1
265.2 SPN 3661/FMI 3 - GHG17

SPN 3661/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2
Filter System" .
3

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground
Note : The use of extension harness J49120 will ease installation of test MCM.
13. Reconnect all connections and start engine. Bring to operating temperature of 71°C (160°F). Does the fault
become active?
4
265.3 SPN 3661/FMI 4 - GHG17

SPN 3661/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
Filter System" .
6

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
become active?
7
265.4 SPN 3661/FMI 5 - GHG17

Injector Cylinder #3 Amplifier Control Valve Abnormal Operation (Open)
SPN 3661/FMI 5
Operation (Open)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8
Filter System" .
9

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
WARNING
ENGINE EXHAUST
10
WARNING
PERSONAL INJURY
become active?
11
265.5 SPN 3661/FMI 6 - GHG17

Injector Cylinder #3 Amplifier Control Valve, Valve Shorted Circuit
SPN 3661/FMI 6
Circuit
Dash Lamps MIL, CEL
Verification Engine rpm 1400 to 1500 (One minute)
1. Check for multiple codes. Is fault code SPN 168 or 723 / FMI any present?
1.a Yes; service those faults first. Verify repair.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect and inspect the front rocker 14-pin injector harness connector.
5. Inspect the front injector harness 14-pin injector connector for bent or spread pins. Inspect the connector
6. Using the appropriate chart below, measure the resistance values between the corresponding pins on the
valve cover side of the front injector harness as listed below. Are the resistances in range?
12

8. Remove the front injector harness from the engine.
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" ,
9.a Yes; replace the front injector harness.
9.b No; replace the injector with the out-of-range resistance.
13
valve cover 14-pin connector and the MCM 120-pin connector. Are the resistances within range.
14

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
Note : The use of extension harness J49120 will ease installation of test MCM.
13. Reconnect all connectors and start the engine. Bring the engine up to operating temperature of 71°C
(160°F). Does fault become active?
15
16
265.2 SPN 3661/FMI 3 - GHG17

SPN 3661/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
17
Filter System" .
18

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


19
265.3 SPN 3661/FMI 4 - GHG17

SPN 3661/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
20
Filter System" .
21

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


22
265.4 SPN 3661/FMI 5 - GHG17

SPN 3661/FMI 5
Operation (Open)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
23
Filter System" .
24

5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground


25
265.5 SPN 3661/FMI 6 - GHG17

Injector Cylinder #3 Amplifier Control Valve, Valve Shorted Circuit
SPN 3661/FMI 6
Circuit
Dash Lamps MIL, CEL
Verification Engine rpm 1400 to 1500 (One minute)
1. Check for multiple codes. Is fault code SPN 168 or 723 / FMI any present?
1.a Yes; service those faults first. Verify repair.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
4. Disconnect and inspect the front rocker 14-pin injector harness connector.
5. Inspect the front injector harness 14-pin injector connector for bent or spread pins. Inspect the connector
6. Using the appropriate chart below, measure the resistance values between the corresponding pins on the
valve cover side of the front injector harness as listed below. Are the resistances in range?
26

8. Remove the front injector harness from the engine.
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" ,
9.a Yes; replace the front injector harness.
27
valve cover 14-pin connector and the MCM 120-pin connector. Are the resistances within range.

Valve Cover 14-pin Valve Cover 14 pin Resistance 1K or
Harness Connector Resistance 1 or less
5 13 5 and ground
8 14 8 and ground
9 10 9 and ground
12 12 12 and ground
28


29
1
267.2 SPN 3662/FMI 3 - GHG17

SPN 3662/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
1. Check for multiple codes. SPN fault code 168 or 723 / FMI any present?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : Do NOT touch the metal ohmmeter leads with your hands while taking the measurements.
pins on the valve cover side of the rear fuel injector harness listed below. Are the values within range?
2
Filter System" .
3

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


4
267.3 SPN 3662/FMI 4 - GHG17

SPN 3662/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Note : DO NOT touch the metal ohmmeter leads with your hands while the measurements are taken.
5
Filter System" .
6
Note : DO NOT touch the metal ohmmeter leads with your hands while taking the measurements.

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


7
267.4 SPN 3662/FMI 5 - GHG17

SPN 3662/FMI 5
Operation (OPEN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8
Filter System" .
9

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


10
267.5 SPN 3662/FMI 6 - GHG17

SPN 3662/FMI 6
Circuit
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5. Inspect the rear injector harness 14–pin injector connector for bent or spread pins. Inspect the connector
pins on the valve cover side of the rear injector harness listed below. Are the resistances within range?
11
Rear Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Rear Injector Harness 14-Pin Connector Resistance Chart (Using J-48671-10 Injector Breakout Box)
8. Remove the rear injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
9.a Yes; replace the rear injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-
Filter System" .
System" .
12
Note : DO NOT touch the metal ohmmeter leads with your hands while taking the measurements.

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


13
1
268.2 SPN 3663/FMI 3 - GHG17

SPN 3663/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
Verification Engine rpm1400 - 1500 (One minute)
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
pins on the valve cover side of the rear fuel injector harness listed below. Are the values within range?
2
Note: Ensure J-48671-10 ground strap is connected to the cylinder head.
Filter System" .
3
cover 14-pin connector and the MCM 120-pin connector. Are the values within range?

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


4
268.3 SPN 3663/FMI 4 - GHG17

SPN 3663/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
9. Using the chart below, measure and record the resistance resistances between the injector pins listed
below. Are the values within range?
Filter System" .
6

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


7
268.4 SPN 3663/FMI 5 - GHG17

SPN 3663/FMI 5
Operation (OPEN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8
9. Using the chart below, measure and record the resistance between the injector pins listed below. Are the
values within range?
Filter System" .
9

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


10
268.5 SPN 3663/FMI 6 - GHG17

Injector Cylinder #5 Spill Control Valve - Valve Shorted Circuit
Check as follows:
SPN 3663/FMI 6
Description Injector Cylinder #5 Spill Control Valve, Valve Shorted Circuit
Monitored Parameter Injector Cylinder #5 Spill Control Valve
Typical Enabling Conditions Injector open greater than threshold
Dash Lamps MIL, CEL
11
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
Injector #4 Amplifier 0.5 to 2.0* Greater than 100k* Greater than 100k* Greater than 100k*
12

8. Remove the rear injector harness from the engine.
Injector #4 Amplifier 2.0 or less* Greater than 100k* Greater than 100k* Greater than 100k*
Injector #5 Amplifier 2.0 or less* Greter than 100k* Greater than 100k* Greater than 100k*
Injector #6 Amplifier 2.0 or less* Greater than 100k* Greater than 100k* Greater than 100k*
9.a Yes; replace the rear injector harness.

Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System"

13
14

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


15
1
269.2 SPN 3664/FMI 3 - GHG17

SPN 3664/FMI 3
Operation (MAX)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2
Filter System" .
3

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


4
269.3 SPN 3664/FMI 4 - GHG17

SPN 3664/FMI 4
Operation (MIN)
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
Filter System" .
6

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


7
269.4 SPN 3664/FMI 5 - GHG17

SPN 3664/FMI 5
Operation (OPEN)
Dash Lamps MIL, CEL

WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
8
Filter System" .
9

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


10
269.5 SPN 3664/FMI 6 - GHG17

SPN 3664/FMI 6
Circuit
Dash Lamps MIL, CEL
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11
8. Remove the rear injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
9.a Yes; replace the rear injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-
Filter System" .
System" .
12

5 7 5 and ground
8 4 8 and ground
9 8 9 and ground
12 6 12 and ground


13
270.1 SPN 3695/FMI 9 - GHG17

SPN 3695/FMI 9
Description This fault code sets when the Common Powertrain Controller
(CPC) does not see the Diesel Particulate Filter (DPF) Inhibit
Switch over the J-1939 CAN.
Monitored Parameter Diesel Particulate Filter (DPF) Inhibit Switch
Dash Lamps CEL
Verification Cycle the Key to Power Down, then Cycle the Key Back On
Note : This fault code only sets when the CPC is parameterized to receive the Diesel Particulate Filter (DPF)
Inhibit Switch from another module over the J1939 CAN.
Check as follows:
3. Has the CPC been reprogrammed recently?
3.a Yes; Reprogram the CPC using the latest software and the correct VIN. If the fault returns Go to step 4.
4. Check for other fault codes. Are there any communication fault codes present in the other modules?
1
270.2 SPN 3695/FMI 13 - GHG17

SPN 3695/FMI 13
Description Signal Not Available on the CPC DPF Inhibit Switch
Dash Lamps CEL
Check as follows:
1. Check for multiple codes. Is (CPC) SPN 168/FMI 0/14/18 or (MCM) SPN 625/FMI 9 present?
2. Measure resistance between the DPF inhibit switch connector, harness side and ground. Is the resistance
greater than 10k ohms?
2.b No; repair a short to ground on the DPF inhibit switch circuit from pin 13 of the CPC connector #4 to
the DPF inhibit switch.
3.b No; check the other vehicle modules for communication faults. Follow the appropriate troubleshooting
for the fault. If no other faults are found, Go to step 4.
4. Cycle the key to power down, then cycle the key back on. Did SPN 3695/FMI 13 return active?
2
270.3 SPN 3695/FMI 14 - GHG17

SPN 3695/FMI 14
Description Loss of Communication Occurred on the CPC DPF Inhibit
Switch
Dash Lamps CEL
Check as follows:
3
270.4 SPN 3695/FMI 19 - GHG17

SPN 3695/FMI 19
Description A Communication Error Occurred on the CPC DPF Inhibit
Switch
Dash Lamps CEL
Check as follows:
4
271.1 SPN 3696/FMI 4 - GHG17

SPN 3696/FMI 4
Description DPF Regeneration Switch is shorted to ground
Monitored Parameter 4/17 Regen switch
Typical Enabling Conditions Key ON and engine OFF
Monitor Sequence
Typical Duration
Dash Lamps
Engine Reaction
Verification Cycle the key to power down, then cycle the key back on
2. Measure resistance at the DPF Regen Switch connector, harness side. Is the resistance greater than 10k
ohms?
2.a Yes; repair a short to ground on the DPF regen switch circuit from CPC connector 4, pin 17 (4/17) to
the DPF Regen Switch.
3.b No; Check the other vehicle modules for communication faults. Follow the appropriate troubleshooting
4. Is the vehicle either a Cascadia or M2 Chassis?
4.b No; the vehicle is neither a Cascadia nor an M2 Chassis, Go to step 7.
5. Is the vehicle an M2 Chassis?
1
5.a Yes; Verify CPC parameter PGR001/007, CM1 DPF Source Addr SAE J1939 is set to 33. Go to step 6.
5.b No; Verify CPC parameter PGR001/007, CM1 DPF Source Addr SAE J1939 is set to 49. Go to step 6.
6.b No; Release the vehicle.
7. Using DiagnosticLink , go to the Program Device screen. Add the Engine Serial Number (ESN) and
connect to server.
8. Using DiagnosticLink Compare Parameter feature, compare the parameters on the CPC to the ones under
Server Data. Set CPC parameter PGR001/007, CM1 DPF Source Addr SAE J1939 on the CPC the same
as on the server. Go to step 9.
9.a Yes; Contact the chassis OEM for appropriate parameter settings.
2
271.2 SPN 3696/FMI 9 - GHG17

SPN 3696/FMI 9
Description Loss of communication occurred on the CPC DPF switch
source address
Monitored Parameter CM1 DPF Source Addr SAE J1939
Monitor Sequence
Typical Duration
Dash Lamps
1. Check for multiple codes. Is either (CPC) SPN 168/FMI 0/14/18 or (MCM) SPN 625/FMI 9 present?
connect to server.
3
271.3 SPN 3696/ FMI 13 - GHG17

Diesel Particulate Filter Regen Force MUX Switch Message Contains SNV Indicator
SPN 3696/FMI 13
Description Signal not available on the CPC DPF switch source address
Monitor Sequence
Typical Duration
Dash Lamps

connect to server.
4
271.4 SPN 3696/FMI 14 - GHG17

SPN 3696/FMI 14
Description Loss of communication occurred on the CPC DPF switch
source address
Monitor Sequence
Typical Duration
Dash Lamps
connect to server.
7. Using DiagnosticLink Compare Parameter feature, compare the parameters on the CPC to the parameters
under Server Data. Set CPC parameter PGR001/007, CM1 DPF Source Addr SAE J1939 on the CPC the
same as on the server. Go to step 8.
5
271.5 SPN 3696/FMI 19 - GHG17

SPN 3696/FMI 19
Description A communication error occurred on the CPC DPF switch
source address
Monitor Sequence
Typical Duration
Dash Lamps
connect to server.
7. Using DiagnosticLink Compare Parameter feature, compare the parameters on the CPC to the parameters
under Server Data. Set CPC parameter PGR001/007, CM1 DPF Source Addr SAE J1939 on the CPC the
same as on the server. Go to step 8.
6
SPN 3711 (MCM;ACM) (GHG17)
272.1 SPN 3711/FMI 31 - GHG17

High Idle Regeneration (Aborted) – Low Exhaust Temperature
The fault indicates that the High Idle Regeneration (HIR) was aborted due to the Diesel Oxidation Catalyst (DOC)
inlet temperature not reaching the minimum of 270°C (518°F) to initiate dosing during an HIR. The CEL and MIL
lamps will remain ON until the fault is resolved or a successful regeneration is completed.
2. Check fault codes; are SPN 3242/FMI 8 or SPN 3242/FMI 20 active or previously active?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Monitor the Diesel Oxidation Catalyst (DOC) inlet temperature sensor and DOC outlet temperature sensor.
Continue idling for 10 minutes. Is the DOC inlet temperature within 13.89°C (25°F) of the DOC outlet
temperature?
4.a Yes; replace the DOC inlet temperature sensor and perform an HIR.
4.b No; For a DD16 engine, Go to step 5. For a DD13 or a DD15, Go to step 6.
5. Using DiagnosticLink, perform an Intake Throttle Service Routine. Is the commanded position achieved?
5.b No; replace the Intake Throttle Valve (ITV).
6. Inspect the exhaust system for leaks. Are any leaks found?
7. Pressurize the intake tract and inspect for leaks. Are any leaks found?
1
WARNING
HOT EXHAUST
8. Perform a Parked Regen. View the Jake Brake® -1 (PWM 13). Is the MCM commanding Jake Brake 1 on?
8.b No; the oil temperature may be too cold. The oil temperature needs to be above 50ºC (122°F) for the
Jake Brakes to turn on.
9. Using DiagnosticLink during the regen, view AS087 Actual Fuel Mass. Is the fuel mass above 100 mg/st?
9.a Yes; send in the log file to the Detroit™ Customer Support Center at CSC@daimler.com. Call 800-445-
1980 for further analysis and instruction.
10. Install a test MCM using the extension harness and perform a regen. Is the fuel mass above 100 mg/st?
WARNING
PERSONAL INJURY
11. Remove the valve cover. Inspect the front top of the exhaust rocker arm shaft. It should state "TOP
FRONT". Refer to section "Checking for Poor Engine Brake Performance" .
11.a If the rocker arm does NOT state "TOP FRONT" then remove and inspect it for correct installation and
part.
11.b If the rocker arm does state "TOP FRONT", Go to step 12.
12. Using DiagnosticLink, Service Routines, Cylinder Cut-Out, cut out cylinders one, two, and three. On the
Jake Brake solenoid there is a button to push called the Jake Brake Override. Push and hold the Jake
Brake override button. Does the engine quit running?
12.a Yes; replace the exhaust rocker arm shaft. The plug in the rocker arm shaft is missing (cannot be
seen), causing oil to activate the rear Jake Brakes.
13. When the Jake override button is pushed down, do you see all the Jake Brake rocker arm pistons come out
of the Jake Brake rocker arms for cylinders one, two, and three?
13.a Yes; replace the solenoid and assemble the engine to perform a regen.
14. Remove the front (Bank 1) engine brake solenoid from the cam frame. This will require the removal of the
front injector harness. Make sure both injector harnesses (front and rear) are unplugged. Crank the engine;
is there oil coming out of the port in the cam frame housing?
14.a Yes; replace the solenoid. Go to step 15.
14.b No; replace the cam frame housing.
15. Push on the Jake Brake override button again. Do the Jake Brake pistons activate for cylinders one, two
and three?
15.a Yes; assemble the engine and try a regen.
2
WARNING
EYE INJURY
15.b No; remove the Jake Brake solenoid and the exhaust rocker arm shaft. Blow compressed shop air
through the cam frame to the solenoid gallery, inspecting for a blockage. Remove the rockers for
cylinders one, two and three. Blow compressed shop air through the rocker arm inspecting for
blockage. If no blockage is found, replace the Jake Brake rockers that did not have the pistons
activate.
3
273.1 SPN 3713/FMI 31 - GHG17

High Idle Regeneration Aborted - Low Regeneration Temperature
The fault indicates that the High Idle Regeneration (HIR) was aborted due to the Diesel Oxidation Catalyst (DOC)
outlet temperature not reaching the expected target temperature to complete a HIR. If there are any other
regeneration or fuel system related faults address those first. The CEL and MIL lamp will remain ON until a fault is
resolved or a successful regeneration is completed. Retain log file if customer assistance is required.
1
274.1 SPN 3716/FMI 31- GHG17

SPN 3716/FMI 31
Description This Fault Logs when the Coolant Temperature Fails to Reach
60°C (140°F) During High Idle Regeneration Initiation
Monitored Parameter Engine Coolant Temperature
Dash Lamps CEL
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
2. Check for multiple fault codes. Are fault codes SPN 110/FMI 3, FMI 4 or FMI 10 present?
3. Using DiagnosticLink, compare engine coolant temperature and engine oil temperature. Are the
temperatures within 12°C (21.6°F) of each other?
3.b No; replace the coolant temperature sensor. Verify repair. Refer to section "Removal of the Engine Coolant Outlet
Temperature Sensor" .
4. Check for proper operation of the engine cooling fan. Is the fan running longer than desired?
5. Check coolant thermostat operation. Refer to section "Low Engine Coolant Temperature" . Does the thermostat
operate correctly?
5.a Yes; replace the coolant temperature sensor. Refer to section "Removal of the Engine Coolant Outlet Temperature
5.b No; replace the engine coolant thermostat. Refer to section "Removal of the Engine Coolant Thermostat and Seal" .
Verify repair.
1
275.1 SPN 3719/FMI 0 - GHG17

Check as follows:
Note : When this code is detected, the operator has two minutes to initiate regeneration request.
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Perform a parked regeneration.

Note : Do not interrupt regeneration once it has been initiated.
2. Clear all codes following the completion of the parked regeneration.
1
275.2 SPN 3719/FMI 15 - GHG17

Diesel Particulate Filter Zone 3 Condition
Silent Code that Logs when the Diesel Particulate Filter Regeneration Lamp is Flashing in "Regen Zone 3"
Note : This code is informational only and used by service to help understand which dash lights illuminated during
normal service. A stationary regeneration is required if the fault code is active. No action is required for an inactive
fault code.
2
275.3 SPN 3719/FMI 16 - GHG17

Check as follows:
Note : When this code is detected, the operator has two minutes to initiate regeneration request.
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Perform a parked regeneration.

Note : Do not interrupt regeneration once it has been initiated.
2. Clear all codes following the completion of the parked regeneration.
3
275.4 SPN 3719/FMI 31 - GHG17

fault code.
4
276.1 SPN 3719/FMI 0 - GHG17

DPF Filter Soot Level is Very High
SPN 3719/ FMI 0

Description Diesel Particular Filter (DPF) is at a Very High Soot Level
Monitored Parameter DPF Zone
Typical Enabling Conditions Soot Sensor Enabled
Monitor Sequence Continuously
Typical Duration
Dash Lamps SEL
Check as follows:
3. Check for multiple codes. Are any Aftertreatment Control Module (ACM) fault codes also present, including
ACM code SPN 3719/FMI 0?
3.a Yes; troubleshoot the other faults first.
4.b No; reprogram the CPC with the correct information as necessary. Go to step 5.
WARNING
HOT EXHAUST
5. Clear fault codes and verify repair by performing a Parked Regeneration.
1
276.2 SPN 3719/FMI 16 - GHG17

DPF Filter Soot Level is High
SPN 3719/FMI 16
Description Diesel Particulate Filter is at a high soot level
Monitored Parameter DPF Zone
Typical Duration
Dash Lamps CEL
Check as follows:
3. Check for multiple codes. Are any ACM fault codes also present, including ACM code SPN 3719/FMI 16?
3.a Yes; troubleshoot the other faults first.
configuration?
power down. Verify repair by performing a Parked Regeneration.
2
276.3 SPN 3719/FMI 31 - GHG17

Silent Code that Logs when the Diesel Particulate Filter Regeneration Lamp is Flashing in "Regen Zone 2"
fault code.
3
277.1 SPN 3720/FMI 15 - GHG17

Diesel Particulate Filter Has Reached the End of its Service Life
Replace DPF and perform the Ash Accumulator reset using DiagnosticLink .
The DPF lamp will illuminate and code 3720/15 will log when the truck reaches the appropriate mileage interval.
This fault indicates that the DPF needs to be replaced and the DPF Ash Accumulator Routine in DiagnosticLink
must be completed. This routine can be found in the Actions drop-down menu and must be completed after the
DPF has been replaced.
Cleaning accumulated ash from the DPF is a necessary part of vehicle maintenance and is a customer charge.
The recommended service is to remove the DPF and replace with a reliabilt® Clean DPF. The reliabilt® Clean
DPF has a parts warranty and the same cleaning interval as the original DPF.
Note : Using alternate cleaning methods may result in the cleaned DPF failing to reach the next Ash clean
interval. The customer may experience damage to the Diesel Oxidation Catalyst (DOC) or DPF assemblies as a
result of alternate cleaning methods.
Refer to section "Resetting the Diesel Particulate Filter Ash Accumulators" Refer to section "Resetting the Diesel
Particulate Filter Ash Accumulators"
1
278.1 SPN 3720/FMI 14 - GHG17

Check as follows:
3. Select Diesel Particulate Filter (DPF) ash accumulator from the actions drop-down menu.
4. Choose Aftertreatment Control Module (ACM) replacement option, then select set ash volume button.
5. Verify that the ACM value has changed in the DPF ash accumulator window and that the 3720/14 MCM
fault is no longer active. ACM will change to a value that should be within 5% of the MCM displayed volume
within 5-10 seconds of executing the routine. Clear all faults and release vehicle.
1
278.1 SPN 3840/FMI 3 – GHG17

SPN 3840/FMI 3
Dash Lamps CEL
Check as follows:
3. Verify parameters - go to the parameters work window
4. Verify that the parameter in PGR009 frequency outputs are set to the specific component to which this is
1
278.2 SPN 3840/FMI 4 - GHG17

SPN 3840/FMI 4
Dash Lamps CEL
Check as follows:
2
278.3 SPN 3840/FMI 5 - GHG17

SPN 3840/FMI 5
Dash Lamps CEL
Check as follows:
3
279.1 SPN 3841/FMI 3 – GHG17

SPN 3841/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1
279.2 SPN 3841/FMI 4 - GHG17

SPN 3841/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
2
279.3 SPN 3841/FMI 5 - GHG17

SPN 3841/FMI 5
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3
281.1 SPN 3842/FMI 3 - GHG17

SPN 3842/FMI 3
Dash Lamps CEL
Verification Key On
Repair the short to power between pin 2 of the CPC connector #3 and the wired component. For wiring schematic
1
281.2 SPN 3842/FMI 4 - GHG17

SPN 3842/FMI 4
Dash Lamps CEL
Verification Key On
2
281.3 SPN 3842/FMI 5 - GHG17

SPN 3842/FMI 5
Dash Lamps CEL
Verification Key On
3
281.1 SPN 3843/FMI 3 - GHG17

SPN 3843/FMI 3
Description CPC Input 1 01 Short to Voltage
Monitored Parameter CPC Input 1/01
Dash Lamps CEL
WARNING
ENGINE EXHAUST

4. Verify that the parameter set to 1 01 DI Selection is set to the specific component to which this is
1
281.2 SPN 3843/FMI 4 - GHG17

SPN 3843/FMI 4
Description CPC Input 1 01 Short to Ground
Dash Lamps CEL
WARNING
ENGINE EXHAUST

2
282.1 SPN 3844/FMI 3 - GHG17

SPN 3844/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

1
2
282.2 SPN 3844/FMI 4 - GHG17

SPN 3844/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

3
283.1 SPN 3845/FMI 3 - GHG17

SPN 3845/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1

2
283.2 SPN 3845/FMI 4 - GHG17

SPN 3845/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
3

4
284.1 SPN 3846/FMI 3 - GHG17

SPN 3846/FMI 3
Dash Lamps CEL
Check as follows:

4. Verify that the parameters for Cruise Control Enable are configured correctly. Are the parameters
configured correctly?
1
4.b No; configure the parameter correctly.
2
284.2 SPN 3846/FMI 4 - GHG17

SPN 3846/FMI 4
Dash Lamps CEL
Check as follows:

4. Verify that the parameter for Cruise Control Enable is configured correctly. Is the parameter configured
correctly?
3
4
285.1 SPN 3847/FMI 3 - GHG17

SPN 3847/FMI 3
Dash Lamps CEL
Check as follows:

1
285.2 SPN 3847/FMI 4 - GHG17

SPN 3847/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

2
287.1 SPN 3848/FMI 3 - GHG17

SPN 3848/FMI 3
Dash Lamps CEL
Check as follows:

4. Verify that the parameter set to Resume/Accel Enable is configured correctly. Is the parameter configured
correctly?
1
2
287.2 SPN 3848/FMI 4 - GHG17

SPN 3848/FMI 4
Dash Lamps CEL
Check as follows:

4. Verify that the parameter set to Resume/Accel Enable is configured correctly. Is the parameter configured
correctly?
3
4
288.1 SPN 3849/FMI 3 - GHG17

SPN 3849/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

1
2
288.2 SPN 3849/FMI 4 - GHG17

SPN 3849/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

3
288.1 SPN 3850/FMI 3 - GHG17

SPN 3850/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

1
2
288.2 SPN 3850/FMI 4 - GHG17

SPN 3850/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

3
289.1 SPN 3851/FMI 3 - GHG17

SPN 3851/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1

2
289.2 SPN 3851/FMI 4 - GHG17

SPN 3851/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
3

4
291.1 SPN 3852/FMI 3 - GHG17

SPN 3852/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1. Has the Common Powertrain Controller (CPC) been recently changed or reprogrammed?

1
2
291.2 SPN 3852/FMI 4 - GHG17

SPN 3852/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

3
292.1 SPN 3853/FMI 3 - GHG17

SPN 3853/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

4. Verify that the parameter set to Mode of AC Status Input is configured correctly. Is the parameter
1
2
292.2 SPN 3853/FMI 4 - GHG17

SPN 3853/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

4. Verify that the parameter set to Mode of AC Status Input is configured correctly. Is the parameter
3
292.1 SPN 3854/FMI 3 - GHG17

SPN 3854/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
1
2
292.2 SPN 3854/FMI 4 - GHG17

SPN 3854/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:

3
4
293.1 SPN 3855/FMI 3 - GHG17

SPN 3855/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST

1
2
293.2 SPN 3855/FMI 4 - GHG17

SPN 3855/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

3
295.1 SPN 3856/FMI 3 - GHG17

SPN 3856/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST

1
2
295.2 SPN 3856/FMI 4 - GHG17

SPN 3856/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

3
296.1 SPN 3857/FMI 3 - GHG17

SPN 3857/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

4. Verify that the parameter set to Service Brake Switch Config is configured correctly. Is the parameter
2
296.2 SPN 3857/FMI 4 - GHG17

SPN 3857/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4. Verify that the parameter set to Service Brake Switch Config is configured correctly. Is the parameter
4
297.1 SPN 3858/FMI 3 - GHG17

SPN 3858/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
297.2 SPN 3858/FMI 4 - GHG17

SPN 3858/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
297.1 SPN 3859/FMI 3 - GHG17

SPN 3859/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

4. Verify that the parameter set to Trans Neutral Input Config is configured correctly. Is the parameter
2
297.2 SPN 3859/FMI 4 - GHG17

SPN 3859/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4. Verify that the parameter set to Trans Neutral Input Config is configured correctly. Is the parameter
4
298.1 SPN 3860/FMI 3 - GHG17

SPN 3860/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
298.2 SPN 3860/FMI 4 - GHG17

SPN 3860/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4
300.1 SPN 3861/FMI 3 - GHG17

SPN 3861/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
300.2 SPN 3861/FMI 4 - GHG17

SPN 3861/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4
301.1 SPN 3862/FMI 3 - GHG17

SPN 3862/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
2. Connect to DiagnosticLink
1

2
301.2 SPN 3862/FMI 4 - GHG17

SPN 3862/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
3

4
301.1 SPN 3863/FMI 3 - GHG17

SPN 3863/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
301.2 SPN 3863/FMI 4 - GHG17

SPN 3863/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4
302.1 SPN 3864/FMI 3 – GHG17

SPN 3864/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

2
302.2 SPN 3864/FMI 4 - GHG17

SPN 3864/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

4
303.1 SPN 3865/FMI 3 - GHG17

SPN 3865/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
303.2 SPN 3865/FMI 4 - GHG17

SPN 3865/FMI 4
Dash Lamps CEL

3
304.1 SPN 3866/FMI 3 – GHG17

SPN 3866/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1
304.2 SPN 3866/FMI 4 - GHG17

SPN 3866/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
2
305.1 SPN 3867/FMI 3 – GHG17

SPN 3867/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
305.2 SPN 3867/FMI 4 - GHG17

SPN 3867/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

3
4
306.1 SPN 3868/FMI 3 – GHG17

SPN 3868/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1

2
306.2 SPN 3868/FMI 4 - GHG17

SPN 3868/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

3
4
307.1 SPN 3869/FMI 3 - GHG17

SPN 3869/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
4. Verify that the parameters in PGR013 are set to the specific component to which this is configured. Are the
parameters configured correctly?
1
307.2 SPN 3869/FMI 4 - GHG17

SPN 3869/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
2
309.1 SPN 3870/FMI 3 – GHG17

SPN 3870/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST
1
309.2 SPN 3870/FMI 4 - GHG17

SPN 3870/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST
2
310.1 SPN 3871/FMI 2 - GHG17

Transmission Speed Failure
1.a Yes; insure the Transmission Speed Sensor (TSS) parameters are configured correctly for the vehicle
application. If the fault returns, Go to step 2.
2. Is the TSS hardwired or transmitted via J1939?
2.a Hardwired; Go to step 3.
2.b J1939; refer to the Application and Installation manual for the correct parameter configuration. If the
troubleshooting.
3. Disconnect the TSS harness connector; refer to OEM literature for location.
4. Inspect the TSS harness connector for bent, spread, or corroded pins.
5. Disconnect the CPC connector #3 or 4. Refer to OEM literature for TSS connector pin out.
6. Measure the resistance between CPC connector #3 pins 13 and 14 or connector #4 pins 4 and 5.
6.a If the resistance is less than 10K ohms, repair the short between CPC connector #3 pins 13 and 14 or
connector #4 pins 4 and 5 and the TSS connector.
7. Measure the resistance between CPC connector #3 pin 13 or connector #4 pin 4 and battery ground.
7.a If the resistance is less than 10K ohms, repair the wire between CPC connector #3 pin 13 or connector
#4 pin 4 and the TSS+ harness connection.
8. Measure the resistance between CPC connector #3 pin 13 or connector #4 pin 4 and the TSS+ harness
connection.
8.a If the resistance is greater than 5 ohms, repair the wire between CPC connector #3 pin 13 or connector
9. Measure the resistance between CPC connector #3 pin14 or connector #4 pin 5 and the VSS- harness
connector.
9.a If resistance is greater than 5 ohms, repair the wire between CPC connector #3 pin 14 or connector #4
pin 5 and the TSS- harness connection.
9.b If the resistance is less than 5 ohms, refer to OEM literature for TSS sensor diagnostics.
1
310.2 SPN 3871/FMI 3 - GHG17

Transmission Speed Sensor 4 04 or 3 13 Circuit Failed High
application. If fault returns, Go to step 2.
2.b J1939; refer to the Application and Installation manual for the correct parameter configuration. If the
troubleshooting.
5. Disconnect CPC connector #3 or 4. Refer to OEM literature for TSS connector pinout.
connector.
6.a If the resistance is greater than 5 ohms, repair the wire between CPC connector#3 pin 13 or connector
connector.
7.a If resistance is greater than 5 ohms, repair the wire between CPC connector #3 pin 14 or connector #4
2
310.3 SPN 3871/FMI 4 - GHG17

Transmission Speed Sensor 4 04 or 3 13 Circuit Failed Low
application. If fault returns, Go to step 2.
2.b J1939; refer to the Application and Installation manual for the correct parameter configuration. If
troubleshooting.
5. Disconnect CPC connector #3 or 4. Refer to OEM literature for TSS connector pinout.
6. Measure the resistance between CPC connector #3 pin 13 or connector #4 pin 4 and battery ground.
6.a If the resistance is less than 10K ohms, repair the wire between CPC connector #3 pin13 or connector
7. Measure the resistance between CPC connector #3 pins 13 and 14 or connector #4 pins 4 and 5.
7.a If the resistance is less than 10K ohms, repair the short between CPC connector #3 pins 13 and 14 or
connector #4 pins 4 and 5 and the TSS connector.
7.b If the resistance is greater than 10K ohms, refer to OEM literature for TSS sensor diagnostics.
3
310.4 SPN 3871/FMI 5 - GHG17

Transmission Speed Sensor 4 04 or 3 13 Circuit Failed Open
application. If the fault returns, Go to step 2.
2.b J1939; refer to the Application and Installation manual for the correct parameter configuration. If
troubleshooting.
5. Disconnect CPC connector #3 or 4. Refer to OEM literature for TSS connector pin out.
connector.
6.a If the resistance is greater than 5 ohms, repair the wire between CPC connector #3 pin 13 or connector
connector.
7.a If resistance is greater than 5 ohms, repair the wire between CPC connector #3 pin14 or connector #4
4
311.1 SPN 3872/FMI 3 – GHG17

SPN 3872/FMI 3
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1

4. Verify that the parameter set to 3 05 AO_01 Selection is set to the specific component to which this is
2
311.2 SPN 3872/FMI 4 - GHG17

SPN 3872/FMI 4
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3

ohms?
5.b No; repair an open circuit ground between pin 5 of the CPC connector #3 and the wired component.
4
312.1 SPN 3873/FMI 3 – GHG17

SPN 3873/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST

1
312.2 SPN 3873/FMI 4 - GHG17

SPN 3873/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

ohms?
2
312.1 SPN 3873/FMI 3 – GHG17

SPN 3873/FMI 3
Dash Lamps CEL
WARNING
ENGINE EXHAUST

3
312.2 SPN 3873/FMI 4 - GHG17

SPN 3873/FMI 4
Dash Lamps CEL
WARNING
ENGINE EXHAUST

ohms?
4
313.1 SPN 3936/FMI 18 - GHG17

Diesel Particulate Filter (DPF) Pressure - Out of Range Low
SPN 3936/FMI 18
(DOC) Inlet Pressure Delta is Below Normal Operating Range
for More Than 10 Seconds
Than 10%
Check as follows:
1. Visually inspect entire exhaust system for signs of leaks or damage. Are there any leaking or damaged
exhaust components?
3. Using the Selective Catalytic Reduction (SCR) voltage service routine, monitor the Diesel Oxidation
Catalyst (DOC) inlet pressure (pin 87) voltages with the key ON, engine OFF.
4. Is the DOC inlet pressure sensor voltage between .44 to .56 volts?
5. Inspect electrical connector between DOC inlet pressure sensor connector and harness for bent, spread, or
corroded pins. Is there any damage found?
6. Inspect the DOC pressure sensor tubes and elbows for leaks, kinks, or blockages. Were any leaks, kinks or
blockages found?
WARNING
ENGINE EXHAUST
1
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
7. Perform a parked regeneration; during the regeneration, monitor (ASL: DOC Inlet Pressure).
8. During the parked regeneration, does either the DOC inlet pressure sensor drop to 0.0 psi at any time?
8.a Yes; replace the failed sensor.
8.b No; clear fault and release unit. The code likely occurred after extended idle and soot buildup has
cleared.
2
313.1 SPN 3936/FMI 18 - GHG17

Type" field.
Diesel Particulate Filter (DPF) Pressure - Out of Range Low
SPN 3936/FMI 18
(DOC) Inlet Pressure Delta is Below Normal Operating Range
for More Than 10 Seconds
Than 10%
Check as follows:
1. Visually inspect entire exhaust system for signs of leaks or damage. Are there any leaking or damaged
exhaust components?
3. Using the Selective Catalytic Reduction (SCR) voltage service routine, monitor the Diesel Oxidation
Catalyst (DOC) inlet pressure (pin 87) voltages with the key ON, engine OFF.
4. Is the DOC inlet pressure sensor voltage between .44 to .56 volts?
5. Inspect electrical connector between DOC inlet pressure sensor connector and harness for bent, spread, or
corroded pins. Is there any damage found?
6. Inspect the DOC pressure sensor tubes and elbows for leaks, kinks, or blockages. Were any leaks, kinks or
blockages found?
3
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
7. Perform a parked regeneration; during the regeneration, monitor (ASL: DOC Inlet Pressure).
8. During the parked regeneration, does either the DOC inlet pressure sensor drop to 0.0 psi at any time?
8.a Yes; replace the failed sensor.
8.b No; clear fault and release unit. The code likely occurred after extended idle and soot buildup has
cleared.
4
5
314.1 SPN 3948/FMI 9 – GHG17

SPN 3948/FMI 9
Dash Lamps None
parameter settings.
configuration?
1
314.1 SPN 3948/FMI 9 – GHG17

SPN 3948/FMI 9
Dash Lamps None
parameter settings.
configuration?
2
315.1 SPN 4041/FMI 0 - GHG17

Common Powertrain Controller Internal Failure
2. Clear faults and retest. Does fault become active?
1
315.2 SPN 4041/FMI 9 - GHG17

2
315.3 SPN 4041/FMI 16 - GHG17

3
315.1 SPN 4041/FMI 0 - GHG17

4
315.2 SPN 4041/FMI 9 - GHG17

5
315.3 SPN 4041/FMI 16 - GHG17

6
316.1 SPN 4077/FMI 0 - GHG17

High Doser Fuel Line Pressure
SPN 4077/FMI 0
Description Hydrocarbon (HC) Doser Fuel Line Pressure High
Monitored Parameter Hydrocarbon (HC) Doser Fuel Line Pressure
Typical Duration 1 Minute
Dash Lamps MIL, CEL
steps.
2. Replace the Fuel Doser Injector Valve and clean the cavity in the flanged manifold/S-pipe. Refer to section
"Removal of the Hydrocarbon Fuel Doser Injector Valve" .
3. Connect DiagnosticLink Standard.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

Note : Purge routine may have to be performed three times to remove all air. Do not exceed three purge attempts.
WARNING
HOT EXHAUST
5. Using DiagnosticLink Standard, perform Purge Hydrocarbon Doser Service Routine.

6. Using DiagnosticLink Standard, initiate a Parked Regeneration. Does regen complete?
6.b No; replace Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
Verify repairs.
1
316.2 SPN 4077/FMI 3 - GHG17

Doser Fuel Line Pressure Sensor Circuit Failed High
SPN 4077/FMI 3
detects that the Hydrocarbon (HC) Doser Fuel Line Pressure
(FLP) Sensor Circuit is failed high.
Monitored Parameter Hydrocarbon (HC) Doser Fuel Line Pressure Sensor
Dash Lamps MIL, CEL
Check as follows:
3. Is the engine equipped with a DD15 AT engine?
2
4.a Yes; repair the circuit between pin 104 of the 120-pin Motor Control Module (MCM) and pin 2 of the
Fuel Doser Line Pressure sensor electrical connector/pin 2 of the Fuel Compensation Pressure sensor.
Verify repair.
5. Is fault code SPN 3510/FMI 3 also present?
5.a Yes; diagnose SPN 3510/FMI 3 first; Refer to section "SPN 3510/FMI 3 - GHG17" .
7. Disconnect the hydrocarbon doser fuel line pressure sensor (1).
8. Disconnect the 120-pin Motor Control Module (MCM) connector.

9. Measure the resistance from pin 111 of the 120-pin MCM connector harness side and pin 1 of the
hydrocarbon doser fuel line pressure sensor electrical connector harness side. Is the resistance less than 5
ohms?
9.b No; repair the circuit between pin 111 of the 120-pin MCM connector and pin 1 of the hydrocarbon
doser fuel line pressure sensor electrical connector. Verify repair.
ohms?
10.a Yes; replace the Motor Control Module (MCM), Refer to section "Removal of the Motor Control Module" . Verify
repair.
10.b No; repair the circuit between pin 2 of the hydrocarbon doser fuel line pressure sensor and the circuit
splice. Verify repair.
3
Fuel Line Pressure sensor electrical connector/ pin 4 of the Fuel Compensation Pressure sensor
electrical connector. Verify repair.
12.a Yes; diagnose fault code SPN 3510/FMI 3 first, Refer to section "SPN 3510/FMI 3 - GHG17".

ohms?
4
316.3 SPN 4077/FMI 4 - GHG17

Doser Fuel Line Pressure Sensor Circuit Failed Low
SPN 4077/FMI 4
(FLP) Sensor Circuit is failed low.
Dash Lamps MIL, CEL
Check as follows:
3.a Yes; diagnose SPN 3510/FMI 4; Refer to section "SPN 3510/FMI 4 - GHG17" .
4. Is this vehicle equipped with a DD15 AT engine?
5

5. Disconnect the Hydrocarbon doser fuel line pressure sensor (1). Is fault code SPN 4077/FMI 4 still present?
5.a Yes; repair the circuit between pin 111 of the 120-pin MCM connector and pin 1 of the hydrocarbon
doser fuel line pressure sensor connector. Verify repair.
5.b No; replace the hydrocarbon doser block; Refer to section "Removal of the Hydrocarbon Doser Block " . Verify
repair.
6
repair.
7
316.4 SPN 4077/FMI 14 - GHG17

Doser Fuel Line Pressure Failed Self-Test
SPN 4077/FMI 14
Description This fault will set when the Doser Line Pressure is less than
20.6 kPa (3 psi), once all conditions are met.

Typical Duration Seven seconds
Dash Lamps MIL, CEL
Engine Reaction Derate 10%, Diesel Particulate Filter (DPF) Inhibit
Regeneration
Check as follows:
Note : This fault code may have been caused by an exceeded temperature threshold due to a small capacity
single fuel tank and extended PTO mode operation.
steps.
• Faults are listed in diagnostic priority from top to bottom:
• SPN 3480/FMI 3 or 4
• SPN 4077/FMI 3 or 4
• SPN 3480/FMI 1
Note : Any trace of fuel visible on the Hydrocarbon (HC) doser block, dosing fuel line, or fuel doser injector valve
is an indication of a fuel leak that can cause this fault.
5. Visually inspect HC doser block assembly, dosing fuel line and fuel doser injector valve for external leaks.
Are any external leaks are present?
5.b No; replace the Hydrocarbon Doser Fuel Injector Valve and clean the cavity in the flanged manifold/S-
pipe. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector Valve" . Go to step 6.
WARNING
ENGINE EXHAUST
8
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

7. Perform two consecutive HC Doser Purge routines.
WARNING
HOT EXHAUST
8. Perform a parked regeneration to confirm the repair. Refer to section "Performing a Parked Regeneration - GHG17" .
9. Is SPN 4077 FMI 14 still active?
9.a Yes; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " then Go to step 10.
10. Perform two consecutive HC Doser Purge routines and verify repairs.
9
316.1 SPN 4077/FMI 0 - GHG17

High Doser Fuel Line Pressure
SPN 4077/FMI 0
Description Hydrocarbon (HC) Doser Fuel Line Pressure High
Monitored Parameter Hydrocarbon (HC) Doser Fuel Line Pressure
Typical Duration 1 Minute
Dash Lamps MIL, CEL
steps.
2. Replace the Fuel Doser Injector Valve and clean the cavity in the flanged manifold/S-pipe. Refer to section
"Removal of the Hydrocarbon Fuel Doser Injector Valve" .
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

Note : Purge routine may have to be performed three times to remove all air. Do not exceed three purge attempts.
WARNING
HOT EXHAUST
5. Using DiagnosticLink Standard, perform Purge Hydrocarbon Doser Service Routine.

6. Using DiagnosticLink Standard, initiate a Parked Regeneration. Does regen complete?
10
6.b No; replace Hydrocarbon Fuel Doser Block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " .
Verify repairs.
11
316.2 SPN 4077/FMI 3 - GHG17

Doser Fuel Line Pressure Sensor Circuit Failed High
SPN 4077/FMI 3
(FLP) Sensor Circuit is failed high.
Dash Lamps MIL, CEL
Check as follows:
3. Is the engine equipped with a DD15 AT engine?
12
Fuel Doser Line Pressure sensor electrical connector/pin 2 of the Fuel Compensation Pressure sensor.
Verify repair.
5.a Yes; diagnose SPN 3510/FMI 3 first; Refer to section "SPN 3510/FMI 3 - GHG17" .

ohms?
ohms?
10.a Yes; replace the Motor Control Module (MCM), Refer to section "Removal of the Motor Control Module" . Verify
repair.
10.b No; repair the circuit between pin 2 of the hydrocarbon doser fuel line pressure sensor and the circuit
splice. Verify repair.
13
Fuel Line Pressure sensor electrical connector/ pin 4 of the Fuel Compensation Pressure sensor
electrical connector. Verify repair.
12.a Yes; diagnose fault code SPN 3510/FMI 3 first, Refer to section "SPN 3510/FMI 3 - GHG17".

ohms?
14
316.3 SPN 4077/FMI 4 - GHG17

Doser Fuel Line Pressure Sensor Circuit Failed Low
SPN 4077/FMI 4
(FLP) Sensor Circuit is failed low.
Dash Lamps MIL, CEL
Check as follows:
3.a Yes; diagnose SPN 3510/FMI 4; Refer to section "SPN 3510/FMI 4 - GHG17" .
4. Is this vehicle equipped with a DD15 AT engine?
15

doser fuel line pressure sensor connector. Verify repair.
repair.
16
repair.
17
316.4 SPN 4077/FMI 14 - GHG17

Doser Fuel Line Pressure Failed Self-Test
SPN 4077/FMI 14
Description This fault will set when the Doser Line Pressure is less than
20.6 kPa (3 psi), once all conditions are met.

Typical Duration Seven seconds
Dash Lamps MIL, CEL
Engine Reaction Derate 10%, Diesel Particulate Filter (DPF) Inhibit
Regeneration
Check as follows:
Note : This fault code may have been caused by an exceeded temperature threshold due to a small capacity
single fuel tank and extended PTO mode operation.
steps.
• Faults are listed in diagnostic priority from top to bottom:
• SPN 3480/FMI 3 or 4
• SPN 4077/FMI 3 or 4
• SPN 3480/FMI 1
Note : Any trace of fuel visible on the Hydrocarbon (HC) doser block, dosing fuel line, or fuel doser injector valve
is an indication of a fuel leak that can cause this fault.
5. Visually inspect HC doser block assembly, dosing fuel line and fuel doser injector valve for external leaks.
Are any external leaks are present?
5.b No; replace the Hydrocarbon Doser Fuel Injector Valve and clean the cavity in the flanged manifold/S-
pipe. Refer to section "Removal of the Hydrocarbon Fuel Doser Injector Valve" . Go to step 6.
WARNING
ENGINE EXHAUST
18
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

7. Perform two consecutive HC Doser Purge routines.
WARNING
HOT EXHAUST
8. Perform a parked regeneration to confirm the repair. Refer to section "Performing a Parked Regeneration - GHG17" .
9. Is SPN 4077 FMI 14 still active?
9.a Yes; replace the HC doser block. Refer to section "Removal of the Hydrocarbon Fuel Doser Block " then Go to step 10.
10. Perform two consecutive HC Doser Purge routines and verify repairs.
19
317.1 SPN 4193/FMI 3 - GHG17

Engine Coolant Inlet Temperature Circuit Failed High
SPN 4193/FMI 3
Description Engine Coolant Inlet Temperature Circuit Failed High
Monitored Parameter Engine Coolant Inlet Temperature Sensor
Dash Lamps MIL, CEL
Engine Reaction
Fig 0.1, Engine Coolant Inlet Temperature Circuit
1. Disconnect the engine coolant inlet temperature sensor.

4. Measure the voltage between pins 1 and 2 of the engine coolant inlet temperature sensor harness
connector.
4.a If the voltage is between 2.8 and 3 volts, replace the engine coolant inlet temperature sensor. Refer to
section "Removal of the Engine Coolant Inlet Temperature Sensor" .
1

5. Measure voltage between pin 2 of the engine coolant inlet temperature sensor and ground.
5.a If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the engine coolant inlet
temperature sensor connector and pin 55 of the MCM 120-pin connector.
5.b If the voltage is less than 2.8 volts, repair the wire between pin 2 of the engine coolant inlet
connector.
6.a If the voltage is greater than 3 volts, repair the short to power on one of the following MCM pins: 77, 80,
108 or 110.
6.b If no voltage is present, repair the open between pin 55 of the MCM 120-pin connector and the engine
coolant outlet temperature, engine coolant inlet temperature, engine oil temperature and the supply fuel
temperature sensors.
2
317.2 SPN 4193/FMI 4 - GHG17

Engine Coolant Inlet Temperature Circuit Failed Low
SPN 4193/FMI 4
Description Engine Coolant Inlet Temperature Circuit Failed Low
Dash Lamps MIL, CEL
Engine Reaction
1. Disconnect the engine coolant inlet temperature sensor connector.

4. Measure the resistance between pins 1 and 2 on the coolant inlet temperature sensor connector.
4.a If the resistance is less than 1k ohms, repair the short to ground between pin 2 of the engine coolant
inlet sensor harness connector and pin 80 of the MCM 120-pin connector.
3
4.b If the resistance is greater than 1k ohms, replace the engine coolant inlet temperature sensor. Refer to
4
317.3 SPN 4193/FMI 20 - GHG17

Coolant Inlet Temperature Signal Not Plausible
SPN 4193/FMI 20
detects that the engine coolant inlet temperature is greater
than 20°C (36°F) degrees from the expected temperature
after the engine has been turned off for 8 hours.
Monitored Parameter
Coolant inlet temperature
Dash Lamps MIL
operating temperature. Then verify that the engine coolant
inlet temperature is within 20°C (36°F) of the engine coolant
outlet temperature.
Possible causes:
been changed?
5. Monitor and record the engine coolant inlet temperature.
WARNING
PERSONAL INJURY
5
WARNING
ENGINE EXHAUST

8. Monitor engine coolant inlet temperature. Has the temperature increased from the previously recorded
value?
9. Compare the engine coolant inlet temperature to the engine coolant outlet temperature. Is the difference
10. Disconnect and inspect the engine coolant inlet temperature sensor electrical connector. Is there damage
10.b No; replace the engine coolant inlet temperature sensor. Verify repair.
6
317.1 SPN 4193/FMI 3 - GHG17

Engine Coolant Inlet Temperature Circuit Failed High
SPN 4193/FMI 3
Description Engine Coolant Inlet Temperature Circuit Failed High
Dash Lamps MIL, CEL
Engine Reaction
1. Disconnect the engine coolant inlet temperature sensor.

7
connector.
4.a If the voltage is between 2.8 and 3 volts, replace the engine coolant inlet temperature sensor. Refer to

5. Measure voltage between pin 2 of the engine coolant inlet temperature sensor and ground.
5.a If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the engine coolant inlet
5.b If the voltage is less than 2.8 volts, repair the wire between pin 2 of the engine coolant inlet
connector.
6.a If the voltage is greater than 3 volts, repair the short to power on one of the following MCM pins: 77, 80,
108 or 110.
6.b If no voltage is present, repair the open between pin 55 of the MCM 120-pin connector and the engine
coolant outlet temperature, engine coolant inlet temperature, engine oil temperature and the supply fuel
temperature sensors.
8
317.2 SPN 4193/FMI 4 - GHG17

Engine Coolant Inlet Temperature Circuit Failed Low
SPN 4193/FMI 4
Description Engine Coolant Inlet Temperature Circuit Failed Low
Dash Lamps MIL, CEL
Engine Reaction
1. Disconnect the engine coolant inlet temperature sensor connector.

4. Measure the resistance between pins 1 and 2 on the coolant inlet temperature sensor connector.
4.a If the resistance is less than 1k ohms, repair the short to ground between pin 2 of the engine coolant
inlet sensor harness connector and pin 80 of the MCM 120-pin connector.
9
4.b If the resistance is greater than 1k ohms, replace the engine coolant inlet temperature sensor. Refer to
10
317.3 SPN 4193/FMI 20 - EuroV

Coolant Inlet Temperature Signal Not Plausible
SPN 4193/FMI 20
detects that the engine coolant inlet temperature is greater
than 20°C (36°F) from the expected temperature after the
engine has been turned off for eight hours.
Monitored Parameter
Coolant inlet temperature
(104°F), engine OFF for no less than eight hours.
Dash Lamps MIL
operating temperature. Then verify that the engine coolant
inlet temperature is within 20°C (36°F) of the engine coolant
outlet temperature.
Possible causes:
Note : The use of an external heating unit while the engine has been shut down for a minimum of eight hours can
been changed?
5. Monitor and record the engine coolant inlet temperature.
WARNING
PERSONAL INJURY
11
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

8. Monitor engine coolant inlet temperature. Has the temperature increased from the previously recorded
value?
9. Compare the engine coolant inlet temperature to the engine coolant outlet temperature. Is the difference
10. Disconnect and inspect the engine coolant inlet temperature sensor electrical connector. Is there damage
10.b No; replace the engine coolant inlet temperature sensor. Verify repair.
12
318.1 SPN 4206/FMI 2 - GHG17

2.a Yes; Replace the Common Powertrain Controller (CPC) and reprogram with the latest software
release.
1
319.1 SPN 4207/FMI 2 - GHG17

1
319.1 SPN 4207/FMI 2 - GHG17

2
320.1 SPN 4257/FMI 3 - GHG17

Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Battery
SPN 4257/FMI 3
Description Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to
Battery
Monitored Parameter Injector Amplifier Control Valve Cylinder 1, 2, 3
Typical Enabling Conditions fis_nop_act is greater than 1.85
Dash Lamps MIL, CEL
Verification Engine rpm 1400 - 1500 (1 minute)
Check as follows:
3. Measure the voltage between pin 5 on the Motor Control Module (MCM) engine harness side of the front
fuel injector harness 14-pin connector and battery ground.
1
3.a If there is voltage present, repair the short to power between pin 5 of the engine harness side front fuel
injector harness 14-pin connector and pin 13 of the MCM 120-pin connector.
3.b If there is no voltage present, Go to step 4.
4. Measure the voltage between pin 12 on the MCM side of the engine harness side front fuel injector harness
14-pin connector and ground.
4.a If there is voltage present, repair the short to power between pin 12 of the engine harness side front
fuel injector harness connector and pin 12 of the MCM 120-pin connector.
5. Measure the voltage between pin 9 on the MCM side of the front fuel injector harness 14-pin connector and
ground.
5.b If there is no voltage present, repair the short to power between pin 8 of the front fuel injector harness
2
320.2 SPN 4257/FMI 4 - GHG17

Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Ground
SPN 4257/FMI 4
Description This code sets when the MCM detects that there is a short to
ground on the circuits for the injector amplifier control valve on
cylinders 1, 2 and or 3.
Typical Enabling Conditions Fuel injector system nozzle opening pressure reading greater
than 1.85
Dash Lamps MIL, CEL
Fig 0.1, Tool J-48671-10 Injector Breakout Box
3
Fig 0.2, Tool J-48671-HDE DD13/15 Injector Breakout Box Harness Adaptor
4
Check as follows:
5
1. Disconnect the front fuel injector harness 14-pin connector. Go to step 2.

2. Inspect both sides of the front fuel injector harness 14-pin connectors for oil intrusion. Is there any oil
present in the connectors?
2.a Yes; replace the under valve cover harness and clean the engine side harness connector.
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" . Verify repair.
3. Inspect the front fuel injector harness 14-pin connectors for spread or damaged pins. Are there any spread
or damaged pins?
4. Measure the resistance between pin 5 on the value cover side of the front fuel injector harness 14-pin
connector and ground. If you are using tools J-48671-10 and J-48671-HDE, measure between fuel injector
#4 pin 1 and ground. Is the resistance less than 5 ohms?
6. Disconnect the electrical harness connecter on fuel injector #1. Go to step 7.
7. Measure the resistance between pin 5 on the valve cover side of the front fuel injector harness 14-pin
#1 pin 1 and ground. Is the resistance greater than 5 ohms?
Refer to section "Removal of the Fuel Injector - Two-Filter System" . Verify repair.
#2 pin 1 and ground. Is the resistance greater than five ohms?
9.a Yes; replace injector #2.
11.b No; replace the under valve cover harness.
13. Measure the resistance between pin 5 of the engine harness side of the front fuel injector harness 14-pin
connector and ground. Is the resistance greater than 5 ohms?
13.b No; repair the short to ground between pin 13 of the MCM 120-pin connector and pin 5 of the front fuel
injector harness 14-pin connector. Verify repair.
6
16.b No; repair the short between pin 12 of the MCM 120-pin connector and pin 12 of the front fuel injector
harness 14-pin connector. Verify repair.
7
320.1 SPN 4257/FMI 3 - GHG17

SPN 4257/FMI 3
Battery
Dash Lamps MIL, CEL
Check as follows:
3. Measure the voltage between pin 5 on the Motor Control Module (MCM) engine harness side of the front
fuel injector harness 14-pin connector and battery ground.
8
3.a If there is voltage present, repair the short to power between pin 5 of the engine harness side front fuel
injector harness 14-pin connector and pin 13 of the MCM 120-pin connector.
4. Measure the voltage between pin 12 on the MCM side of the engine harness side front fuel injector harness
14-pin connector and ground.
4.a If there is voltage present, repair the short to power between pin 12 of the engine harness side front
fuel injector harness connector and pin 12 of the MCM 120-pin connector.
5. Measure the voltage between pin 9 on the MCM side of the front fuel injector harness 14-pin connector and
ground.
5.b If there is no voltage present, repair the short to power between pin 8 of the front fuel injector harness
9
320.2 SPN 4257/FMI 4 - GHG17

SPN 4257/FMI 4
cylinders 1, 2 and or 3.
Typical Enabling Conditions Fuel injector system nozzle opening pressure reading greater
than 1.85
Dash Lamps MIL, CEL
10
11
Check as follows:
12
1. Disconnect the front fuel injector harness 14-pin connector. Go to step 2.

2. Inspect both sides of the front fuel injector harness 14-pin connectors for oil intrusion. Is there any oil
present in the connectors?
3. Inspect the front fuel injector harness 14-pin connectors for spread or damaged pins. Are there any spread
or damaged pins?
4. Measure the resistance between pin 5 on the value cover side of the front fuel injector harness 14-pin
#4 pin 1 and ground. Is the resistance less than 5 ohms?
#1 pin 1 and ground. Is the resistance greater than 5 ohms?
13
16.b No; repair the short between pin 12 of the MCM 120-pin connector and pin 12 of the front fuel injector
14
1
321.2 SPN 4258/FMI 3 - GHG17

SPN 4258/FMI 3
Battery
Dash Lamps MIL, CEL

harness 14-pin connector and ground.
3.a If there is voltage present, repair the short to power between pin 1 of the Rear fuel injector Harness 14-
4. Measure the voltage between pin 8 on the MCM side of the rear fuel injector harness 14-pin connector and
ground.
4.a If there is voltage present, repair the short to power between pin 8 of the rear fuel injector harness
connector and pin 8 of the 120-pin MCM connector.
4.b If there is no voltage present, repair the short to power between pin 12 of the rear fuel injector harness
2
321.3 SPN 4258/FMI 4 - GHG17

SPN 4258/FMI 4
cylinders 4, 5 and/or 6.
Typical Enabling Conditions Fuel injector system nozzle opening pressure greater than
1.85
Dash Lamps MIL, CEL
3
4
Check as follows:
5
1. Disconnect the rear fuel injector Harness 14-pin connector. Go to step 2.

2. Inspect both sides of the rear fuel injector harness 14-pin connector for oil intrusion. Is there any oil present
in the connectors?
3. Inspect the rear fuel injector harness 14-pin connectors for spread or damaged pins. Are there any spread
or damaged pins?
4. Measure the resistance between pin 5 on the valve cover side of the rear fuel injector harness 14-pin
connector and ground. If you are using tools J-48671-10 and J-48671-HDE, measure between pin 1 of fuel
injector #4 pin 1 and ground. Is the resistance less than 5 ohms?
injector #4 pin 1 and ground. Is the resistance greater than 5 ohms?
Refer to section "Removal of the Fuel Injector - Two-Filter System" .Verify repair.
13. Measure the resistance between pin 5 of the engine harness side of the rear fuel injector harness 14-pin
13.b No; repair the short to ground between pin 7 of the MCM 120-pin connector and pin 5 of the rear fuel
6
16.b No; repair the short between pin 6 of the MCM 120-pin connector and pin 12 of the rear fuel injector
7
8
321.2 SPN 4258/FMI 3 - GHG17

SPN 4258/FMI 3
Battery
Dash Lamps MIL, CEL

harness 14-pin connector and ground.
3.a If there is voltage present, repair the short to power between pin 1 of the Rear fuel injector Harness 14-
4. Measure the voltage between pin 8 on the MCM side of the rear fuel injector harness 14-pin connector and
ground.
4.a If there is voltage present, repair the short to power between pin 8 of the rear fuel injector harness
4.b If there is no voltage present, repair the short to power between pin 12 of the rear fuel injector harness
9
321.3 SPN 4258/FMI 4 - GHG17

SPN 4258/FMI 4
cylinders 4, 5 and/or 6.
Typical Enabling Conditions Fuel injector system nozzle opening pressure greater than
1.85
Dash Lamps MIL, CEL
10
11
Check as follows:
12
1. Disconnect the rear fuel injector Harness 14-pin connector. Go to step 2.

2. Inspect both sides of the rear fuel injector harness 14-pin connector for oil intrusion. Is there any oil present
in the connectors?
3. Inspect the rear fuel injector harness 14-pin connectors for spread or damaged pins. Are there any spread
or damaged pins?
injector #4 pin 1 and ground. Is the resistance less than 5 ohms?
13
16.b No; repair the short between pin 6 of the MCM 120-pin connector and pin 12 of the rear fuel injector
14
322.1 SPN 4331/FMI 15 - GHG17

DEF Dosing Quantity Low
SPN 4331/FMI 15
Description The Fault Indicates Low DEF Delivery
Monitored Parameter NOx Conversion Efficiency
Typical Enabling Conditions Closed Loop DEF Dosing
Dash Lamps None
Verification Parked SCR Efficiency Test Followed By a Full Parked
Regeneration
Check as follows:
2. Visually check all DEF supply lines for physical damage (kinks, cracks, leaks, disconnects). Is any damage
found?
2.a Yes; repair as necessary; Go to step 3.
3. Using a refractometer from the DEF Test Kit W060589001900, measure the DEF percentage. Is DEF
percentage between 31 and 34%?
3.b No; Clean/flush the DEF tank. Go to step 4. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
4. Unbolt DEF Dosing Unit from aftertreatment. Do not disconnect DEF hoses or electrical connector. Refer to
section "Removal of the Diesel Exhaust Fluid Dosing Unit" .
Note : Monitor and record the DEF Pump Speed and DEF Pump Pressure values during DEF quantity test. The
values will be used in the next step.
5. Perform DEF Quantity Test service routine and record the amount of DEF dispensed, pump speed and
DEF pressure. Is the dispensed DEF fluid level between 108 and 132 mL?
5.b No; replace the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . To verify
repairs, Go to step 8.
Note : Normal values for DEF pump speed and pressure are as follows:Normal DEF Pump Speed: Greater than
750 rpm, less than 1800 rpm.Normal DEF Pump Pressure: Greater than 9 bar, less than 11 bar.
6. Did the DEF Quantity Test service routine DEF pump speed and DEF pressure values match normal
values?
6.a Yes; replace the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . To verify
7. Inspect the DEF pump harness connector for bent, spread or corroded pins. Is any damage found?
7.a Yes; repair as necessary. To verify repairs, Go to step 8.
7.b No; replace DEF pump. To verify repairs, Go to step 8. Refer to section "Removal of the Diesel Exhaust Fluid Pump
Module" .
1
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start the engine and perform a Parked SCR Efficiency test to clear fault and verify repairs. Refer to section
"GHG17 Perform Parked SCR Efficiency Test" .
2
322.1 SPN 4331/FMI 15 - GHG17

DEF Dosing Quantity Low
SPN 4331/FMI 15
Description The Fault Indicates Low DEF Delivery
Dash Lamps None
Verification Parked SCR Efficiency Test Followed By a Full Parked
Regeneration
Check as follows:
2. Visually check all DEF supply lines for physical damage (kinks, cracks, leaks, disconnects). Is any damage
found?
2.a Yes; repair as necessary; Go to step 3.
3.b No; Clean/flush the DEF tank. Go to step 4. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
4. Unbolt DEF Dosing Unit from aftertreatment. Do not disconnect DEF hoses or electrical connector. Refer to
Note : Monitor and record the DEF Pump Speed and DEF Pump Pressure values during DEF quantity test. The
values will be used in the next step.
5. Perform DEF Quantity Test service routine and record the amount of DEF dispensed, pump speed and
DEF pressure. Is the dispensed DEF fluid level between 108 and 132 mL?
5.b No; replace the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . To verify
Note :
6. Did the DEF Quantity Test service routine DEF pump speed and DEF pressure values match normal
values?
6.a Yes; replace the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . To verify
7. Inspect the DEF pump harness connector for bent, spread or corroded pins. Is any damage found?
7.a Yes; repair as necessary. To verify repairs, Go to step 8.
7.b No; replace DEF pump. To verify repairs, Go to step 8. Refer to section "Removal of the Diesel Exhaust Fluid Pump
Module" .
3
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start the engine and perform a Parked SCR Efficiency test to clear fault and verify repairs. Refer to section
"GHG17 Perform Parked SCR Efficiency Test" .
4
323.1 SPN 4332/FMI 31 – GHG17

The fault indicates the High Idle Regeneration (HIR) was aborted due to Diesel Oxidation Catalyst (DOC) inlet
temperature not reaching the minimum of 270°C (518°F) to initiate dosing during an HIR. The Malfunction
Indicator Lamp (MIL) will remain ON until the fault is resolved or a successful regeneration is complete.
SPN 4332/FMI 31
Description DOC Inlet Temperature Out of Range Low
Monitored Parameter DOC temperature
Typical Enabling Conditions Regeneration
Dash Lamps MIL
Note : Retain log file if customer assistance is required.

2. Check fault codes. Are SPN 3242/FMI 8 or SPN 3242/FMI 20 active or previously active?
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Monitor the DOC inlet temperature sensor and the DOC outlet temperature sensor. Continue idling for 10
minutes. Is the DOC inlet temperature drifted low?
4.a Yes; replace the DOC inlet temperature sensor and perform a Parked Regen.
5. If equipped with an Intake Throttle valve, use DiagnosticLink to perform an Intake Throttle Service Routine.
Is the commanded position achieved?
5.b No; replace the Intake Throttle Valve (ITV).
6. Inspect the exhaust system for leaks. Are any leaks found?
1

7. Pressurize the intake tract and inspect for leaks. Are any leaks found?
WARNING
HOT EXHAUST
8. Perform a Parked Regeneration. Refer to section "Performing a Parked Regeneration - GHG17" . Does the regen
complete?
8.b No; check engine brakes for proper operation. Repair as necessary.
2
324.1 SPN 4334/FMI 3 - GHG17

Diesel Exhaust Fluid Pressure Sensor Circuit Failed High
SPN 4334/FMI 3
Description Diesel Exhaust Fluid (DEF) Pressure Sensor Circuit Voltage
Above Normal, or Shorted to High Source
Monitored Parameter Diesel Exhaust Fluid (DEF) Pressure Sensor
Dash Lamps MIL, CEL
8-Pin Circuit ACM-Pin Connector

1 Metering Valve Low Side 28
2 Metering Valve High Side 33
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
Check as follows:
1.a If SPN 4334/FMI 3 and SPN 3510/FMI 3 are present, repair short to voltage (greater than 5.0V)
between pin 8 of the DEF pressure sensor and pin 100 of the Aftertreatment Control Module (ACM)
120-pin connector.
4. Inspect the dosing unit connector and the dosing unit harness connector for signs of damage, bent, spread,
broken, pushed out (unseated) or corroded pins or wire damage near the connector. Is any damage found?
6. Using DiagnosticLink , does the SPN 4334/FMI 3 change to SPN 3361/FMI 5 with the DEF dosing unit
disconnected?
repairs.
7. Measure the voltage between pin 8 of the DEF dosing unit connector harness side and ground. Is the
voltage greater than 0.5V?
7.a Yes; repair short to supply voltage between pin 8 of the DEF dosing unit and pin 100 of the ACM.
1

11. Measure the resistance between pin 7 of the DEF dosing unit connector, harness side and pin 99 of the
ACM 120-pin connector, harness side. Is the resistance less than 5 ohms?
For Two-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
11.b No; repair the open wire between pin 7 of the DEF dosing unit and pin 99 of the ACM 120-pin
connector. Inspect all intermediate connections in chassis wiring. Refer to OEM wiring diagrams for
exact routing.
2
324.2 SPN 4334/FMI 4 - GHG17

Diesel Exhaust Fluid Pressure Sensor Circuit Failed Low
SPN 4334/FMI 4
Below Normal, or Shorted to Low Source
Dash Lamps MIL, CEL

4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
3
Check as follows:
1.a If SPN 4334/FMI 4, and SPN 3510/FMI 4 are present, repair short to ground between pin 5 of the DEF
dosing unit and pin 84 of the Aftertreatment Control Module (ACM).
4. Inspect the DEF dosing unit connector and the DEF dosing unit harness side connector for signs of
damage, bent, spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector.
Is any damage found?
7. Measure the resistance between pin 7 and pin 8 on the DEF dosing unit connector, harness side. Is the
7.b No; repair the short in the wire harness between pin 7 and pin 8 of the DEF dosing unit. Check
intermediate connections in chassis wiring; refer to OEM wiring diagrams for exact routing. Verify
repairs.
8. Measure the resistance between pin 8 on the DEF dosing unit connector, harness side, and chassis
ground. Is the resistance greater than 10K ohms?
8.b No; repair the short in the wire harness between pin 8 of the DEF dosing unit and ground. Check
repairs.
9. Measure the resistance between pin 8 of the DEF dosing unit connector, harness side, and pin 100 of the
ACM 120-pin connector, harness side. Is the resistance less than five ohms?
9.b No; repair the open wire between pin 8 of the DEF dosing unit connector and pin 100 of the ACM 120-
pin connector. Check intermediate connections in chassis wiring; refer to OEM wiring diagrams for
exact routing. Verify repairs.
WARNING
ENGINE EXHAUST
4
12. Measure the voltage between pin 84 of the ACM 120-pin connector, component side, and ground. Is the
repairs.
12.b No; replace ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repairs.
5
324.1 SPN 4334/FMI 3 - GHG17

Diesel Exhaust Fluid Pressure Sensor Circuit Failed High
SPN 4334/FMI 3
Above Normal, or Shorted to High Source
Dash Lamps MIL, CEL

4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
Check as follows:
1.a If SPN 4334/FMI 3 and SPN 3510/FMI 3 are present, repair short to voltage (greater than 5.0V)
between pin 8 of the DEF pressure sensor and pin 100 of the Aftertreatment Control Module (ACM)
120-pin connector.
4. Inspect the dosing unit connector and the dosing unit harness connector for signs of damage, bent, spread,
6. Using DiagnosticLink , does the SPN 4334/FMI 3 change to SPN 3361/FMI 5 with the DEF dosing unit
disconnected?
repairs.
7. Measure the voltage between pin 8 of the DEF dosing unit connector harness side and ground. Is the
voltage greater than 0.5V?
6
7.a Yes; repair short to supply voltage between pin 8 of the DEF dosing unit and pin 100 of the ACM.
11. Measure the resistance between pin 7 of the DEF dosing unit connector, harness side and pin 99 of the
ACM 120-pin connector, harness side. Is the resistance less than 5 ohms?
For Two-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
11.b No; repair the open wire between pin 7 of the DEF dosing unit and pin 99 of the ACM 120-pin
connector. Inspect all intermediate connections in chassis wiring. Refer to OEM wiring diagrams for
exact routing.
7
324.2 SPN 4334/FMI 4 - GHG17

Diesel Exhaust Fluid Pressure Sensor Circuit Failed Low
SPN 4334/FMI 4
Below Normal, or Shorted to Low Source
Dash Lamps MIL, CEL

4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
8
Check as follows:
1.a If SPN 4334/FMI 4, and SPN 3510/FMI 4 are present, repair short to ground between pin 5 of the DEF
dosing unit and pin 84 of the Aftertreatment Control Module (ACM).
4. Inspect the DEF dosing unit connector and the DEF dosing unit harness side connector for signs of
damage, bent, spread, broken, pushed out (unseated) or corroded pins or wire damage near the connector.
Is any damage found?
7. Measure the resistance between pin 7 and pin 8 on the DEF dosing unit connector, harness side. Is the
7.b No; repair the short in the wire harness between pin 7 and pin 8 of the DEF dosing unit. Check
repairs.
8. Measure the resistance between pin 8 on the DEF dosing unit connector, harness side, and chassis
8.b No; repair the short in the wire harness between pin 8 of the DEF dosing unit and ground. Check
repairs.
WARNING
ENGINE EXHAUST
9
12. Measure the voltage between pin 84 of the ACM 120-pin connector, component side, and ground. Is the
repairs.
12.b No; replace ACM. Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repairs.
10
325.1 SPN 4354/FMI 3 - GHG17

Line Heater #1 Circuit Failed High
become active?
6. Disconnect the line heater #1 harness connector.
7.b If connector shows no signs of damage, repair the short to battery (12 volts) between pin 1 of the line
heater #1 harness connector and pin 6 of the ACM 120-pin connector.
1
325.2 SPN 4354/FMI 4 - GHG17

Line Heater #1 Circuit Failed Low
2. Disconnect the line heater #1 connector.
5. Measure the resistance between pin 1 on the harness side of the line heater #1 connector and ground.
5.a If the resistance is less than 1k ohms, repair the wire between pin 1 of the line heater #1 connector and
5.b If the resistance is greater than 1k ohms, replace the line heater #1. Refer to OEM procedures.
2
325.3 SPN 4354/FMI 5 - GHG17

Line Heater 1 Open Circuit
1.a If SPN 4354/FMI 5 and SPN 4356/FMI 5 are present, repair open between pin 9 of the ACM 120-pin
connector and pin 2 of line heaters 1 and 3.
2. Disconnect line heater 1.
4. Measure the voltage between pin 2 on the harness side of line heater 1 connector and ground.
4.a If the voltage is greater than 11.75, Go to step 5.
4.b If the voltage is less than 11.75, repair wire between pin 2 on the harness side of line heater 1
connector and pin 9 of the ACM.
5.a If the voltage is between 2.25 and 2.50, Go to step 6.
5.b If the voltage is not between 2.25 and 2.50, repair wire between pin 1 on the harness side of line heater
1 connector and pin 6 of the ACM.
6. Measure the resistance on the heating element side of line heater 1. If resistance is not within this range,
replace the line heating element. Refer to table below for proper resistance values.
Diesel Exhaust Fluid Line Heater Resistance Chart

Length (mm) Length (inches) Nominal Resistance Min Resistance Max Resistance
(ohms) (ohms) (ohms)
500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
3
325.1 SPN 4354/FMI 3 - GHG17

become active?
4
325.2 SPN 4354/FMI 4 - GHG17

5.b If the resistance is greater than 1k ohms, replace the line heater #1. Refer to OEM procedures.
5
325.3 SPN 4354/FMI 5 - GHG17


500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
6
326.1 SPN 4355/FMI 3 - GHG17

become active?
1
326.2 SPN 4355/FMI 4 - GHG17

5.b If the resistance is greater than 1k ohms, replace the line heater #2.
2
326.3 SPN 4355/FMI 5 - GHG17


500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
3
327.1 SPN 4356/FMI 3 - GHG17

become active?
6. Disconnect the Line Heater #3 harness connector.
7.b If connector shows no signs of damage, repair the short to battery (12 volts) between pin 1 of the Line
Heater #3 harness connector and pin 18 of the ACM 120-pin connector.
1
327.2 SPN 4356/FMI 4 - GHG17

2
327.3 SPN 4356/FMI 5 - GHG17


500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
3
328.1 SPN 4357/FMI 3 - GHG17

3. Perform the Output Component Test.
Note : The ignition must be cycled between each Output Component Test.
5. Repeat Output Component Test three times. Does the fault become active?
1
328.2 SPN 4357/FMI 4 - GHG17

5.a If the resistance is less than 1K ohms, repair the wire between pin 1 of the line heater #4 connector
and pin 32 of the ACM 120-pin connector.
2
328.3 SPN 4357/FMI 5 - GHG17


500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
3
328.1 SPN 4357/FMI 3 - GHG17

3. Perform the Output Component Test.
Note : The ignition must be cycled between each Output Component Test.
5. Repeat Output Component Test three times. Does the fault become active?
4
328.2 SPN 4357/FMI 4 - GHG17

5.a If the resistance is less than 1K ohms, repair the wire between pin 1 of the line heater #4 connector
5
328.3 SPN 4357/FMI 5 - GHG17


500 19.6 16 12.8 19.2
1000 39.3 9.8 7.84 11.76
1200 47.2 8.6 6.88 10.32
1400 55.1 7.8 6.24 9.36
1600 62.9 7 5.6 8.4
1800 70.8 6.1 4.88 7.32
2000 78.7 5.6 4.48 6.72
2200 86.6 5.2 4.16 6.24
2400 94.4 4.9 3.92 5.88
2600 102.3 4.6 3.68 5.52
6
329.1 SPN 4360/FMI 2 - GHG17

Selective Catalyst Reduction Inlet Temperature - Not Plausible
SPN 4360/FMI 2
Description This fault sets if SCR Inlet temperature is 70°C (126°F) higher
compared to all other aftertreatment temperature sensors
after 8-hour cold soak.
Monitored Parameter Selective Catalyst Reduction (SCR) Inlet Temperature versus
all other ATS temperature sensors.
Dash Lamps MIL
Verification Ignition off / 8-hour cold soak
Check as follows:
4. Disconnect and inspect the SCR inlet temperature sensor electrical connector, harness side.
5.b No; replace the SCR inlet temperature sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet
1
329.2 SPN 4360/FMI 3 - GHG17

SPN 4360/FMI 3
Description Selective Catalyst Reduction (SCR) Inlet Temperature Sensor
Circuit Failed High
Monitored Parameter SCR Inlet Temperature Sensor
Dash Lamps MIL, CEL
Engine Reaction Derate
1. Disconnect the Selective Catalyst Reduction (SCR) inlet temperature sensor connector.
2. Inspect the sensor harness for bent, spread, or corroded pins. Is any damage found?
4. Measure the voltage between pins 1 and 2 of the SCR inlet temperature sensor connector (harness side).
4.a Yes; replace the SCR inlet temperature sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet

5. Measure the voltage between pin 2 on the harness side of the SCR inlet temperature sensor connector and
5.a Yes; repair the circuit between pin 1 on the harness side of the SCR inlet temperature sensor
connector and pin 75 of the ACM 120-pin connector.
5.b No; repair the circuit between pin 2 on the harness side of the SCR inlet temperature sensor connector
2
329.3 SPN 4360/FMI 4 - GHG17

SPN 4360/FMI 4
Circuit Failed Low
Dash Lamps MIL, CEL

2. Disconnect the Selective Catalyst Reduction (SCR) inlet temperature sensor harness connector.
3. Inspect the sensor harness electrical connector for signs of damage, bent, spread, broken, pushed out
(unseated) or corroded pins or damaged near the connector. Was any damage found?
repair.
5. Check the fault codes. Is fault code SPN 4360/ FMI 3 now active?
5.a Yes; replace the SCR Inlet Temperature Sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet

8. Measure the resistance between pin 2 of the SCR inlet temperature sensor connector, harness side and
ground. Is the resistance greater than 10K ohm?
8.b No; this indicated a short to ground. Repair the wire between pin 2 of the SCR inlet temperature sensor
connector and pin 76 of the ACM 120-pin connector. Verify repair.
3
329.4 SPN 4360/FMI 8 - GHG17

SPN 4360/FMI 8
Description This Fault Code Sets when the Aftertreatment Control Module
(ACM) Detects a Momentary Abnormal Selective Catalyst
Reduction (SCR) Inlet Temperature Reading
Monitored Parameter Selective Catalyst Reduction Inlet Temperature Sensor
Typical Enabling Conditions Non-Regen Mode
Dash Lamps None
Verification SCR Efficiency Test
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
3.a Yes; diagnose the fault codes SPN 4360/FMI 3 and/or 4 first.
4. Move the SCR inlet temperature sensor harness around while watching the SCR sensor voltage using
DiagnosticLink. Does the voltage fluctuate when the harness is shaken?
4.a Yes; replace the harness. Verify repair.
5. Disconnect the SCR inlet temperature sensor electrical connector.
6. Inspect the SCR inlet temperature sensor and harness connector for signs of damage, bent, spread,
broken, unseated (pushed out) or corroded pins, signs of water intrusion or damaged wires near the
connector. Was any damage found?
4
6.a Yes; repair the harness as necessary. Verify repair.

5
329.5 SPN 4360/FMI 15 – GHG17

Selective Catalyst Reduction Inlet Temperature High
SPN 4360/FMI 15
Description Selective Catalyst Reduction (SCR) Inlet Temperature High
Monitored Parameter SCR Inlet Temperature
Dash Lamps MIL, CEL
2. Is SPN 3246/FMI 15 (Diesel Particulate Filter (DPF) outlet over temperature) also present?
2.a Yes; refer to SPN 3246/FMI 15 for diagnostics.
3. Monitor parameter AS095 SCR Inlet Temperature Voltage, while flexing (wiggle testing) the harness. Are
any sudden voltage changes detected?
3.a Yes; repair harness as necessary.
4. Disconnect the SCR inlet temperature sensor.
5. Inspect the SCR inlet temperature sensor harness connector for bent, spread or corroded pins.
5.b If no pin damage is found, replace the SCR inlet temperature sensor.
6
329.6 SPN 4360/FMI 20 - GHG17

SPN 4360/FMI 20
Drift High in Range
Typical Enabling Conditions Coolant is greater than 60°C (140°F), exhaust mass flow
greater than 600kg/h
Dash Lamps MIL, CEL
Check as follows:
1. Check for multiple fault codes. Are fault codes SPN 3246/ FMI 2, 8, 15, 20, 21 or FMI 4363/ FMI 8, 10 also
present?
2. Visually inspect the exhaust system from the turbocharger outlet to the aftertreatment inlet. Are there any
visible signs of damage or soot trails indicating a leak in the exhaust?
2.a Yes; repair the exhaust leak and verify the repair.
3. Disconnect the Diesel Particulate Filter (DPF) outlet temperature sensor.
connector.
4.a If signs of damage is found, repair as necessary. Verify Repair.
4.b If no signs of damage is found, Go to step 5.
5. Remove the DPF outlet temperature sensor from the aftertreatment.
For 1-Box™ : Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
For 2-Box: Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
6. Measure the resistance across the DPF outlet temperature sensor at the pigtail connector (refer to chart),
compare to current ambient temperature. Is the resistance within range?
7

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
6.a Yes; re-install the DPF outlet temperature sensor.

For 1-Box™: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Go to step 7.
For 2-Box: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Go to step 7.
6.b No; replace the DPF outlet temperature sensor. Verify repair.
For 1-Box™: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
For 2-Box: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
7. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side. Are there
any spread pins, damaged pins, corrosion or signs of fretting present?
7.b No; replace the SCR outlet temperature sensor.
For 1-Box™: Refer to section "Removal of the Selective Catalyst Reduction Outlet Temperature Sensor" . Verify repair.
For 2-Box: Refer to section "Removal of the Selective Catalytic Reduction Outlet Temperature Sensor" . Verify repair.
8
329.7 SPN 4360/FMI 31 - GHG17

SPN 4360/FMI 31
Description Selective Catalyst Reduction (SCR) Inlet Temperature Low
Monitored Parameter DPF Outlet and SCR Outlet Temperature Sensors
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
2. Check for multiple fault codes. Are any of the following faults active: SPN 4363/FMI 3 or 4, SPN 3246/FMI
3, 4, or 21?
2.a Yes; Refer to section "SPN 3246/FMI 15 - GHG17" for diagnostics.
4. Disconnect the DPF outlet temperature sensor harness. Inspect harness for bent, spread, corroded pins or
damages wires. Was any damage found?
4.a Yes, repair as necessary. Verify repairs.
4.b No; reconnect the DPF outlet temperature sensor. Go to step 5.
9
5. Disconnect the SCR outlet temperature sensor harness. Inspect harness for bent, spread, corroded pins or
damaged wires. Was any damage found?
5.b No; reconnect the SCR inlet temperature sensor. Go to step 6.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

temperature sensor.
8. After the routine has run for 25 minutes monitor the DOC inlet, DOC outlet, DPF outlet and SCR outlet
temperature sensors. Are all the temperature sensors reading within 25°C (45°F) of each other?
8.a Yes; perform a parked SCR efficiency test to verify the fault.
8.b No; replace the temperature sensor that is drifted more than 25°C (45°F) from the others. Verify repair.
10
329.1 SPN 4360/FMI 2 - GHG17

Selective Catalyst Reduction Inlet Temperature - Not Plausible
SPN 4360/FMI 2
Description This fault sets if SCR Inlet temperature is 70°C (126°F) higher
Monitored Parameter Selective Catalyst Reduction (SCR) Inlet Temperature versus
all other ATS temperature sensors.
Dash Lamps MIL
Check as follows:
4. Disconnect and inspect the SCR inlet temperature sensor electrical connector, harness side.
11
329.2 SPN 4360/FMI 3 - GHG17

SPN 4360/FMI 3
Circuit Failed High
Dash Lamps MIL, CEL
1. Disconnect the Selective Catalyst Reduction (SCR) inlet temperature sensor connector.
2. Inspect the sensor harness for bent, spread, or corroded pins. Is any damage found?
4. Measure the voltage between pins 1 and 2 of the SCR inlet temperature sensor connector (harness side).

5. Measure the voltage between pin 2 on the harness side of the SCR inlet temperature sensor connector and
5.a Yes; repair the circuit between pin 1 on the harness side of the SCR inlet temperature sensor
5.b No; repair the circuit between pin 2 on the harness side of the SCR inlet temperature sensor connector
12
329.3 SPN 4360/FMI 4 - GHG17

SPN 4360/FMI 4
Circuit Failed Low
Dash Lamps MIL, CEL

2. Disconnect the Selective Catalyst Reduction (SCR) inlet temperature sensor harness connector.
3. Inspect the sensor harness electrical connector for signs of damage, bent, spread, broken, pushed out
(unseated) or corroded pins or damaged near the connector. Was any damage found?
repair.
5. Check the fault codes. Is fault code SPN 4360/ FMI 3 now active?
5.a Yes; replace the SCR Inlet Temperature Sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet

8. Measure the resistance between pin 2 of the SCR inlet temperature sensor connector, harness side and
ground. Is the resistance greater than 10K ohm?
8.b No; this indicated a short to ground. Repair the wire between pin 2 of the SCR inlet temperature sensor
connector and pin 76 of the ACM 120-pin connector. Verify repair.
13
329.4 SPN 4360/FMI 8 - GHG17

SPN 4360/FMI 8
Description This Fault Code Sets when the Aftertreatment Control Module
(ACM) Detects a Momentary Abnormal Selective Catalyst
Reduction (SCR) Inlet Temperature Reading
Monitored Parameter Selective Catalyst Reduction Inlet Temperature Sensor
Dash Lamps None
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
3.a Yes; diagnose the fault codes SPN 4360/FMI 3 and/or 4 first.
4. Move the SCR inlet temperature sensor harness around while watching the SCR sensor voltage using
5. Disconnect the SCR inlet temperature sensor electrical connector.
6. Inspect the SCR inlet temperature sensor and harness connector for signs of damage, bent, spread,
connector. Was any damage found?
14

15
329.5 SPN 4360/FMI 15 – GHG17

Selective Catalyst Reduction Inlet Temperature High
SPN 4360/FMI 15
Description Selective Catalyst Reduction (SCR) Inlet Temperature High
Dash Lamps MIL, CEL
2.a Yes; refer to SPN 3246/FMI 15 for diagnostics.
3. Monitor parameter AS095 SCR Inlet Temperature Voltage, while flexing (wiggle testing) the harness. Are
any sudden voltage changes detected?
3.a Yes; repair harness as necessary.
4. Disconnect the SCR inlet temperature sensor.
5. Inspect the SCR inlet temperature sensor harness connector for bent, spread or corroded pins.
5.b If no pin damage is found, replace the SCR inlet temperature sensor.
16
329.6 SPN 4360/FMI 20 - GHG17

SPN 4360/FMI 20
Drift High in Range
Typical Enabling Conditions Coolant is greater than 60°C (140°F), exhaust mass flow
greater than 600kg/h
Dash Lamps MIL, CEL
Check as follows:
1. Check for multiple fault codes. Are fault codes SPN 3246/ FMI 2, 8, 15, 20, 21 or FMI 4363/ FMI 8, 10 also
present?
3. Disconnect the Diesel Particulate Filter (DPF) outlet temperature sensor.
connector.
4.a If signs of damage is found, repair as necessary. Verify Repair.
4.b If no signs of damage is found, Go to step 5.
5. Remove the DPF outlet temperature sensor from the aftertreatment.
For 1-Box™ : Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
For 2-Box: Refer to section "Removal of the Diesel Particulate Filter Outlet Temperature Sensor" .
6. Measure the resistance across the DPF outlet temperature sensor at the pigtail connector (refer to chart),
compare to current ambient temperature. Is the resistance within range?
17

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
6.a Yes; re-install the DPF outlet temperature sensor.

For 1-Box™: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Go to step 7.
For 2-Box: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Go to step 7.
6.b No; replace the DPF outlet temperature sensor. Verify repair.
For 1-Box™: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
For 2-Box: Refer to section "Installation of the Diesel Particulate Filter Outlet Temperature Sensor" . Verify repair.
7. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side. Are there
any spread pins, damaged pins, corrosion or signs of fretting present?
7.b No; replace the SCR outlet temperature sensor.
For 1-Box™: Refer to section "Removal of the Selective Catalyst Reduction Outlet Temperature Sensor" . Verify repair.
For 2-Box: Refer to section "Removal of the Selective Catalytic Reduction Outlet Temperature Sensor" . Verify repair.
18
329.7 SPN 4360/FMI 31 - GHG17

SPN 4360/FMI 31
Description Selective Catalyst Reduction (SCR) Inlet Temperature Low
Monitored Parameter DPF Outlet and SCR Outlet Temperature Sensors
Dash Lamps MIL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
2. Check for multiple fault codes. Are any of the following faults active: SPN 4363/FMI 3 or 4, SPN 3246/FMI
3, 4, or 21?
2.a Yes; Refer to section "SPN 3246/FMI 15 - GHG17" for diagnostics.
4. Disconnect the DPF outlet temperature sensor harness. Inspect harness for bent, spread, corroded pins or
damages wires. Was any damage found?
4.b No; reconnect the DPF outlet temperature sensor. Go to step 5.
19
5. Disconnect the SCR outlet temperature sensor harness. Inspect harness for bent, spread, corroded pins or
damaged wires. Was any damage found?
5.b No; reconnect the SCR inlet temperature sensor. Go to step 6.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

temperature sensor.
8. After the routine has run for 25 minutes monitor the DOC inlet, DOC outlet, DPF outlet and SCR outlet
temperature sensors. Are all the temperature sensors reading within 25°C (45°F) of each other?
8.a Yes; perform a parked SCR efficiency test to verify the fault.
8.b No; replace the temperature sensor that is drifted more than 25°C (45°F) from the others. Verify repair.
20
330.1 SPN 4363/FMI 0 - GHG17

SCR Outlet Temperature High
SPN 4363/FMI 0
Description Selective Catalyst Reduction (SCR) Outlet Temperature High
Monitored Parameter SCR Outlet Temperature
Dash Lamps MIL, CEL
Engine Reaction Derate 25% , 30 seconds shut down.
Check as follows:
2.a Yes; Refer to section "SPN 3246/FMI 15 - GHG17" .
3. Check the Motor Control Module (MCM), Aftertreatment Control Module (ACM), Common Powertrain
Controller (CPC) and Transmission Control Module (TCM) software levels. Compare the current software
levels to the server. Are the MCM, ACM, CPC and TCM software at the latest levels?
3.b No; update the software levels and verify repair. If the fault code does not return, release the vehicle. If
the fault code returns, Go to step 4.
4. Disconnect the SCR outlet temperature sensor.
5. Inspect the SCR outlet temperature sensor and harness connector for bent, spread or corroded pins. Is any
damage found?
6. Remove the SCR temperature sensor and let the sensor adjust to ambient room temperature. Go to step 7.
Refer to section "Removal of the Selective Catalytic Reduction Outlet Temperature Sensor" .
7. SCR temperature sensor Test - Measure the resistance between pin 1 and 2 of the SCR Temperature
sensor connectors (Refer to chart for resistance values).
7.a If the resistance is out of range, replace the suspect temperature sensor.
7.b If the resistance is in range, reinstall the sensors and Go to step 8.
1

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start the engine and run a Parked Regen. During the last 10% of the parked regen period, is the Selective
Catalyst Reduction (SCR) inlet temperature more than 38° C (68.4° F) lower than SCR outlet temperature?
8.b No; Clear fault and release unit. Code likely occurred after extended idle and was caused by
hydrocarbon burn off.
temperature sensor. Refer to section "GHG17 Perform Performance Check - Low Temperature ATD" . Are the SCR inlet
2
and SCR outlet temperatures within 25° C (45° F) during the last five minutes of this test?
9.a Yes; replace the DOC/SCR module. This indicates an internal failure of the DOC/SCR module.
9.b No; replace the drifted SCR temperature sensor and verify repair.
3
330.2 SPN 4363/FMI 2 - GHG17

Selective Catalyst Reduction Outlet Temperature - Not Plausible
SPN 4363/FMI 2
Description This fault sets if the SCR outlet temperature is 70°C (126°F)
sensors after 8-hour cold soak.
Monitored Parameter Selective Catalyst Reduction (SCR) Outlet Temperature vs. all
other ATS temperature sensors
Typical Enabling Conditions Engine off more than 8 hours, Battery Voltage greater than
Monitor Sequence Key ON, engine OFF for more than 60 seconds
Dash Lamps MIL
Verification Ignition off/ 8-hour cold soak
Check as follows:
4. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side.
5.b No; replace the SCR outlet temperature sensor. Refer to section "Removal of the Selective Catalytic Reduction
Outlet Temperature Sensor" . Verify repair.
4
330.3 SPN 4363/FMI 3 - GHG17

Selective Catalyst Reduction Outlet Temperature Sensor Circuit Failed High
SPN 4363/FMI 3
Description Selective Catalyst Reduction (SCR) Outlet Temperature
Sensor Circuit Failed High
Monitored Parameter SCR Outlet Temperature Sensor
Dash Lamps MIL, CEL
1. Disconnect the Selective Catalyst Reduction (SCR) outlet temperature sensor connector.
3. SCR Outlet Temperature Test - Measure the resistance between pin 1 and 2 of the SCR outlet temperature
3.a If the resistance are out of range, replace the SCR outlet temperature sensor.
3.b If the resistance are in range, Go to step 4.

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
5
5. Measure the voltage between pin 2 on the harness side of the SCR outlet temperature sensor connector
and ground.
SCR outlet temperature sensor connector and pin 78 of the ACM 120-pin connector.
5.b If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the SCR
5.c If the voltage is between 2.75 and 3 volts, Go to step 6.
6. Measure the voltage between pin 1 on the harness side of the SCR outlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the SCR outlet
6.b If no voltage is present, repair the open between pin 1 on the harness side of the SCR outlet
6
330.4 SPN 4363/FMI 4 - GHG17

Selective Catalyst Reduction Outlet Temperature Sensor Circuit Failed Low
SPN 4363/FMI 4
Sensor Circuit Failed Low
Dash Lamps MIL, CEL
1. Ensure the ignition is OFF.

2. Disconnect the Selective Catalyst Reduction (SCR) outlet temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the SCR outlet temperature sensor connector
and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the SCR outlet temperature
5.b If the resistance is greater than 1K ohms, replace the SCR outlet temperature sensor.
7
330.5 SPN 4363/FMI 8 - GHG17

SCR Outlet Temperature Signal Spike
SPN 4363 /FMI 8

Description This fault code sets when the Aftertreatment Control Module
(ACM) detects a momentary abnormal Selective Catalyst
Reduction (SCR) outlet temperature reading.
Monitored Parameter Selective Catalyst Reduction Outlet Temperature sensor
Dash Lamps MIL, CEL
Verification SCR efficiency test
Check as follows:
4. Shake the SCR outlet temperature sensor harness while watching the SCR sensor voltage using
5. Disconnect and inspect the SCR outlet temperature sensor electrical connector. Are there any spread pins,
damaged pins, corrosion or signs of fretting present?
8
330.6 SPN 4363/FMI 20 - GHG17

SCR Temperature Drift - Inlet Low/Outlet High
SPN 4363/FMI 20
(ACM) detects that the Selective Catalyst Reduction (SCR)
outlet temperature sensor reading and SCR outlet model
temperature is greater than 70°C (158°F).
Typical Enabling Conditions Exhaust flow greater than 600 Kg/hr, coolant temperature
greater than 60°C (140°F). Non-regen mode.
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 4363/FMI 3 or 4 also present?
4. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side. For 1-
BOX™, Refer to section "1-BOX™ Aftertreatment Device Sensor Locations" or for Two-BOX, Refer to section "2-BOX (2V2)
Aftertreatment Device Sensor Locations" . Are there any spread pins, damaged pins, corrosion or signs of fretting
present?
9
330.1 SPN 4363/FMI 0 - GHG17

SCR Outlet Temperature High
SPN 4363/FMI 0
Description Selective Catalyst Reduction (SCR) Outlet Temperature High
Dash Lamps MIL, CEL
Engine Reaction Derate 25% , 30 seconds shut down.
Check as follows:
2.a Yes; Refer to section "SPN 3246/FMI 15 - GHG17" .
4. Disconnect the SCR outlet temperature sensor.
5. Inspect the SCR outlet temperature sensor and harness connector for bent, spread or corroded pins. Is any
damage found?
6. Remove the SCR temperature sensor and let the sensor adjust to ambient room temperature. Go to step 7.
Refer to section "Removal of the Selective Catalytic Reduction Outlet Temperature Sensor" .
7. SCR temperature sensor Test - Measure the resistance between pin 1 and 2 of the SCR Temperature
sensor connectors (Refer to chart for resistance values).
7.a If the resistance is out of range, replace the suspect temperature sensor.
7.b If the resistance is in range, reinstall the sensors and Go to step 8.
10

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
8. Start the engine and run a Parked Regen. During the last 10% of the parked regen period, is the Selective
Catalyst Reduction (SCR) inlet temperature more than 38° C (68.4° F) lower than SCR outlet temperature?
8.b No; Clear fault and release unit. Code likely occurred after extended idle and was caused by
hydrocarbon burn off.
temperature sensor. Refer to section "GHG17 Perform Performance Check - Low Temperature ATD" . Are the SCR inlet
11
and SCR outlet temperatures within 25° C (45° F) during the last five minutes of this test?
9.a Yes; replace the DOC/SCR module. This indicates an internal failure of the DOC/SCR module.
12
330.2 SPN 4363/FMI 2 - GHG17

Selective Catalyst Reduction Outlet Temperature - Not Plausible
SPN 4363/FMI 2
Description This fault sets if the SCR outlet temperature is 70°C (126°F)
sensors after 8-hour cold soak.
Monitored Parameter Selective Catalyst Reduction (SCR) Outlet Temperature vs. all
Typical Enabling Conditions Engine off more than 8 hours, Battery Voltage greater than
Monitor Sequence Key ON, engine OFF for more than 60 seconds
Dash Lamps MIL
Check as follows:
4. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side.
13
330.3 SPN 4363/FMI 3 - GHG17

Selective Catalyst Reduction Outlet Temperature Sensor Circuit Failed High
SPN 4363/FMI 3
Sensor Circuit Failed High
Dash Lamps MIL, CEL
1. Disconnect the Selective Catalyst Reduction (SCR) outlet temperature sensor connector.
3. SCR Outlet Temperature Test - Measure the resistance between pin 1 and 2 of the SCR outlet temperature
3.a If the resistance are out of range, replace the SCR outlet temperature sensor.
3.b If the resistance are in range, Go to step 4.

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
14
5. Measure the voltage between pin 2 on the harness side of the SCR outlet temperature sensor connector
and ground.
SCR outlet temperature sensor connector and pin 78 of the ACM 120-pin connector.
5.b If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side of the SCR
5.c If the voltage is between 2.75 and 3 volts, Go to step 6.
6. Measure the voltage between pin 1 on the harness side of the SCR outlet temperature sensor and ground.
6.a If voltage is present, repair the short to power between pin 1 on the harness side of the SCR outlet
6.b If no voltage is present, repair the open between pin 1 on the harness side of the SCR outlet
15
330.4 SPN 4363/FMI 4 - GHG17

Selective Catalyst Reduction Outlet Temperature Sensor Circuit Failed Low
SPN 4363/FMI 4
Sensor Circuit Failed Low
Dash Lamps MIL, CEL
1. Ensure the ignition is OFF.

2. Disconnect the Selective Catalyst Reduction (SCR) outlet temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the SCR outlet temperature sensor connector
and ground.
5.a If the resistance is less than 1K ohms, repair the wire between pin 2 of the SCR outlet temperature
5.b If the resistance is greater than 1K ohms, replace the SCR outlet temperature sensor.
16
330.5 SPN 4363/FMI 8 - GHG17

SCR Outlet Temperature Signal Spike
SPN 4363 /FMI 8

(ACM) detects a momentary abnormal Selective Catalyst
Reduction (SCR) outlet temperature reading.
Monitored Parameter Selective Catalyst Reduction Outlet Temperature sensor
Dash Lamps MIL, CEL
Verification SCR efficiency test
Check as follows:
4. Shake the SCR outlet temperature sensor harness while watching the SCR sensor voltage using
5. Disconnect and inspect the SCR outlet temperature sensor electrical connector. Are there any spread pins,
damaged pins, corrosion or signs of fretting present?
17
330.6 SPN 4363/FMI 20 - GHG17

SCR Temperature Drift - Inlet Low/Outlet High
SPN 4363/FMI 20
(ACM) detects that the Selective Catalyst Reduction (SCR)
outlet temperature sensor reading and SCR outlet model
temperature is greater than 70°C (158°F).
Typical Enabling Conditions Exhaust flow greater than 600 Kg/hr, coolant temperature
greater than 60°C (140°F). Non-regen mode.
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 4363/FMI 3 or 4 also present?
4. Disconnect and inspect the SCR outlet temperature sensor electrical connector, harness side. For 1-
BOX™, Refer to section "1-BOX™ Aftertreatment Device Sensor Locations" or for Two-BOX, Refer to section "2-BOX (2V2)
Aftertreatment Device Sensor Locations" . Are there any spread pins, damaged pins, corrosion or signs of fretting
present?
18
331.1 SPN 4364/FMI 1 - GHG17

SPN 4364/FMI 1
(ACM) Detects Poor Selective Catalyst Reduction (SCR) NOx
Conversion Efficiency.
Monitored Parameter SCR Inlet NOx Sensor and SCR Outlet NOx Sensor
Typical Enabling Conditions Diesel Exhaust Fluid (DEF) Dosing Enabled, 1000 to 2100
rpm, 15 to 100% Load
Dash Lamps MIL
1. Refer to section "SPN 4364/FMI 17 - GHG17" and follow the diagnostic procedure.
1
331.2 SPN 4364/FMI 17 - GHG17

SPN 4364/FMI 17
Conversion Efficiency
Dash Lamps MIL
Possible causes:
• Contaminated DEF
• Incorrect concentration of urea in the DEF
• Biased NOx sensor
• Excessive DEF build-up in the exhaust
• Improper DPF maintenance
• Over temp aftertreatment
NOTICE
DEF crystallization inside the SCR mixing chamber or around the dosing unit does not
indicate a failed/leaking DEF doser. Do not replace the DEF dosing unit unless directed.
NOTICE
either sensor unless directed to within the troubleshooting.
Check as follows:
3. Check for other fault codes. Are there any air management system fault codes present, such as Intake
Throttle Valve (ITV), Intake Manifold Pressure (IMP), Intake Air Temperature (IAT), or turbocharger?
3.a Yes; diagnose the air management system fault codes first.
4. Are there any Exhaust Gas Recirculation (EGR) system fault codes present?
4.a Yes; repair the EGR system fault codes first.
5. Are there any fuel system fault codes present?
5.a Yes; diagnose the fuel system fault codes first.
2

6. Are there any other NOx sensor fault codes present?
6.a Yes; diagnose the other NOx sensor fault codes first.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
7.a Yes; warm up the engine and perform a Parked SCR Efficiency Test to verify repairs and clear fault
codes. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
8. Are there any ACM temperature or pressure fault codes present?
8.a Yes; diagnose the fault first.
10. Use DEF test strip A0005850202 to check for diesel fuel or oil contamination of the DEF fluid. Refer to section
contaminated?
10.a Yes; for diesel fuel or oil contamination, refer to the following table for a list of parts that must be
replaced. Refill the new DEF tank with new DEF. Verify repair; perform a Parked SCR Efficiency Test
to clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
3
Parts to be replaced for diesel fuel or oil in the DEF system. Refer to the GHG17 DD Platform Workshop Manual
(DDC-SVC-MAN-0190) for proper repair procedures.
11.b No; drain and flush the DEF tank and the DEF system with water. Refill the DEF tank with new DEF.
Verify repair; perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to section "GHG17
Perform Parked SCR Efficiency Test" .

13. Inspect the area around the DEF dosing unit gasket for DEF crystallization. Is there any DEF crystallization
build-up present?
13.a Yes; this indicates the gasket has failed, NOT the DEF dosing unit. Replace the gasket after
completing the DEF quantity test in the next step. Go to step 14.
Fig 0.1, Normal DEF Crystallization in the DEF Doser Port Hole
4
15. Find the graduated cylinder provided in DEF test kit W060589001900, which is used in DEF quantity tests;
Refer to section "Diesel Exhaust Fluid Quantity Test - GHG17" .
16. Perform a DEF Quantity Test service routine.

17. Monitor the amount of DEF dispensed. Is the amount of DEF dispensed between 108 and 132 mL?
17.a Yes; reinstall the DEF dosing unit. Use a new gasket and bolts, as they are one-time use. Refer to section
"Installation of the Diesel Exhaust Fluid Dosing Unit " . Go to step 18.
17.b No; replace the DEF dosing unit. Use a new gasket and bolts, as they are one-time use. Refer to section
"Installation of the Diesel Exhaust Fluid Dosing Unit " . Verify repair; perform a Parked SCR Efficiency Test to
clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
18. Disconnect the DEF dosing unit electrical connector.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
19. Start the engine and perform a complete parked regeneration. Refer to section "Performing a Parked Regeneration -
GHG17" . The regen will burn off any DEF deposits in the aftertreatment before checking the NOx sensors.
NOTICE
the sensor readings within 50 parts per million (ppm) of each other?
20.b No; replace the inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go
to step 21.
Monitor the inlet NOx sensor and outlet NOx sensor. During the last five minutes of the parked regen, are
5
21.b No; replace the outlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
Go to step 22.
22. Reconnect the DEF dosing unit electrical connector.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
23. Start the engine and perform a parked regeneration. Monitor the NOx conversion efficiency. Is the NOx
conversion efficiency above 85%?
regeneration procedures. Perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to
section "GHG17 Perform Parked SCR Efficiency Test" .
load.
24. Review the last seven minutes of the parked regeneration log data from step 23. The illustration below
identifies the last seven minutes of the parked regen.
6
25. Is the Selective Catalyst Reduction (SCR) inlet temperature lower than SCR outlet temperature by more
than 38°C (68.4°F)?
Example: SCR outlet temperature is 588°C (1090°F) - SCR Inlet Temp 398°C (748°F) = 171°C (340°F).
Difference between inlet and outlet is 171°C (341°F), which is greater than 38°C (68.4°F)?
7

25.b No; for a 1-Box™ system, replace the DOC/SCR module. For a Two-Box system, replace the SCR
module. Complete the ATD checklist to identify cause of failure. Go to step 26.
26. Perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR
Efficiency Test" .
27. Review the data from the "Perform the GHG17 Perform Performance Check - Low Temperature ATD"
check in step 20. Are the calculated SCR inlet temperature and SCR outlet temperatures sensor readings
within 25°C (45°F) at the end of the low temp regen?
27.a Yes; this indicates internal structural damage for a 1-Box. Replace the DOC/SCR module. The ATD
checklist is NOT required since the ATD is the primary failed part. This image below illustrates the
possible internal damage to the aftertreatment. Go to step 28.
8
27.b No; replace the drifted temperature sensor and verify repair. Go to step 28.
28. Perform a Parked SCR Efficiency Test to clear the fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test"
.
9
331.1 SPN 4364/FMI 1 - GHG17

Type" field.
SPN 4364/FMI 1
Conversion Efficiency.
Dash Lamps MIL
1. Refer to section "SPN 4364/FMI 17 - GHG17" and follow the diagnostic procedure.
10
331.2 SPN 4364/FMI 17 - GHG17

Type" field.
SPN 4364/FMI 17
Conversion Efficiency
Dash Lamps MIL
Possible causes:
• Contaminated DEF
• Incorrect concentration of urea in the DEF
• Biased NOx sensor
• Excessive DEF build-up in the exhaust
• Improper DPF maintenance
• Over temp aftertreatment
NOTICE
DEF crystallization inside the SCR mixing chamber or around the dosing unit does not
indicate a failed/leaking DEF doser. Do not replace the DEF dosing unit unless directed.
NOTICE
either sensor unless directed to within the troubleshooting.
Check as follows:
3. Check for other fault codes. Are there any air management system fault codes present, such as Intake
Throttle Valve (ITV), Intake Manifold Pressure (IMP), Intake Air Temperature (IAT), or turbocharger?
3.a Yes; diagnose the air management system fault codes first.
4. Are there any Exhaust Gas Recirculation (EGR) system fault codes present?
11
4.a Yes; repair the EGR system fault codes first.

5. Are there any fuel system fault codes present?
5.a Yes; diagnose the fuel system fault codes first.
6. Are there any other NOx sensor fault codes present?
6.a Yes; diagnose the other NOx sensor fault codes first.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
7.a Yes; warm up the engine and perform a Parked SCR Efficiency Test to verify repairs and clear fault
codes. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
8. Are there any ACM temperature or pressure fault codes present?
8.a Yes; diagnose the fault first.
10. Use DEF test strip A0005850202 to check for diesel fuel or oil contamination of the DEF fluid. Refer to section
contaminated?
10.a Yes; for diesel fuel or oil contamination, refer to the following table for a list of parts that must be
replaced. Refill the new DEF tank with new DEF. Verify repair; perform a Parked SCR Efficiency Test
to clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
12
Parts to be replaced for diesel fuel or oil in the DEF system. Refer to the GHG17 DD Platform Workshop Manual
(DDC-SVC-MAN-0190) for proper repair procedures.
11.b No; drain and flush the DEF tank and the DEF system with water. Refill the DEF tank with new DEF.
Verify repair; perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to section "GHG17

13. Inspect the area around the DEF dosing unit gasket for DEF crystallization. Is there any DEF crystallization
build-up present?
13.a Yes; this indicates the gasket has failed, NOT the DEF dosing unit. Replace the gasket after
completing the DEF quantity test in the next step. Go to step 14.
Fig 331.2, Normal DEF Crystallization in the DEF Doser Port Hole
13
15. Find the graduated cylinder provided in DEF test kit W060589001900, which is used in DEF quantity tests;
Refer to section "Diesel Exhaust Fluid Quantity Test - GHG17" .
16. Perform a DEF Quantity Test service routine.

17. Monitor the amount of DEF dispensed. Is the amount of DEF dispensed between 108 and 132 mL?
17.a Yes; reinstall the DEF dosing unit. Use a new gasket and bolts, as they are one-time use. Refer to section
"Installation of the Diesel Exhaust Fluid Dosing Unit " . Go to step 18.
17.b No; replace the DEF dosing unit. Use a new gasket and bolts, as they are one-time use. Refer to section
"Installation of the Diesel Exhaust Fluid Dosing Unit " . Verify repair; perform a Parked SCR Efficiency Test to
clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
18. Disconnect the DEF dosing unit electrical connector.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
19. Start the engine and perform a complete parked regeneration. Refer to section "Performing a Parked Regeneration -
GHG17" . The regen will burn off any DEF deposits in the aftertreatment before checking the NOx sensors.
NOTICE
the sensor readings within 50 parts per million (ppm) of each other?
20.b No; replace the inlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go
to step 21.
Monitor the inlet NOx sensor and outlet NOx sensor. During the last five minutes of the parked regen, are
14
21.b No; replace the outlet NOx sensor. Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
Go to step 22.
22. Reconnect the DEF dosing unit electrical connector.
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
WARNING
PERSONAL INJURY
23. Start the engine and perform a parked regeneration. Monitor the NOx conversion efficiency. Is the NOx
conversion efficiency above 85%?
regeneration procedures. Perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to
section "GHG17 Perform Parked SCR Efficiency Test" .
load.
24. Review the last seven minutes of the parked regeneration log data from step 23. The illustration below
identifies the last seven minutes of the parked regen.
15
25. Is the Selective Catalyst Reduction (SCR) inlet temperature lower than SCR outlet temperature by more
than 38°C (68.4°F)?
Example: SCR outlet temperature is 588°C (1090°F) - SCR Inlet Temp 398°C (748°F) = 171°C (340°F).
Difference between inlet and outlet is 171°C (341°F), which is greater than 38°C (68.4°F)?
16

25.b No; for a 1-Box™ system, replace the DOC/SCR module. For a Two-Box system, replace the SCR
module. Complete the ATD checklist to identify cause of failure. Go to step 26.
26. Perform a Parked SCR Efficiency Test to clear the regulatory fault. Refer to section "GHG17 Perform Parked SCR
Efficiency Test" .
27. Review the data from the "Perform the GHG17 Perform Performance Check - Low Temperature ATD"
check in step 20. Are the calculated SCR inlet temperature and SCR outlet temperatures sensor readings
within 25°C (45°F) at the end of the low temp regen?
27.a Yes; this indicates internal structural damage for a 1-Box. Replace the DOC/SCR module. The ATD
checklist is NOT required since the ATD is the primary failed part. This image below illustrates the
possible internal damage to the aftertreatment. Go to step 28.
17
27.b No; replace the drifted temperature sensor and verify repair. Go to step 28.
28. Perform a Parked SCR Efficiency Test to clear the fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test"
.
18
332.1 SPN 4374/FMI 0 – GHG17

SPN 4374/FMI 0
Description This Code Sets When the Diesel Exhaust Fluid (DEF) Pump
Speed is Higher than Normal For a Given DEF Pressure
Monitored Parameter DEF Pump Speed, DEF Pressure
Typical Duration Continuous Until Resolved
Dash Lamps MIL, CEL
Verification SCR ADS Self-Check
Possible causes:
• Restriction in the DEF line between the DEF tank and the DEF pump
• Restriction in the DEF line between the DEF pump and the DEF dosing unit
• Air in the DEF line between the DEF tank and the DEF pump
• Restriction in the DEF pump
• Failed DEF pump
Check as follows:
NOTICE
Customers in colder climates where winter ambient air temperatures generally stay below
-11° C (12°F) need to verify that the DEF is not frozen before troubleshooting this fault
code.
3. Check for multiple codes. Are codes SPN 4334/FMI 3, 4, SPN 4375/FMI 3, 4, or SPN 3361/FMI 3, 4, 5 also
present?
3.a Yes; diagnose and repair the other fault codes first. Verify repair.
5. Inspect the DEF tank vent tube. Is there any blockage or restriction?
5.a Yes; clear the restricted vent tube. Go to step 6.
6. Using DEF test strip A0005850202, check for diesel fuel or oil contamination of the DEF fluid. Does the test
strip indicate contamination?
6.a Yes; replace the following components and refill the system with new DEF:
• DEF tank
• DEF tank header
• DEF supply line from the DEF tank to the DEF pump
• DEF line from the DEF pump to the DEF dosing unit
• DEF return line from the DEF dosing unit to the DEF tank
• DEF pump
1
• DEF dosing unit

WARNING
EYE INJURY
7. Inspect the DEF line that runs from the DEF pump to the DEF dosing unit. Is the DEF line damaged,
pinched, or kinked?
7.a Yes; replace the DEF line from the DEF pump to the DEF dosing unit.
8. Inspect the DEF line that runs from the DEF tank to the DEF pump. Is the DEF line damaged, pinched, or
kinked?
8.a Yes; replace the DEF line from the DEF tank to the DEF pump.
9. Disconnect the DEF supply line at the dosing unit. Fill the graduated cylinder supplied in DEF test kit (P/N:
W060589001900) with water. Place the end of the DEF line into the graduated cylinder as far as possible.
Note : Place the graduated cylinder in a secondary container to catch over flowing DEF fluid, making sure you still
have clear sight of the end of the DEF line.
10. Using DiagnosticLink, perform the Selective Catalyst Reduction Airless Dosing System (SCR ADS) Self-
Check routine. When the service routine is running, visually inspect the DEF line for continuous air bubbles
coming from the line and DEF flow.
11. Were any bubbles coming from the DEF pump supply line indicating a crack in the DEF pump feed line?
11.a Yes; replace the DEF supply line from the DEF tank to the DEF pump. Verify repair.
12. Remove the DEF tank header.
13. Inspect inside the DEF tank for debris that may be floating around or stuck to the DEF tank header pick up
screen. Was any debris found?
13.a Yes; flush out the DEF tank and clean the DEF tank header filter screen. Go to step 14.
NOTICE
The RS SUPPLY KIT contains all the necessary parts for steps 14-17.
14. Using the DEF/Doser Kit (RS SUPPLY KIT - available through eParts catalog), replace the DEF pump
module filter. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module Filter" . Go to step 15.
15. Replace the DEF pump inlet screen. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module Inlet Screen" . Go
to step 16.
16. Replace DEF Pressure Relief Valve (PRV). Refer to section "Removal of the Diesel Exhaust Fluid Pump Pressure Relief
17. Replace DEF dosing unit inlet screen. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit Inlet Screen" . Go
to step 18.
Note : If air pressure is greater than 827 kPa (120 psi), use a pressure regulator.
18. Prime pump with shop air. Using a rubber tipped air gun to seal around the DEF pump inlet fitting, apply
clean regulated shop air to the DEF pump inlet fitting for three to five seconds.
2
19. Connect all DEF lines and electrical connections. Go to step 20.
20. Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine. Did the SCR
ADS test pass?
20.a Yes; clear the codes and release the vehicle.
20.b No; replace the DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" .
3
332.2 SPN 4374/FMI 1 – GHG17

SPN 4374/FMI 1
Description Over Pressurized Diesel Exhaust Fluid (DEF) System
Monitored Parameter DEF Pump Speed vs. DEF Pressure
Typical Enabling Conditions DEF Pump Enabled OR On-Off-Cycle Request
Dash Lamps MIL, CEL
Verification ADS Self-check
Check as follows:
3. Check for multiple codes. Are any other faults active in addition to SPN 4374/FMI 1?
3.a Yes; Diagnose and repair the other faults first. Verify repair.
5. Disconnect the DEF dosing unit electrical harness connector.
6. Inspect the DEF dosing unit electrical harness wiring and connector for signs of damage, bent, spread,
corroded or unseated (pushed out) pins, moisture in the connector or wire damage near the connector. Is
any damage found?
6.a Yes; repair as necessary. Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS)
Self-Check Routine to verify repairs.
6.b No; Reconnect harness connector. Go to step 7.
7. Disconnect the DEF return line from the DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Lines" .
Connect a temporary drain hose from the DEF dosing unit return fitting into a DEF-safe container.
9. Perform SCR ADS Self-Check Routine. Did the SCR ADS test pass with flow from dosing unit return line
into the DEF-safe container?
9.a Yes; Replace DEF return line. Go to step 10.
9.b No; replace DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify repair.
10. Reconnect all DEF lines and connectors. Perform SCR ADS Self-Check Routine to prime the system. Did
the SCR ADS Self-Check Routine complete successfully?
10.b No; replace DEF dosing unit. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" . Verify repairs.
4
332.3 SPN 4374/FMI 3 – GHG17

SPN 4374/FMI 3
Description DEF pump speed signal above measurement range
Monitored Parameter DEF pump speed frequency
Typical Enabling Conditions DEF pump enabled OR on-off-cycle request
Typical Duration 2 minutes
Dash Lamps MIL, CEL
Verification SCR ADS Self-check
Note : Retain a log file if Detroit™ Customer Assistance is required.

2. Turn the ignition ON (key ON, engine OFF). Are other codes present?
2.a Yes; repair other codes first.
4. Inspect the DEF pump harness wiring and connector for damage, wire chafing, bent, spread or corroded
pins.
4.a If damage is found, repair as necessary. Go to step 7.
DEF Pump Connector

4-Pin Circuit ACM - Pin Connecto
r
1 RPM Pump Feedback 95
2 Pump Supply 1
3 Pump RPM Control 20
4 Pump GND 31
ADS test pass with DEF pump speed and DEF pressure values in normal range?
5.a Yes; clear codes and release vehicle.
5.b No; replace the DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Go to step 6.
7. Verify repairs by running Selective Catalytic Reduction Airless Dosing System – SCR ADS Self-Check
Routine. Does ADS Self-Check Routine pass?
7.b No; turn OFF ignition. Install a test ACM. Go to step 8.
8. Rerun ADS Self-Check Routine to verify repairs. Does test pass with no codes?
8.a Yes; replace ACM. Verify repairs by running SCR ADS Self-Check Routine.
8.b No; Check the ATS harness connectors for corroded or spread pins. Repair as necessary.
5
332.4 SPN 4374/FMI 4 - GHG17

SPN 4374/FMI 4
Description DEF pump speed signal below measurement range
Monitored Parameter DEF pump speed vs. DEF Pressure
Dash Lamps MIL, CEL

2.a Yes; Repair other codes first.
4. Inspect DEF pump harness wiring and connector for damage, wire chafing, bent, spread or corroded pins.
6. Check resistance between DEF pump connector pin 1 and ACM connector pin 95. Is resistance less than
five ohms?
DEF Pump Connector

r
2 Pump Supply 1
4 Pump GND 31

6.b No; repair open in wire between DEF pump connector pin 1 and ACM connector pin 95. Go to step 11.
7. Check resistance between DEF pump connector pin 1 and battery ground. Is resistance greater than 10K
ohms?
7.b No; repair short in wire between DEF pump connector pin 1 and chassis ground. Go to step 11.
8. Check resistance between DEF pump connector pins 1 and 2. Is the resistance greater than 10K ohms?
8.b No; repair short in wire between DEF pump connector pins 1 and pin 2. Go to step 11.
6
10.a Yes; install a test ACM. Go to step 11.

11. Reconnect ACM and DEF pump electrical connectors.
12. Turn the ignition ON (key ON, engine OFF). Does fault return?
12.a Yes; replace the DEF Pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by
running Selective Catalytic Reduction Airless Dosing System – SCR ADS Self-Check Routine.
12.b No; turn OFF ignition. Replace ACM.
7
332.5 SPN 4374/FMI 19 - GHG17

Diesel Exhaust Fluid System is Not Being Controlled as Expected
SPN 4374/FMI 19
Description DEF system is not being controlled as expected
Monitored Parameter DEF Pump Speed and Pump Duty Cycle
Typical Enabling Conditions DEF pump operation is above or below defined thresholds
Dash Lamps MIL, CEL

3.a If other faults are active, troubleshoot the other faults first.
pins.
5. Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self Check Routine. Did the SCR
Acceptable DEF Pump Speed: greater than 750 rpm, DEF Pump Speed less than 1800 rpm.
Acceptable DEF Pressure: greater than 9000 mbar, DEF Pressure less than 11000 mbar (130 to 160 psi).

5.b No; replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Go to step 6.
6. Clear codes, cycle ignition and start engine. Idle for five minutes. Does the fault return?
6.a Yes; install test ACM and repeat test. Repair as necessary.
6.b No; verify repairs and release.
8
332.5 SPN 4374/FMI 19 - GHG17

SPN 4374/FMI 19
Dash Lamps MIL, CEL

pins.

9
332.1 SPN 4374/FMI 0 – GHG17

Type" field.
SPN 4374/FMI 0
Speed is Higher than Normal For a Given DEF Pressure
Dash Lamps MIL, CEL
Possible causes:
• Failed DEF pump
Check as follows:
NOTICE
code.
present?
10
• DEF tank
• DEF tank header
• DEF pump
• DEF dosing unit
WARNING
EYE INJURY
pinched, or kinked?
kinked?
NOTICE
to step 16.
11
to step 18.
20. Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine two times to
further prime the system. Ignore the results of these two tests and Go to step 21.
ADS test pass?
12
332.2 SPN 4374/FMI 1 – GHG17

SPN 4374/FMI 1
Description Over Pressurized Diesel Exhaust Fluid (DEF) System
Dash Lamps MIL, CEL
Verification ADS Self-check
Check as follows:
3.a Yes; Diagnose and repair the other faults first. Verify repair.
any damage found?
6.b No; Reconnect harness connector. Go to step 7.
9.a Yes; Replace DEF return line. Go to step 10.
13
332.3 SPN 4374/FMI 3 – GHG17

SPN 4374/FMI 3
Description DEF pump speed signal above measurement range
Monitored Parameter DEF pump speed frequency
Dash Lamps MIL, CEL

2.a Yes; repair other codes first.
pins.
DEF Pump Connector

r
2 Pump Supply 1
4 Pump GND 31
5.b No; replace the DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Go to step 6.
7. Verify repairs by running Selective Catalytic Reduction Airless Dosing System – SCR ADS Self-Check
Routine. Does ADS Self-Check Routine pass?
7.b No; turn OFF ignition. Install a test ACM. Go to step 8.
8. Rerun ADS Self-Check Routine to verify repairs. Does test pass with no codes?
8.a Yes; replace ACM. Verify repairs by running SCR ADS Self-Check Routine.
14
332.4 SPN 4374/FMI 4 - GHG17

SPN 4374/FMI 4
Description DEF pump speed signal below measurement range
Monitored Parameter DEF pump speed vs. DEF Pressure
Dash Lamps MIL, CEL

2.a Yes; Repair other codes first.
4. Inspect DEF pump harness wiring and connector for damage, wire chafing, bent, spread or corroded pins.
6. Check resistance between DEF pump connector pin 1 and ACM connector pin 95. Is resistance less than
five ohms?
DEF Pump Connector

r
2 Pump Supply 1
4 Pump GND 31

6.b No; repair open in wire between DEF pump connector pin 1 and ACM connector pin 95. Go to step 11.
7. Check resistance between DEF pump connector pin 1 and battery ground. Is resistance greater than 10K
ohms?
7.b No; repair short in wire between DEF pump connector pin 1 and chassis ground. Go to step 11.
15
10.a Yes; install a test ACM. Go to step 11.

11. Reconnect ACM and DEF pump electrical connectors.
12. Turn the ignition ON (key ON, engine OFF). Does fault return?
12.a Yes; replace the DEF Pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by
12.b No; turn OFF ignition. Replace ACM.
16
332.5 SPN 4374/FMI 11 – GHG17

SPN 4374/FMI 11
Speed is Lower than Normal for a Given DEF Pressure
Typical Duration Two Minutes
Dash Lamps MIL, CEL
Verification ADS Self-Check
Check as follows:
any damage found?
6.b No; reconnect harness connector. Go to step 7.
9.a Yes; replace DEF return line. Go to step 10.
17
332.6 SPN 4374/FMI 14 – GHG17

SPN 4374/FMI 14
Speed is Higher than Normal for a Given DEF Pressure
Dash Lamps MIL, CEL
Possible causes:
• Failed DEF pump
Check as follows:
NOTICE
code.
present?
• DEF tank
• DEF tank header
• DEF pump
18
• DEF dosing unit

WARNING
EYE INJURY
pinched, or kinked?
kinked?
NOTICE
to step 16.
to step 18.
19
ADS test pass?
20
332.7 SPN 4374/FMI 19 - GHG17

SPN 4374/FMI 19
Dash Lamps MIL, CEL

pins.

21
333.1 SPN 4375/FMI 3 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed High
SPN 4375/FMI 3
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed High
Monitored Parameter DEF Pump
Typical Enabling Conditions DEF Pump On
Dash Lamps MIL, CEL
Verification SCR ADS Self Check
3. Perform a Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine.
4.b No; clear the fault code and release the vehicle.
6. Inspect the sensor harness for bent, spread or corroded pins.
6.b If connector shows no sign of damage, repair the short-to-battery (12 volts) between pin 3 of the DEF
Pump harness connector and pin 20 of the ACM 120-pin connector.

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
1
333.2 SPN 4375/FMI 4 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed Low
SPN 4375/FMI 4
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed Low
Dash Lamps MIL, CEL

2.a If the pins are bent, spread or corroded, repair as necessary. Go to step 8.
4. Clear codes.
5. Using DiagnosticLink , recheck for codes.
6. Is SPN 4375/FMI 4 active with DEF pump disconnected?
6.b No, Replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
Note : SPN 3475/FMI 5 may occur with DEF pump disconnected.

7. Conduct a wiggle test on ACM 120-Pin connector, DEF pump harness connector. Does fault code go
inactive?
7.a Yes; Repair the short-to-ground between pin 3 of the DEF pump harness connector and pin 20 of the
ACM 120-pin connector. Go to step 8.
8. Run ADS Self-Check to verify repairs. Does test pass with no codes?
2
333.3 SPN 4375/FMI 5 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed Open
SPN 4375/FMI 5
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed Open
Dash Lamps MIL, CEL

3

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
4. Measure resistance between DEF pump pins 2 and 3. Is resistance greater than 6K ohms?
4.a Yes, Replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by
5. Check resistance between pin 3 of the DEF pump connector and pin 20 of the ACM 120-pin connector. Is
5.b No, Repair open in wire between pin 3 of the DEF pump connector and pin 20 of the ACM 120-pin
connector. Go to step 9.
7. Install a test ACM.
8. Turn ignition ON (key ON, engine OFF). Using DiagnosticLink, does fault return?
8.a Yes, Check the ATS harness connectors for corroded or spread pins. Repair as necessary. Go to step 9.
8.b No, Turn the ignition OFF. Replace ACM. Go to step 9.
9. Rerun SCR ADS Self-Check to verify repairs. Does test pass with no codes?
9.a Yes, release vehicle.
9.b No, Check the ATS harness connectors for corroded or spread pins. Repair as necessary. Run the
SCR ADS Self-Check to verify the repairs.
4
333.1 SPN 4375/FMI 3 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed High
SPN 4375/FMI 3
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed High
Typical Enabling Conditions DEF Pump On
Dash Lamps MIL, CEL
3. Perform a Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine.
4.b No; clear the fault code and release the vehicle.
6.b If connector shows no sign of damage, repair the short-to-battery (12 volts) between pin 3 of the DEF
Pump harness connector and pin 20 of the ACM 120-pin connector.

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
5
333.2 SPN 4375/FMI 4 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed Low
SPN 4375/FMI 4
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed Low
Dash Lamps MIL, CEL

4. Clear codes.
5. Using DiagnosticLink , recheck for codes.
6. Is SPN 4375/FMI 4 active with DEF pump disconnected?
6.b No, Replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
Note : SPN 3475/FMI 5 may occur with DEF pump disconnected.

7. Conduct a wiggle test on ACM 120-Pin connector, DEF pump harness connector. Does fault code go
inactive?
7.a Yes; Repair the short-to-ground between pin 3 of the DEF pump harness connector and pin 20 of the
ACM 120-pin connector. Go to step 8.
8. Run ADS Self-Check to verify repairs. Does test pass with no codes?
6
333.3 SPN 4375/FMI 5 - GHG17

Diesel Exhaust Fluid Pump Circuit Failed Open
SPN 4375/FMI 5
Description Diesel Exhaust Fluid (DEF) Pump Circuit Failed Open
Dash Lamps MIL, CEL

7

Pin 2 Pump Supply 1
Pin 4 Pump GND 31
4. Measure resistance between DEF pump pins 2 and 3. Is resistance greater than 6K ohms?
4.a Yes, Replace DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repairs by
7. Install a test ACM.
8. Turn ignition ON (key ON, engine OFF). Using DiagnosticLink, does fault return?
8.a Yes, Check the ATS harness connectors for corroded or spread pins. Repair as necessary. Go to step 9.
8.b No, Turn the ignition OFF. Replace ACM. Go to step 9.
9. Rerun SCR ADS Self-Check to verify repairs. Does test pass with no codes?
9.a Yes, release vehicle.
9.b No, Check the ATS harness connectors for corroded or spread pins. Repair as necessary. Run the
SCR ADS Self-Check to verify the repairs.
8
334.1 SPN 4752/FMI 0 - GHG17

Exhaust Gas Recirculation Cooler Performance Monitor
SPN 4752/FMI 0
Description Exhaust Gas Recirculation (EGR) Cooler Performance
Monitor
Monitored Parameter Intake manifold temperature sensor
Typical Enabling Conditions Engine running greater than 5 minutes, EGR mass flow
greater than .08, intake manifold temperature less than 125°C
(257°F), engine speed 1200 to 2500 rpm, engine torque 500
to 2500 N·m (368.6 to 1844 lb·ft), coolant temperature greater
than 65°C (149°F), ambient temperature less than 45°C
(113°F) ambient, coolant temperature greater than 65°C
(149°F), ambient temperature greater than -8°C (17.6°F)
ambient, barometric pressure greater than 755 mbar (10.95
psi).
Dash Lamps MIL, CEL
Engine Reaction
Verification When ambient temperature less than 45°C (113°F), start
engine, warm up so coolant temperature greater than 65°C
(149°F), ambient barometric pressure greater than 755 mbar
(10.95 psi)
1. Are there any cooling system or fan operation concerns?

1.a Yes, repair those failures, clear codes and release vehicle.
4. Monitor the intake manifold air temperature; is the intake manifold air temperature reading greater than
93°C (200°F )?
4.a Yes, replace the intake manifold air temperature sensor. Refer to section "Removal of the Intake Manifold Air

6. Disconnect the intake manifold air temperature sensor harness connector.
7. Inspect the intake manifold air temperature sensor harness connector for bent, spread or corroded pins.
7.a If pin damage is found, replace the intake manifold temperature sensor harness connector and intake
manifold temperature sensor. Refer to section "Removal of the Intake Manifold Air Temperature Sensor" .
8. Visually inspect the entire EGR system for evidence of external leakage (e.g. soot, coolant deposits at
joints).
8.a If external leakage is found, repair as necessary.
8.b If no external leakage is found, Go to step 9.
9. Remove the following components:
Refer to section "Removal of the Mixer Pipe" .
1
9.a If excessive build up or blockage is found, clean piping and replace EGR cooler.
Refer to section "Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly" .
Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler" .
9.b If there is no excessive buildup or blockage, replace the intake manifold air temperature sensor. Refer to
section "Removal of the Intake Manifold Air Temperature Sensor" .
2
334.2 SPN 4752/FMI 15 - GHG17

SPN 4752/FMI 15
Monitor
(257°F), engine speed 1200 to 2500 RPM, engine torque 500
to 2500 N·m, coolant temperature greater than 65°C (149°F),
ambient temperature less than 45°C (113°F) ambient, coolant
temperature greater than 65°C (149°F), ambient temperature
greater than -8°C (17.6°F) ambient, barometric pressure
greater than 755 mbar (10.95 psi).
Dash Lamps MIL
Engine Reaction
engine, warm up such that coolant temperature greater than
65°C (149°F), insure ambient barometric pressure greater
than 755 mbar (10.95 psi)
Check as follows:
1. Is there any cooling system or fan operation concerns?
1.a Yes, repair those failures; clear codes and release vehicle.
93°C (200°F )?

7. Inspect the intake manifold air temperature sensor harness connector for bent, spread, or corroded pins.
joints).
8.b If no external leakage is found Go to step 9.
3
4
334.1 SPN 4752/FMI 0 - GHG17

SPN 4752/FMI 0
Monitor
Monitored Parameter Intake manifold temperature sensor
(257°F), engine speed 1200 to 2500 rpm, engine torque 500
to 2500 N·m (368.6 to 1844 lb·ft), coolant temperature greater
than 65°C (149°F), ambient temperature less than 45°C
(113°F) ambient, coolant temperature greater than 65°C
(149°F), ambient temperature greater than -8°C (17.6°F)
ambient, barometric pressure greater than 755 mbar (10.95
psi).
Dash Lamps MIL, CEL
Engine Reaction
engine, warm up so coolant temperature greater than 65°C
(149°F), ambient barometric pressure greater than 755 mbar
(10.95 psi)
1. Are there any cooling system or fan operation concerns?

1.a Yes, repair those failures, clear codes and release vehicle.
93°C (200°F )?

7. Inspect the intake manifold air temperature sensor harness connector for bent, spread or corroded pins.
joints).
8.b If no external leakage is found, Go to step 9.
5

6
334.2 SPN 4752/FMI 15 - GHG17

SPN 4752/FMI 15
Monitor
(257°F), engine speed 1200 to 2500 RPM, engine torque 500
to 2500 N·m, coolant temperature greater than 65°C (149°F),
ambient temperature less than 45°C (113°F) ambient, coolant
temperature greater than 65°C (149°F), ambient temperature
greater than -8°C (17.6°F) ambient, barometric pressure
greater than 755 mbar (10.95 psi).
Dash Lamps MIL
Engine Reaction
engine, warm up such that coolant temperature greater than
65°C (149°F), insure ambient barometric pressure greater
than 755 mbar (10.95 psi)
Check as follows:
1. Is there any cooling system or fan operation concerns?
1.a Yes, repair those failures; clear codes and release vehicle.
93°C (200°F )?

7. Inspect the intake manifold air temperature sensor harness connector for bent, spread, or corroded pins.
joints).
8.b If no external leakage is found Go to step 9.
7
8
335.1 SPN 4765/FMI 0 - GHG17

SPN 4765/FMI 0
Dash Lamps CEL
Check as follows:
steps.
4. Check for multiple fault codes. Are codes other than SPN 4765/FMI 0 active?
4.b No; if only SPN 4765/FMI 0 and related codes are present, Go to step 5.
(1400°F)?
WARNING
ENGINE EXHAUST
corroded pins. If the temperature sensor connector is OK, check wiring from the Aftertreatment Control
Module (ACM), ACM 120-pin connector pin 27. Was any damage found?
Balance" .

11.a Yes; repair the faulty fuel injector/cylinder, and repeat the idle speed balance test to verify the repair.
Go to step 21.
1

12. Remove the Aftertreatment Device (ATD). Refer to section "Removal of the 1-BOX™ from the Vehicle" .
13. Disassemble the ATD and inspect the inlet face of the DPF substrate for contamination.
14. Was coolant contamination found (white residue on inlet face of the DPF and a sweet smell from exhaust)?
15. Was oil contamination found (oil residue or paste on DPF Inlet face or an oil lacquer on the inlet flange)?
16. Was fuel contamination found (inlet flange washed clean)?
20. Question the operator about excessive oil consumption. Possible causes of excessive oil consumption are:
• Excessive idle time
• Defective turbine wheel seal
• Turbocharger bearing failure
• Worn exhaust valve seals
• Defective crankcase breather system
• Stuck rings
23. Install the ATD. Refer to section "Installation of the 1-BOX™ Aftertreatment Control Module" .
2
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Note : The parked regeneration is successful if the DOC outlet temperature is within 100C (212F) of the DOC
Model Delay.
24. Perform a parked regeneration. Verify repairs.
Refer to section "Performing a Parked Regeneration - GHG17"
Refer to section "Resetting the Diesel Particulate Filter Ash Accumulators"
3
335.1 SPN 4765/FMI 0 - GHG17

SPN 4765/FMI 0
Dash Lamps CEL
Check as follows:
steps.
4. Check for multiple fault codes. Are codes other than SPN 4765/FMI 0 active?
4.b No; if only SPN 4765/FMI 0 and related codes are present, Go to step 5.
(1400°F)?
WARNING
ENGINE EXHAUST
corroded pins. If the temperature sensor connector is OK, check wiring from the Aftertreatment Control
Module (ACM), ACM 120-pin connector pin 27. Was any damage found?
Balance" .
4

11.a Yes; repair the faulty fuel injector/cylinder, and repeat the idle speed balance test to verify the repair.
Go to step 21.

12. Remove the Aftertreatment Device (ATD). Refer to section "Removal of the 1-BOX™ from the Vehicle" .
13. Disassemble the ATD and inspect the inlet face of the DPF substrate for contamination.
14. Was coolant contamination found (white residue on inlet face of the DPF and a sweet smell from exhaust)?
15. Was oil contamination found (oil residue or paste on DPF Inlet face or an oil lacquer on the inlet flange)?
16. Was fuel contamination found (inlet flange washed clean)?
20. Question the operator about excessive oil consumption. Possible causes of excessive oil consumption are:
• Excessive idle time
• Defective turbine wheel seal
• Turbocharger bearing failure
• Worn exhaust valve seals
• Defective crankcase breather system
• Stuck rings
5

23. Install the ATD. Refer to section "Installation of the 1-BOX™ Aftertreatment Control Module" .
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Note : The parked regeneration is successful if the DOC outlet temperature is within 100C (212F) of the DOC
Model Delay.
24. Perform a parked regeneration. Verify repairs.
Refer to section "Performing a Parked Regeneration - GHG17"
Refer to section "Resetting the Diesel Particulate Filter Ash Accumulators"
6
336.1 SPN 4814/FMI 3 - GHG17

Water Pump Circuit Failed High
SPN 4814/FMI 3
Description Water pump circuit short to battery
Monitored Parameter Water pump solenoid PWM11
Typical Enabling Conditions Enabled when engine coolant above 71°C (160°F)
Monitor Sequence Continuous
Typical Duration
Dash Lamps CEL
Verification Engine running, coolant above 71°C (160°F)
1. Disconnect the water pump solenoid harness connector.

2. Inspect the water pump solenoid harness connector for bent, spread, or corroded pins. Is damage found?
4. Measure the voltage between pin 1 of the water pump solenoid connector, harness side and ground. Is the
4.a Yes; repair a shorted circuit between pin 1 of the water pump solenoid connector and pin 37 of the 120-
pin MCM connector.
1
4.b No; install a new MCM. Refer to section "Removal of the Motor Control Module" .
2
336.2 SPN 4814/FMI 4 - GHG17

Water Pump Circuit Failed Low
SPN 4814/FMI 4
Description Water pump circuit short to ground
Typical Duration
Dash Lamps CEL
1. Disconnect the water pump harness connector.

WARNING
PERSONAL INJURY
3
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST

4. Run the engine until inlet coolant temperature sensor reading is greater than 71°C (160°F). Does SPN
4814/FMI 4 remain active?
4.b No; install a new variable speed water pump. Refer to section "Removal of the Variable Speed Water Pump" .
6. Measure the resistance between pin 1 of the water pump solenoid connector, harness side and ground. Is
6.a Yes; Install a new MCM. Refer to section "Removal of the Motor Control Module" .
6.b No; repair the circuit between pin 1 of the water pump solenoid connector and pin 37 of the 120-pin
MCM connector for a short to ground.
4
336.3 SPN 4814/FMI 5 - GHG17

Water Pump Circuit Failed Open
SPN 4814/FMI 5
Description Water pump circuit open
Typical Duration
Dash Lamps CEL

3. Disconnect the water pump solenoid connector.
4. Measure the resistance between pin 1 of the water pump solenoid connector, harness side and pin 37 of
the 120-pin MCM connector . Is the resistance less than five ohms?
4.b No; repair the open circuit between pin 1 of the water pump solenoid connector and pin 37 of the 120-
pin MCM connector.
5

pin MCM connector.
6. Measure the resistance between pin 1 and pin 2 of the water pump solenoid connector, component side ?
6.a Yes; install a new MCM. Refer to section "Removal of the Motor Control Module" .
6
336.1 SPN 4814/FMI 3 - EuroV

Water Pump Circuit Failed High
SPN 4814/FMI 3
Description Water pump circuit short to battery
Typical Duration
Dash Lamps CEL
1. Disconnect the water pump solenoid harness connector.

2. Inspect the water pump solenoid harness connector for bent, spread, or corroded pins. Is damage found?
4. Measure the voltage between pin 1 of the water pump solenoid connector, harness side and ground. Is the
7
4.a Yes; repair a shorted circuit between pin 1 of the water pump solenoid connector and pin 37 of the 120-
pin MCM connector.
4.b No; install a new MCM. Refer to section "Removal of the Motor Control Module" .
8
336.2 SPN 4814/FMI 4 - EuroV

Water Pump Circuit Failed Low
SPN 4814/FMI 4
Description Water pump circuit short to ground
Typical Duration
Dash Lamps CEL

WARNING
PERSONAL INJURY
9
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST

4. Run the engine until inlet coolant temperature sensor reading is greater than 71°C (160°F). Does SPN
4814/FMI 4 remain active?
6. Measure the resistance between pin 1 of the water pump solenoid connector, harness side and ground. Is
6.a Yes; Install a new MCM. Refer to section "Removal of the Motor Control Module" .
6.b No; repair the circuit between pin 1 of the water pump solenoid connector and pin 37 of the 120-pin
MCM connector for a short to ground.
10
336.3 SPN 4814/FMI 5 - EuroV

Water Pump Circuit Failed Open
SPN 4814/FMI 5
Description Water pump circuit open
Typical Duration
Dash Lamps CEL

3. Disconnect the water pump solenoid connector.
pin MCM connector.
11

pin MCM connector.
6. Measure the resistance between pin 1 and pin 2 of the water pump solenoid connector, component side ?
6.a Yes; install a new MCM. Refer to section "Removal of the Motor Control Module" .
12
337.1 SPN 5016/FMI 3 - GHG17

SPN 5016/FMI 3
Description High Side Digital Output Circuit Shorted to Power
Monitored Parameter High Side Digital Output
Dash Lamps MIL, CEL
Note : The supply voltage circuit is networked internal of the Aftertreatment Control Module (ACM). This circuit
supplies voltage to the coolant valve, Diesel Exhaust Fluid (DEF) post run indicator (if equipped), and the inlet
NOx sensor. A short-to-power on any one of those circuits will set this fault code.
1
Signal ACM Pin Component

SCR Supply 12V 106 DEF Post Run Indicator Supply (if
equipped)
SCR Supply 12V 110 N/C
SCR Supply 12V 19 CAN DEF Tank 6-5 Tank Heat Coolant
Valve 2-2
SCR Supply 12V 50 Deutsch 47-14 then NOx1 in 4-1
Check as follows:
1. Check for multiple codes. Is fault code SPN 3216/FMI 13 or SPN 3490/FMI (any) present along with SPN
5016/FMI 3?
1.a Yes; repair the other fault code first.
4. Inspect the ACM 120-pin harness connector for bent, spread, or corroded pins. Is any damage found?
Note : Multiple fault codes will set with ACM 120-pin connector disconnected. Disregard other fault codes at this
time.
5. Turn the ignition ON (key ON, engine OFF) and clear fault codes. Does SPN 5016/FMI 3 become active?
5.a Yes; replace the ACM. Refer to Original Equipment Manufacturer (OEM) procedures. Verify repair.
6. With the key ON, engine OFF, measure the voltage between pin 19 of the ACM 120-pin connector, harness
side, and battery ground. Is any voltage present?
6.a Yes; repair the short to power between pin 19 of the ACM 120-pin connector and pins 3 and 4 of the
DEF coolant valve connector. Verify repair.
7.a Yes; repair the short to power between pin 50 of the ACM 120-pin connector and pin 1 of the NOx inlet
sensor connector. Verify repair.
8. Is the vehicle equipped with a DEF Post Run indicator?
9. With the key ON, engine OFF, measure the voltage between pin 106 of the ACM 120-pin connector,
harness side, and battery ground. Is any voltage present?
9.a Yes; repair the short to power between pin 106 of the ACM 120-pin connector and pin 2 of the DEF
Post Run indicator. Verify repair.
10. Inspect connector cavity 106 of the ACM 120-pin connector, harness side. Is a wire populated in cavity
106?
10.a Yes; repair the short to power on pin 106 of the ACM 120-pin connector. Repair connector as needed.
Verify repair.
Note : ACM pin 110 is not populated from the factory. The ACM 120-pin connector should be equipped with a
cavity plug in cavity 110 of the 120-pin connector.
2
110?
Verify repair.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Repair the connector as
needed. Verify repair.
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Repair the connector as
3
337.2 SPN 5016/FMI 4 - GHG17

SPN 5016/FMI 4
Description High Side Digital Output Circuit Shorted Low
Dash Lamps MIL, CEL
4

equipped)
Valve 2-2
supplies voltage to the Coolant Valve, DEF Post Run indicator (if equipped), and the Inlet NOx sensor. A short on
any one of those circuits will set this fault code.
Check as follows:
5016/FMI 4?
3. Disconnect the Diesel Exhaust Fluid (DEF) coolant valve. Refer to OEM procedures.
4. Inspect the DEF coolant valve and harness connector for bent, spread or corroded pins. Is any damage
found?
Note : Disregard the additional faults set with components disconnected.
5. Turn the ignition ON (key ON, engine OFF) and clear fault codes. Does the fault become active?
5.b No; replace the DEF tank coolant valve. Refer to OEM procedures. Verify repair.
7. Disconnect the inlet NOx sensor.
8. Inspect the inlet NOx sensor and harness connector for bent, spread or corroded pins. Is any damage
found?
For 1-BOX™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
For 2-BOX, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
12. Disconnect the DEF Post Run indicator. Refer to Original Equipment Manufacturer (OEM) procedures.
13. Inspect the DEF Post Run indicator and harness connector for bent, spread or corroded pins. Is any
damage found?
5

14.b No; replace the DEF Post Run indicator. Refer to OEM procedures. Verify repair.
17. Inspect the ACM 120-pin and harness connector for bent, spread or corroded pins. Is any damage found?
18.a Yes; replace the ACM. Refer to OEM procedures. Verify repair.
20. Measure resistance between pin 19 of the 120-pin ACM connector, harness side, and battery ground. Is the
coolant valve connector. Verify repair.
21.b No; repair the short to ground between pin 50 of the 120-pin ACM connector and pin 1 of the NOx inlet
Note : ACM pin 106 is not populated from the factory if not equipped with a DEF Post Run indicator lamp. The
120-pin ACM connector should be equipped with a cavity plug in the 120-pin connector cavity 106.
22. Measure resistance between pin 106 of the 120-pin ACM connector, harness side, and battery ground. Is
22.b No; repair the short to ground on pin 106 of the 120-pin ACM connector. Verify repair.
Note : ACM Pin 110 is not populated from the factory. The 120-pin ACM connector should be equipped with a
cavity plug in the 120-pin connector cavity 110.
23. Inspect connector cavity #110 of the 120-pin ACM connector, harness side. Is a wire populated in cavity
110?
23.a Yes; repair the short to ground on pin 110 of the 120-pin ACM connector. Repair connector as needed.
Verify repair.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repair.
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repair.
6
337.1 SPN 5016/FMI 3 - GHG17

SPN 5016/FMI 3
Description High Side Digital Output Circuit Shorted to Power
Dash Lamps MIL, CEL
supplies voltage to the coolant valve, Diesel Exhaust Fluid (DEF) post run indicator (if equipped), and the inlet
NOx sensor. A short-to-power on any one of those circuits will set this fault code.
7

equipped)
Valve 2-2
Check as follows:
5016/FMI 3?
4. Inspect the ACM 120-pin harness connector for bent, spread, or corroded pins. Is any damage found?
8

Note : Multiple fault codes will set with ACM 120-pin connector disconnected. Disregard other fault codes at this
time.
5. Turn the ignition ON (key ON, engine OFF) and clear fault codes. Does SPN 5016/FMI 3 become active?
5.a Yes; replace the ACM. Refer to Original Equipment Manufacturer (OEM) procedures. Verify repair.
6.a Yes; repair the short to power between pin 19 of the ACM 120-pin connector and pins 3 and 4 of the
DEF coolant valve connector. Verify repair.
7.a Yes; repair the short to power between pin 50 of the ACM 120-pin connector and pin 1 of the NOx inlet
9. With the key ON, engine OFF, measure the voltage between pin 106 of the ACM 120-pin connector,
harness side, and battery ground. Is any voltage present?
9.a Yes; repair the short to power between pin 106 of the ACM 120-pin connector and pin 2 of the DEF
Post Run indicator. Verify repair.
106?
Verify repair.
Note : ACM pin 110 is not populated from the factory. The ACM 120-pin connector should be equipped with a
cavity plug in cavity 110 of the 120-pin connector.
110?
Verify repair.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Repair the connector as
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Repair the connector as
9
337.2 SPN 5016/FMI 4 - GHG17

SPN 5016/FMI 4
Description High Side Digital Output Circuit Shorted Low
Dash Lamps MIL, CEL
10

equipped)
Valve 2-2
supplies voltage to the Coolant Valve, DEF Post Run indicator (if equipped), and the Inlet NOx sensor. A short on
any one of those circuits will set this fault code.
Check as follows:
5016/FMI 4?
3. Disconnect the Diesel Exhaust Fluid (DEF) coolant valve. Refer to OEM procedures.
4. Inspect the DEF coolant valve and harness connector for bent, spread or corroded pins. Is any damage
found?
5.b No; replace the DEF tank coolant valve. Refer to OEM procedures. Verify repair.
7. Disconnect the inlet NOx sensor.
8. Inspect the inlet NOx sensor and harness connector for bent, spread or corroded pins. Is any damage
found?
For 1-BOX™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
For 2-BOX, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Verify repair.
12. Disconnect the DEF Post Run indicator. Refer to Original Equipment Manufacturer (OEM) procedures.
13. Inspect the DEF Post Run indicator and harness connector for bent, spread or corroded pins. Is any
damage found?
11

14.b No; replace the DEF Post Run indicator. Refer to OEM procedures. Verify repair.
17. Inspect the ACM 120-pin and harness connector for bent, spread or corroded pins. Is any damage found?
18.a Yes; replace the ACM. Refer to OEM procedures. Verify repair.
coolant valve connector. Verify repair.
21.b No; repair the short to ground between pin 50 of the 120-pin ACM connector and pin 1 of the NOx inlet
Note : ACM pin 106 is not populated from the factory if not equipped with a DEF Post Run indicator lamp. The
120-pin ACM connector should be equipped with a cavity plug in the 120-pin connector cavity 106.
22. Measure resistance between pin 106 of the 120-pin ACM connector, harness side, and battery ground. Is
22.b No; repair the short to ground on pin 106 of the 120-pin ACM connector. Verify repair.
Note : ACM Pin 110 is not populated from the factory. The 120-pin ACM connector should be equipped with a
cavity plug in the 120-pin connector cavity 110.
23. Inspect connector cavity #110 of the 120-pin ACM connector, harness side. Is a wire populated in cavity
110?
23.a Yes; repair the short to ground on pin 110 of the 120-pin ACM connector. Repair connector as needed.
Verify repair.
For 1-BOX™, Refer to section "Removal of the 1-BOX™ Aftertreatment Control Module" . Verify repair.
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repair.
12
338.1 SPN 5017/FMI 3 - GHG17

NOx Sensor Digital Output 5 Circuit Signal Failed High
Check as follows:
1. Disconnect the Selective Catalyst Reduction (SCR) outlet NOx sensor.
4. Measure the voltage between pin 1 and 4 on the harness side of the SCR outlet NOx sensor connector.
engine ground.
5.a If the voltage is less than 11.5 volts, repair the wire between pin 1 on the harness side of the SCR
outlet NOx sensor connector and pin 42 of the Aftertreatment Control Module (ACM) 120-pin
connector.
outlet NOx sensor connector and pin 43 of the ACM 120-pin connector.
7. Measure the resistance between pin 2 and 3 on the harness side of the SCR outlet NOx sensor connector.
7.a If the resistance is between 50 and 70 ohms, replace the SCR outlet NOx sensor.
For 1-BOX™, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
For 2-BOX, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
9.a If the resistance is less than 1K ohms, repair the short between pins 2 and 3 on the harness side of the
SCR outlet NOx sensor connector and pins 40 and 41 of the ACM 120-pin connector.
12. Test ACM internal resistor; measure the resistance between pins 40 and 41 on the ACM.
1
338.2 SPN 5017/FMI 4 - GHG17

NOx Sensor Digital Output 5 Circuit Signal Failed Low
Check as follows:
engine ground.
connector.
9.a If the resistance is less than 1K ohms, repair short between pins 2 and 3 on the harness side of the
12.a If the resistance is between 50 and 70 ohms, replace the SCR outlet NOx Sensor.
12.b If the resistance is not between 50 and 70 ohms, replace the ACM.
2
338.1 SPN 5017/FMI 3 - GHG17

NOx Sensor Digital Output 5 Circuit Signal Failed High
Check as follows:
engine ground.
connector.
9.a If the resistance is less than 1K ohms, repair the short between pins 2 and 3 on the harness side of the
3
4
338.2 SPN 5017/FMI 4 - GHG17

NOx Sensor Digital Output 5 Circuit Signal Failed Low
Check as follows:
engine ground.
connector.
9.a If the resistance is less than 1K ohms, repair short between pins 2 and 3 on the harness side of the
12.a If the resistance is between 50 and 70 ohms, replace the SCR outlet NOx Sensor.
12.b If the resistance is not between 50 and 70 ohms, replace the ACM.
5
339.1 SPN 5018/FMI 18 - GHG17

SPN 5018/FMI 18
Description Diesel Oxidation Catalyst (DOC) Efficiency Fault
Dash Lamps MIL, CEL
NOTICE
If a High Idle Regen is started, then aborted within the first 12 minutes, more than two
times without shutting down the engine, the Aftertreatment Control Module (ACM) could
falsely set SPN 5018/FMI 18; in this case the code can be ignored.
Check as follows:
3. Check for active DOC or DPF temperature sensor faults. Are there any DOC or Diesel Particulate Filter
(DPF) temperature faults active?
4. Inspect the exhaust system for leaks. Are there any leaks found?
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

6. Run service routine "Perform Performance Check-Low Temp ATD".
7. Monitor the Diesel Oxidation Catalyst (DOC) inlet temperature sensor, the DOC outlet temperature sensor,
and the Diesel Particulate Filter (DPF) outlet temperature sensor for 20 minutes.
1
8. After 20 minutes, are the DOC inlet and DOC outlet temperature sensors readings within 42°C (76°F) of the
DPF outlet temperature sensor?
9. Continue running the routine for 5 minutes. Are the temperatures now within 42°C (76°F) of each other?
10. Stop the "Perform Performance Check-Low Temp ATD" service routine. Shut off the engine.
11. Replace the drifted DOC temperature sensor.
Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor"
Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor"
Verify repair.
12. Stop the "Perform Performance Check-Low Temp ATD" service routine. Shut off the engine, then turn the
ignition to the ON position.
13. Monitor the DOC inlet pressure sensor voltage. Is the voltage 0.44 to 0.56 volt?
14. Inspect the DOC inlet pressure sensor electrical connector for corrosion and spread pins. Is there any
corrosion or spread pins on electrical connector?
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST

16. Perform a parked regeneration and monitor DOC outlet temperature and DOC out model delay. Review the
last 15 minutes of the regen log file.
2
17. Is the DOC outlet temperature reading within 117°C (211°F) of the DOC out model delay?
17.a Yes; diagnostics are completed.
3
339.1 SPN 5018/FMI 18 - GHG17

SPN 5018/FMI 18
Description Diesel Oxidation Catalyst (DOC) Efficiency Fault
Dash Lamps MIL, CEL
NOTICE
If a High Idle Regen is started, then aborted within the first 12 minutes, more than two
times without shutting down the engine, the Aftertreatment Control Module (ACM) could
falsely set SPN 5018/FMI 18; in this case the code can be ignored.
Check as follows:
3. Check for active DOC or DPF temperature sensor faults. Are there any DOC or Diesel Particulate Filter
(DPF) temperature faults active?
4. Inspect the exhaust system for leaks. Are there any leaks found?
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
4
6. Run service routine "Perform Performance Check-Low Temp ATD".

7. Monitor the Diesel Oxidation Catalyst (DOC) inlet temperature sensor, the DOC outlet temperature sensor,
and the Diesel Particulate Filter (DPF) outlet temperature sensor for 20 minutes.
8. After 20 minutes, are the DOC inlet and DOC outlet temperature sensors readings within 42°C (76°F) of the
DPF outlet temperature sensor?
9. Continue running the routine for 5 minutes. Are the temperatures now within 42°C (76°F) of each other?
10. Stop the "Perform Performance Check-Low Temp ATD" service routine. Shut off the engine.
11. Replace the drifted DOC temperature sensor.
Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor"
Refer to section "Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor"
Verify repair.
12. Stop the "Perform Performance Check-Low Temp ATD" service routine. Shut off the engine, then turn the
ignition to the ON position.
13. Monitor the DOC inlet pressure sensor voltage. Is the voltage 0.44 to 0.56 volt?
14. Inspect the DOC inlet pressure sensor electrical connector for corrosion and spread pins. Is there any
corrosion or spread pins on electrical connector?
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
5

16. Perform a parked regeneration and monitor DOC outlet temperature and DOC out model delay. Review the
last 15 minutes of the regen log file.
17. Is the DOC outlet temperature reading within 117°C (211°F) of the DOC out model delay?
17.a Yes; diagnostics are completed.
6
340.1 SPN 5298/FMI 14 - GHG17

SPN 5298/FMI 14
Description Selective Catalytic Reduction (SCR) Abnormal Temperature
Rise
Monitored Parameter Diesel Particulate Filter (DPF) Outlet Temperature, SCR
Outlet Temperature
Dash Lamps MIL, CEL
2. Disconnect the SCR outlet and DPF outlet temperature sensor connectors.
3. Inspect the SCR outlet and DPF outlet temperature sensor harnesses. Are there any signs of bent, spread,
or corroded pin(s)?
WARNING
PERSONAL INJURY
4. Remove the DPF outlet temperature sensor and let the sensor adjust to ambient room temperature. Go to
step 5.
5. DPF Temperature Sensor Test - Measure the resistance between pins 1 and 2 of the DPF temperature
sensor connectors (refer to chart for resistance values). Is the resistance out of range?
5.b No; re-install the sensors. Go to step 6.
6. Remove the SCR outlet temperature sensor and let the sensor adjust to ambient room temperature. Go to
step 7.
7. SCR Outlet Sensor Test - Measure the resistance between pins 1 and 2 of the SCR Temperature sensor
connectors (refer to chart for resistance values). Is the resistance out of range?
1

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
Note : Submit regen log file (if run during diagnostics) with Warranty claim.
8. Start the engine and perform a low temperature Aftertreatment Device (ATD) check using DiagnosticLink to
check for a drifted temperature sensor. Refer to section "GHG17 Perform Performance Check - Low Temperature ATD" .
9. Are the DPF outlet and SCR outlet temperatures sensors within 25°C (45°F) during the last five minutes of
the routine?
9.a Yes; clear the fault and release the vehicle. The fault most likely set from built up hydrocarbons in the
SCR catalyst burning off after extended idling.
2
3
340.1 SPN 5298/FMI 14 - GHG17

SPN 5298/FMI 14
Description Selective Catalytic Reduction (SCR) Abnormal Temperature
Rise
Monitored Parameter Diesel Particulate Filter (DPF) Outlet Temperature, SCR
Outlet Temperature
Dash Lamps MIL, CEL
2. Disconnect the SCR outlet and DPF outlet temperature sensor connectors.
3. Inspect the SCR outlet and DPF outlet temperature sensor harnesses. Are there any signs of bent, spread,
or corroded pin(s)?
WARNING
PERSONAL INJURY
4. Remove the DPF outlet temperature sensor and let the sensor adjust to ambient room temperature. Go to
step 5.
5. DPF Temperature Sensor Test - Measure the resistance between pins 1 and 2 of the DPF temperature
sensor connectors (refer to chart for resistance values). Is the resistance out of range?
6. Remove the SCR outlet temperature sensor and let the sensor adjust to ambient room temperature. Go to
step 7.
7. SCR Outlet Sensor Test - Measure the resistance between pins 1 and 2 of the SCR Temperature sensor
connectors (refer to chart for resistance values). Is the resistance out of range?
4

0 32 197.67 207.62
2 35.6 199.20 209.15
4 39.2 200.73 210.67
6 42.8 202.27 212.20
8 46.4 203.80 213.72
10 50 205.33 215.24
12 53.6 206.85 216.77
14 57.2 208.38 218.29
16 60.8 209.91 219.81
18 64.44 211.43 221.33
20 68 212.96 222.85
22 71.6 214.48 224.37
24 75.2 216.01 225.88
26 78.8 217.53 227.40
28 82.4 219.05 228.91
30 86 220.57 230.43
32 89.6 222.09 231.94
34 93.2 223.61 233.45
36 96.8 225.12 234.96
38 100.4 226.64 236.47
40 104 228.16 237.98
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
Note : Submit regen log file (if run during diagnostics) with Warranty claim.
8. Start the engine and perform a low temperature Aftertreatment Device (ATD) check using DiagnosticLink to
check for a drifted temperature sensor. Refer to section "GHG17 Perform Performance Check - Low Temperature ATD" .
9. Are the DPF outlet and SCR outlet temperatures sensors within 25°C (45°F) during the last five minutes of
the routine?
9.a Yes; clear the fault and release the vehicle. The fault most likely set from built up hydrocarbons in the
SCR catalyst burning off after extended idling.
5
6
341.1 SPN 5319/FMI 14 - GHG17

SPN 5319/FMI 14
Description Soot Sensor Fails to Successfully Regenerate and Clear
Accumulated Ash
Monitored Parameter Soot Sensor Heater
Dash Lamps MIL
Verification Verify Repairs by using DiagnosticLink Soot Sensor Panel
Inspection Routine
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Note : When the engine starts, the soot sensor will cycle through three modes: 1) Protective heating of exhaust
temperature dew point 210°C (410°F) to allow moisture to evaporate, 2) Heater active regeneration 800°C
(1472°F) to clean soot, and 3) Measurement mode for duration of key cycle.
Check as follows:
2. Using DiagnosticLink , check for any communication or voltage fault codes. Are any other fault codes
present?
3. Disconnect the soot sensor electrical connector.
4. Inspect the soot sensor and harness connector for signs of damaged, bent, spread, corroded, or unseated
damage found?
1

4.b No; reconnect the soot sensor. Go to step 5.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

6. Use the soot sensor panel in DiagnosticLink to check the sensor. Start the service routine and wait until the
service routine completes. Did the service routine complete successfully?
6.a Yes; clear the fault and release the vehicle.
6.b No; replace the soot sensor.
Refer to section "Removal of the Soot Sensor"
2V2/2HH Soot Sensor: Refer to section "Removal of the Soot Sensor"

Verify repairs.
2
341.1 SPN 5319/FMI 14 - GHG17

SPN 5319/FMI 14
Description Soot Sensor Fails to Successfully Regenerate and Clear
Accumulated Ash
Monitored Parameter Soot Sensor Heater
Dash Lamps MIL
Verification Verify Repairs by using DiagnosticLink Soot Sensor Panel
Inspection Routine
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
Check as follows:
present?
3
damage found?
4.b No; reconnect the soot sensor. Go to step 5.
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

6. Use the soot sensor panel in DiagnosticLink to check the sensor. Start the service routine and wait until the
service routine completes. Did the service routine complete successfully?
6.a Yes; clear the fault and release the vehicle.
6.b No; replace the soot sensor.
Refer to section "Removal of the Soot Sensor"
2V2/2HH Soot Sensor: Refer to section "Removal of the Soot Sensor"

Verify repairs.
4
342.1 SPN 5323/FMI 13 - GHG17

SPN 5323/FMI 13
Description Excessive Time to Enter Closed Loop Fuel Pressure Control
Typical Enabling Conditions Rail Pressure Governor was Previously Operating in Closed
Loop Mode
Dash Lamps MIL, CEL
The Motor Control Module (MCM) monitors the fuel rail pressure. When fuel rail pressure is less than 200 bar, the
MCM sets the code. This fault can occur due to the conditions listed below:
• External Fuel Leakage Between the High Pressure Pump and Fuel Injectors

DiagnosticLink Standard
Note : It is important to obtain information from the customer on when the Check Engine lamp occurs and if there
Check as follows:
1. Did SPN 157/FMI 16, SPN 5323/FMI 13, or SPN 520268/FMI 18 appear after the fuel system was repaired
or fuel filter maintenance was performed?
1
logged?
4.b No; fuel sloshing in the tank may have caused aerated fuel and set this code. Road test vehicle; if code
5. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, kerosene, coolant. Is
any contamination found?
5.a Yes; refer to the "Contaminated Fluids" section of this manual.
6.a Yes; repair leak(s). Verify repairs.
7. Using DiagnosticLink 8.03 or higher, check for other active codes. Are any of the following codes active?
• SPN 1077/FMI 5, 6 or 14
7.b No; only SPN 1077/FMI 7, 157/FMI 16 or 1077/FMI 31 is present. Go to step 8.
8. Using DiagnosticLink 8.03 or higher, check the value of Pressure Limiting Valve (PLV) openings. With key
ON, engine OFF, select the Actions tab in the top tool bar. Select Fuel System, then Pressure Limiting
Valve (PLV). Change or view (RPG_CTR_PLV_OPEN) under "Extended Data Record #5" list. View and
9. Perform Automatic Fuel System Integrity Check (FSIC) routine using DiagnosticLink 8.03 or higher. With
key ON, Engine OFF, start the Automatic FSIC. The software/tool will ask to start the engine when
log file.
11. In the previous step, was bleed off time greater than two minutes and 30 seconds?
routine?
2

13. Was the fuel temperature rise greater than 5.56 °C (10°F) degrees?
15. Monitor AS124 LPPO sensor. Is the fuel pressure between 496 kPa (72 psi) and 551 kPa (80 psi) at 600
rpm and 689 kPa (100 psi) to 869 kPa (126 psi) at 1800 rpm?
pressures stable with no oscillations? Unstable pressures will have oscillations greater than 10.3 kPa (1.5
psi) at stable engine speed.
17.a Yes; follow repair procedures in " Idle Speed Balance (ISB) Test" and verify repairs. Refer to section "Verify
Repairs" .

3
4

20. Perform Pressure Limiting Valve (PLV) flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel
System" . Did the PLV flow test pass?

21. Inspect the low pressure fuel system for leaks. Refer to section "FIS Low Pressure Leak Test" . Did the low pressure
leak test pass?
5
NOTICE
KM63 GEN2 - Two-Filter System".
24. Using DiagnosticLink 8.03 or higher, navigate to Service Routines and Fuel System Integrity Check test
and select Manual FSIC. Road test the truck. Does the code set?
Is damage found?
27. Inspect chassis fuel system for restrictions or debris. Refer to OEM Procedures. Is there a chassis fuel
system issue?
6
342.1 SPN 5323/FMI 13 - GHG17

SPN 5323/FMI 13
Description Excessive Time to Enter Closed Loop Fuel Pressure Control
Typical Enabling Conditions Rail Pressure Governor was Previously Operating in Closed
Loop Mode
Dash Lamps MIL, CEL
The Motor Control Module (MCM) monitors the fuel rail pressure. When fuel rail pressure is less than 200 bar, the
MCM sets the code. This fault can occur due to the conditions listed below:
• External Fuel Leakage Between the High Pressure Pump and Fuel Injectors

DiagnosticLink Standard
Note : It is important to obtain information from the customer on when the Check Engine lamp occurs and if there
Check as follows:
1. Did SPN 157/FMI 16, SPN 5323/FMI 13, or SPN 520268/FMI 18 appear after the fuel system was repaired
or fuel filter maintenance was performed?
7

logged?
4.b No; fuel sloshing in the tank may have caused aerated fuel and set this code. Road test vehicle; if code
5. Check for fuel contamination, including Diesel Exhaust Fluid (DEF), water, gasoline, kerosene, coolant. Is
any contamination found?
5.a Yes; refer to the "Contaminated Fluids" section of this manual.
6.a Yes; repair leak(s). Verify repairs.
7. Using DiagnosticLink 8.03 or higher, check for other active codes. Are any of the following codes active?
• SPN 1077/FMI 5, 6 or 14
7.b No; only SPN 1077/FMI 7, 157/FMI 16 or 1077/FMI 31 is present. Go to step 8.
8. Using DiagnosticLink 8.03 or higher, check the value of Pressure Limiting Valve (PLV) openings. With key
ON, engine OFF, select the Actions tab in the top tool bar. Select Fuel System, then Pressure Limiting
Valve (PLV). Change or view (RPG_CTR_PLV_OPEN) under "Extended Data Record #5" list. View and
9. Perform Automatic Fuel System Integrity Check (FSIC) routine using DiagnosticLink 8.03 or higher. With
key ON, Engine OFF, start the Automatic FSIC. The software/tool will ask to start the engine when
log file.
11. In the previous step, was bleed off time greater than two minutes and 30 seconds?
routine?
8

13. Was the fuel temperature rise greater than 5.56 °C (10°F) degrees?
15. Monitor AS124 LPPO sensor. Is the fuel pressure between 496 kPa (72 psi) and 551 kPa (80 psi) at 600
rpm and 689 kPa (100 psi) to 869 kPa (126 psi) at 1800 rpm?
pressures stable with no oscillations? Unstable pressures will have oscillations greater than 10.3 kPa (1.5
psi) at stable engine speed.
17.a Yes; follow repair procedures in " Idle Speed Balance (ISB) Test" and verify repairs. Refer to section "Verify
Repairs" .

9
10

20. Perform Pressure Limiting Valve (PLV) flow test. Refer to section "Pressure Limiting Valve Flow Test – Two-Filter Fuel
System" . Did the PLV flow test pass?

21. Inspect the low pressure fuel system for leaks. Refer to section "FIS Low Pressure Leak Test" . Did the low pressure
leak test pass?
11
NOTICE
KM63 GEN2 - Two-Filter System".
24. Using DiagnosticLink 8.03 or higher, navigate to Service Routines and Fuel System Integrity Check test
and select Manual FSIC. Road test the truck. Does the code set?
Is damage found?
27. Inspect chassis fuel system for restrictions or debris. Refer to OEM Procedures. Is there a chassis fuel
system issue?
12
343.1 SPN 5357/FMI 16 - GHG17

SPN 5357/FMI 16
Description Fuel Quantity High Detected
Monitored Parameter Injector Quantity
Typical Enabling Conditions Steady State Drive and No Regen
Dash Lamps MIL, CEL
Verification Steady Engine rpm 1400 to 1500 (Two Minute)
3. Are any other fault codes present?
3.a Yes; repair other faults first.
4. Monitor the intake manifold temperature; is the intake manifold temperature reading greater than 65°C
(150°F)?
4.a Yes; replace the intake manifold temperature sensor. Refer to section "Removal of the Intake Manifold Air

5. Disconnect the intake manifold temperature sensor harness.
6. Inspect the intake manifold temperature sensor harness connector for bent, spread or corroded pins. Is
damage found?
6.a Yes; replace the intake manifold temperature sensor harness connector and intake manifold
temperature sensor. Refer to section "Removal of the Intake Manifold Air Temperature Sensor" .
7. Compare intake manifold pressure to atmospheric (Baro) pressure. Is the intake manifold pressure within
0.4 psi of Baro pressure?
Sensor" .
8. Monitor the Exhaust Gas Recirculation (EGR) delta P voltage (pin 109). Is the EGR delta P voltage
9. Remove the EGR delta P sensor from the mounting pad; leave electrical harness connected. Refer to section
10.b No; replace the EGR delta P sensor. Refer to section "Removal of the Delta P Sensor" .
joints). Is external leakage found?
1
12. Remove the EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for excessive build up
or blockage. Is excessive build up or blockage found?
Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube.
12.a Yes; clean piping and replace the EGR cooler.
For the DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly" .
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler" .
13. Visually inspect the entire exhaust system for leaks, specifically between the turbocharger outlet and the
Aftertreatment Device (ATD) inlet for leaks or damage. Are and leaks or damage found?
14. Inspect the entire air intake system (including clamps) for signs of leaks or damage. Are and leaks or
damage found?
15. Leak check the Charge Air Cooler (CAC); refer to OEM literature for procedure. Does check pass?
WARNING
HOT EXHAUST
16. Start engine, using Diagnostic Link run the NOx Sensor Verification test located in the drop down menu
under Actions / Aftertreatment.
2
17. If the NOx Sensor Verification Panel test fails, replace the Inlet NOx sensor.
3
343.2 SPN 5357/FMI 18 - GHG17

SPN 5357/FMI 18
Description Fuel Quantity Low Detected
Dash Lamps MIL, CEL
Verification Steady Engine rpm 1400 to 1500 (Two Minutes)
Check as follows:
(150°F)?

6. Inspect the intake manifold temperature sensor harness connector for bent, spread or corroded pins. Is pin
damage found?
Sensor" .
4

Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube."
Aftertreatment Device (ATD) inlet for leaks or damage. Are any leaks or damage found?
14. Inspect the entire air intake system (including clamps) for signs of leaks or damage. Are any leaks or
damage found?
WARNING
HOT EXHAUST
5
17. If the NOx Sensor Verification test fails, replace the Inlet NOx sensor.
6
343.1 SPN 5357/FMI 16 - GHG17

SPN 5357/FMI 16
Dash Lamps MIL, CEL
(150°F)?

damage found?
Sensor" .
7
damage found?
WARNING
HOT EXHAUST
8
9
343.2 SPN 5357/FMI 18 - GHG17

SPN 5357/FMI 18
Dash Lamps MIL, CEL
Check as follows:
(150°F)?

damage found?
Sensor" .
10

damage found?
WARNING
HOT EXHAUST
11
12
343.1 SPN 5357/FMI 16 - GHG17

SPN 5357/FMI 16
Dash Lamps MIL, CEL
(150°F)?

damage found?
Sensor" .
13

damage found?
WARNING
HOT EXHAUST
14
15
343.2 SPN 5357/FMI 18 - GHG17

SPN 5357/FMI 18
Dash Lamps MIL, CEL
Check as follows:
(150°F)?

damage found?
Sensor" .
16

damage found?
WARNING
HOT EXHAUST
17
18
344.1 SPN 5358/FMI 16 - GHG17

SPN 5358/FMI 16
Detects that Cylinder #1 Has Low rpm Speed With The
Injector Commanded To Maximum Fueling With All Conditions
Met
Engine Speed Between 1100 rpm to 1400 rpm
Actual Torque Load 40 to 80%
Actual Torque greater than 800 N·m (560 lb·ft) for DD13/DD15
Actual Torque greater than 1000 N·m (738 lb·ft) (between
1100 to 1300 rpm) or 1330 N·m (981 lb·ft) (between 1300 to
1400 rpm) for DD16
No Fuel System Faults
No Circuit Faults
No Air System Faults
Engine Coolant Temperature Greater Than 65°C (149°F)
Engine Fuel Temperature Greater Than 0°C (32°F)
Execution Frequency Once Per Drive Cycle
Dash Lamps MIL
Verification Key-Off For 5 Minutes Followed By A Road Test With All
Conditions Met
Possible causes:
• Drivetrain Vibrations
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

3.a Yes; make necessary repairs, verify repairs.
4. Test drive vehicle to check for drivetrain vibration under heavy load. Are any vibrations found?
4.a Yes; repair cause of vibration.
• SPN 651/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
To-Date," and then selecting "Engine." In the resulting page view, look at the Peak Engine rpm and the
date it occurred. Is the maximum engine speed greater than the values shown in the chart below?
Peak Engine RPM


9. Use DiagnosticLink® to perform the relative compression test. Refer to section "Relative Cylinder Compression Test" .
Is the relative compression reading for cylinder #1 within 10% of the highest cylinder reading?
verify repairs.
3
repairs.
18. Perform the mechanical cylinder compression test. Refer to section "Mechanical Cylinder Compression Test" . Is the
cylinders?

necessary.
4
344.2 SPN 5358/FMI 18 - GHG17

SPN 5358/FMI 18
Detects That Cylinder #1 Has High rpm Speed With The
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Follow troubleshooting procedure for SPN 5358/FMI 16. .
5
345.1 SPN 5359/FMI 16 - GHG17

SPN 5359/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 652/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
3
repairs.
cylinders?

necessary.
4
345.2 SPN 5359/FMI 18 - GHG17

SPN 5359/FMI 18
Description This Fault Code Sets When The Motor Control Module (MCM)
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
5
346.1 SPN 5360/FMI 16 - GHG17

SPN 5360/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Drivetrain Vibration
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 653/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
3
repairs.
cylinders?

necessary.
4
346.2 SPN 5360/FMI 18 - GHG17

SPN 5360/FMI 18
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
5
347.1 SPN 5361/FMI 16 - GHG17

SPN 5361/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 654/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
3
repairs.
cylinders?

necessary.
4
347.2 SPN 5361/FMI 18 - GHG17

SPN 5361/FMI 18
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
5
348.1 SPN 5362/FMI 16 - GHG17

SPN 5362/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 655/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
3
repairs.
cylinders?

necessary.
4
348.2 SPN 5362/FMI 18 - GHG17

SPN 5362/FMI 18
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
5
349.1 SPN 5363/FMI 16 - GHG17

SPN 5363/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
1
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 656/FMI any
2

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
3
repairs.
cylinders?

necessary.
4
349.2 SPN 5363/FMI 18 - GHG17

SPN 5363/FMI 18
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Follow troubleshooting procedure for SPN 5363/FMI 16. Refer to section "SPN 5363/FMI 16 - GHG17" Refer to
5
349.1 SPN 5363/FMI 16 - GHG17

SPN 5363/FMI 16
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
Possible causes:
• Bent Valve
• Bearing Failure
WARNING
PERSONAL INJURY
6
WARNING
PERSONAL INJURY
CAUTION
ELECTRICAL SHOCK
WARNING
BODILY INJURY
WARNING
PERSONAL INJURY

• SPN 656/FMI any
7

• SPN 190/FMI 0, 14, or 15
• SPN 636/FMI 2, 8, 10, or 11
• SPN 723/FMI 8, 10, or 11
• SPN 157/FMI any
• SPN 164/FMI any
Peak Engine RPM


verify repairs.
8
repairs.
cylinders?

necessary.
9
349.2 SPN 5363/FMI 18 - GHG17

SPN 5363/FMI 18
Met
1400 rpm) for DD16
No Circuit Faults
Dash Lamps MIL
Conditions Met
10
350.1 SPN 5395/FMI 15 - GHG17

Idle Fuel Quantity Out of Range
SPN 5395/FMI 15
Description Fuel Quantity Above Normal Operating Range at Idle
Typical Enabling Conditions Engine Idle and no vehicle speed
Typical Duration Two minutes
Dash Lamps MIL
Verification Steady Engine Idle (Two minute)
Check as follows:
Note : This fault code will set with excessive load at idle such as running with engine loaded through FEPTO
equipment without putting the truck in PTO mode.
4. Does this unit run PTO at idle or on start up?
4.a Yes; disable PTO at idle or start up. Verify set up with customer.
4.b No; an issue exists with the adjustment of the equipment/PTO putting additional load on the engine.
Repair as needed. Verify repairs.
1
350.1 SPN 5395/FMI 15 - GHG17

Idle Fuel Quantity Out of Range
SPN 5395/FMI 15
Description Fuel Quantity Above Normal Operating Range at Idle
Typical Enabling Conditions Engine Idle and no vehicle speed
Typical Duration Two minutes
Dash Lamps MIL
Verification Steady Engine Idle (Two minute)
Check as follows:
Note : This fault code will set with excessive load at idle such as running with engine loaded through FEPTO
equipment without putting the truck in PTO mode.
4. Does this unit run PTO at idle or on start up?
4.a Yes; disable PTO at idle or start up. Verify set up with customer.
4.b No; an issue exists with the adjustment of the equipment/PTO putting additional load on the engine.
Repair as needed. Verify repairs.
2
351.1 SPN 5397/FMI 31 - GHG17

Regen Frequency Error
Note : Regeneration must be completed with DiagnosticLink®, dash switch initiated regen will not clear this fault.
2. Verify the ACM software level is up to date. ACM software 7.57.2.0 with fuel map ZGS 002 has
improvements for this fault code. Is your current ACM software up to date?
2.b No; Update the ACM software and release the vehicle.
WARNING
HOT EXHAUST
3. Perform a Parked Regeneration, clear faults, and release vehicle. Refer to section " Performing a Parked
Regeneration Using DiagnosticLink®" .
1
351.1 SPN 5397/FMI 31 - GHG17

Regen Frequency Error
Note : Regeneration must be completed with DiagnosticLink , dash switch initiated regen will not clear this fault.
2. Verify the ACM software level is up to date. ACM software 7.57.2.0 with fuel map ZGS 002 has
improvements for this fault code. Is your current ACM software up to date?
2.b No; Update the ACM software and release the vehicle.
WARNING
HOT EXHAUST
3. Perform a Parked Regeneration, clear faults, and release vehicle. Refer to section " Performing a Parked
Regeneration Using DiagnosticLink®" .
2
352.1 SPN 5418/FMI 3 - GHG17

Quantity Control Valve High Side Error
SPN 5418 FMI 3

Description Quantity Control Valve (High Side) Error
Dash Lamp MIL, CEL
This condition can occur when:

• MCM pin 1 circuit is shorted to ground
• Internal short of the quantity control valve
1.a If SPN 5418/FMI 4 is stored along with SPN 5418/FMI 3, service SPN 5418/FMI 4 first.
2. Disconnect the quantity control valve harness connector.
3. Ensure the multi meter or Digital Voltage Ohm Meter (DVOM) resistance is set to zero.
3.a If meter can auto-zero, perform this function before making a resistance measurement.
3.b If meter can not auto-zero, note the resistance of the leads and subtract it from the measurement taken
in step 4.
4.a If the resistance is less than 1.3 ohms, replace quantity control valve. Refer to section "Removal of the Quantity
4.b If the resistance is between 1.3 ohms and 1.4 ohms, Go to step 5.
5. Disconnect the 120-pin MCM connector and check for corroded, bent or broken pins. Insure both the MCM
and harness connector pins are checked. Repair or replace if needed.
6. Measure the resistance between pin 1 of the quantity control valve harness connector and ground.
6.a If the resistance is greater than 10K ohms, replace quantity control valve. Refer to section "Removal of the
6.b If the resistance is less than 10K ohms, repair the short circuit between pin 1 of the quantity control
valve and ground.
1
352.2 SPN 5418/FMI 4 - GHG17

Quantity Control Valve Low Side Error
SPN 5418 FMI 4

Description Quantity Control Valve (Low Side) Error
Dash Lamps MIL, CEL

• MCM pin 2 circuit is shorted to power
2

in step 3.
4. Disconnect the 120-pin Motor Control Module (MCM) connector and check for corroded, bent or broken
pins. Ensure both the MCM and harness connector pins are checked. Repair or replace if needed
3
6. Measure the voltage at pin 2 of the quantity control valve harness connector.
6.a If the voltage is 0, replace the MCM. Refer to section "Removal of the Motor Control Module" .
6.b If the voltage is greater than 0, repair the short circuit between pin 2 of the quantity control valve
harness connector and battery.
4
352.1 SPN 5418/FMI 3 - GHG17

Quantity Control Valve High Side Error
SPN 5418 FMI 3

Description Quantity Control Valve (High Side) Error
Dash Lamp MIL, CEL

• MCM pin 1 circuit is shorted to ground
1.a If SPN 5418/FMI 4 is stored along with SPN 5418/FMI 3, service SPN 5418/FMI 4 first.
in step 4.
5. Disconnect the 120-pin MCM connector and check for corroded, bent or broken pins. Insure both the MCM
and harness connector pins are checked. Repair or replace if needed.
6. Measure the resistance between pin 1 of the quantity control valve harness connector and ground.
6.a If the resistance is greater than 10K ohms, replace quantity control valve. Refer to section "Removal of the
6.b If the resistance is less than 10K ohms, repair the short circuit between pin 1 of the quantity control
valve and ground.
5
352.2 SPN 5418/FMI 4 - GHG17

Quantity Control Valve Low Side Error
SPN 5418 FMI 4

Description Quantity Control Valve (Low Side) Error
Dash Lamps MIL, CEL

• MCM pin 2 circuit is shorted to power
6

in step 3.
4. Disconnect the 120-pin Motor Control Module (MCM) connector and check for corroded, bent or broken
pins. Ensure both the MCM and harness connector pins are checked. Repair or replace if needed
7
6. Measure the voltage at pin 2 of the quantity control valve harness connector.
6.a If the voltage is 0, replace the MCM. Refer to section "Removal of the Motor Control Module" .
6.b If the voltage is greater than 0, repair the short circuit between pin 2 of the quantity control valve
harness connector and battery.
8
353.1 SPN 5435/FMI 7 – GHG17

Non Diesel Exhaust Fluid Flow Situation
This code sets when the Aftertreatment Control Module (ACM) detects that the Diesel Exhaust Fluid (DEF) pump
speed is too low when activated.
SPN 5435 FMI 7

Description Non DEF Flow Situation
Monitored Parameter DEF Pump Speed
Typical Enabling Conditions DEF Pump Enabled and Cannot Operate Above a DEF Pump
Speed Threshold
Monitor Sequence DEF pump Is Enabled
Execution Frequency Service Tool and Infrequent In-use Checks During On DEF
Dosing Conditions
Dash Lamps MIL, CEL
Verification Selective Catalyst Reduction Airless Dosing System (SCR
ADS) Self-check

1. Connect DiagnosticLink and check for other fault codes. Are fault codes SPN 4374/FMI 3 or 4 present?
1.b No: replace the DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repair.
1
353.1 SPN 5435/FMI 7 – GHG17

Non Diesel Exhaust Fluid Flow Situation
This code sets when the Aftertreatment Control Module (ACM) detects that the Diesel Exhaust Fluid (DEF) pump
speed is too low when activated.
SPN 5435 FMI 7

Description Non DEF Flow Situation
Speed Threshold
Monitor Sequence DEF pump Is Enabled
Dosing Conditions
Dash Lamps MIL, CEL
ADS) Self-check

2
353.2 SPN 5435/FMI 11 - GHG17

SPN 5435 FMI 11
Description This Code Sets when the Aftertreatment Control Module
(ACM) Detects that the Diesel Exhaust Fluid (DEF) Pump
Speed Is Too Low When Activated
Speed Threshold
Monitor Sequence DEF Pump Is Enabled
Dosing Conditions
Dash Lamps MIL, CEL
Verification Use DiagnosticLink to Perform the Selective Catalyst
Reduction Airless Dosing System (SCR ADS) Self-check
3
354.1 SPN 5443/FMI 0 – GHG17

SPN 5443/FMI 0
Description High Hydrocarbon Absorption in the Diesel Particulate Filter
(DPF)
Monitored Parameter Diesel Oxidation Catalyst (DOC) Temperature In
Typical Enabling Conditions High Idle Times
Monitor Sequence Always Enabled
Dash Lamps SEL
Check as follows:
2. Use the chart below to verify the Aftertreatment Control Module (ACM) software level is up to date. Is the
current ACM software and fuel map at or greater than the chart below?
2.b No; update to the latest ACM software configuration on the server. Go to step 3.
ACM 7.56.6.0 software with fuel map ZGS Version
Model ATS Configuration Software Version ACM Fuel Map Version

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2HV / 2HH 7.56.6.0 ZGS 004
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 1-Box FCCC, Terex Crane 7.56.6.0 ZGS 005
DD13 1-Box non-DTNA 7.56.6.0 ZGS 004
DD13 Two-Box 2V2 non-DTNA 7.56.6.0 ZGS 003
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
1
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

5. Using DiagnosticLink, perform a parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17" .
6. When regeneration is complete, clear all fault codes. Verify repairs.
2
354.2 SPN 5443/FMI 15 - GHG17

SPN 5443/FMI 15
(DPF)
Dash Lamps None
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
3
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

6. Clear fault codes after completion of regeneration.
4
354.3 SPN 5443/FMI 16 - GHG17

SPN 5443/FMI 16
Dash Lamps CEL
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
5
WARNING
HOT EXHAUST

6. When regeneration is complete, clear all fault codes.
6
354.1 SPN 5443/FMI 0 – GHG17

SPN 5443/FMI 0
(DPF)
Dash Lamps SEL
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
7
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

6. When regeneration is complete, clear all fault codes. Verify repairs.
8
354.2 SPN 5443/FMI 15 - GHG17

SPN 5443/FMI 15
(DPF)
Dash Lamps None
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
9
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST

6. Clear fault codes after completion of regeneration.
10
354.3 SPN 5443/FMI 16 - GHG17

SPN 5443/FMI 16
Dash Lamps CEL
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005

WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
11
WARNING
HOT EXHAUST

6. When regeneration is complete, clear all fault codes.
12
355.1 SPN 5444/FMI 1 - GHG17

SPN 5444/FMI 1
Description Fault Code Sets When the Engine Oil Separator Speed is less
than 3,000 rpm for 45 Seconds
Monitored Parameter Crankcase Ventilator Oil Separator Speed
Typical Enabling Conditions Engine Coolant Temperature Greater than 65°C (149°F),
Engine Oil Temperature Greater than 65°C (149°F), Engine
rpm Greater than 900 rpm, Ambient Temperature Greater
than -8°C (17.6°F), Barometric Pressure Greater than 10.9 psi
(755 mbar)
Dash Lamps None
Verification Engine Running for Greater than One Minute with the Typical
Enabling Conditions Met
1
Check as follows:
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2. Start and run the engine at idle.

3. Monitor the crankcase ventilator oil separator speed. Is the crankcase ventilator oil separator speed zero
rpm?
4. Monitor the crankcase ventilator oil separator speed. Is the crankcase ventilator oil separator speed less
than 3,000 rpm?
4.a Yes; replace the crankcase breather. Refer to section "Removal of the Crankcase Breather Assembly" .
4.b No; replace the engine crankcase breather oil separator speed sensor and the pigtail.
6. Disconnect and inspect the engine crankcase breather oil separator speed sensor electrical connector. Is
there damage or corrosion present?
6.a Yes; replace the engine crankcase breather oil separator speed sensor and the pigtail.
8. Measure the voltage between pins 1 and 3 of the engine crankcase breather oil separator speed sensor
electrical connector harness side. Is the voltage between 4.5 to 5.5 volts?
9. Measure the voltage between pin 1 of the engine crankcase breather oil separator speed sensor electrical
connector harness side and ground. Is the voltage between 4.5 to 5.5 volts?
9.a Yes; repair the circuit between pin 3 of the engine crankcase breather oil separator speed sensor
electrical connector harness side and the circuit splice.
9.b No; repair the circuit between pin 1 of the engine crankcase breather oil separator speed sensor
11. Measure the resistance between pins 2 and 3 of the engine crankcase breather oil separator speed sensor
electrical connector harness side. Is the resistance more than five ohms?
electrical connector harness side and pin 49 of the MCM 120-pin electrical connector.
2
355.1 SPN 5444/FMI 1 - GHG17

SPN 5444/FMI 1
Description Fault Code Sets When the Engine Oil Separator Speed is less
than 3,000 rpm for 45 Seconds
Monitored Parameter Crankcase Ventilator Oil Separator Speed
Typical Enabling Conditions Engine Coolant Temperature Greater than 65°C (149°F),
Engine Oil Temperature Greater than 65°C (149°F), Engine
rpm Greater than 900 rpm, Ambient Temperature Greater
than -8°C (17.6°F), Barometric Pressure Greater than 10.9 psi
(755 mbar)
Dash Lamps None
Verification Engine Running for Greater than One Minute with the Typical
Enabling Conditions Met
3
Check as follows:
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2. Start and run the engine at idle.

3. Monitor the crankcase ventilator oil separator speed. Is the crankcase ventilator oil separator speed zero
rpm?
4

4. Monitor the crankcase ventilator oil separator speed. Is the crankcase ventilator oil separator speed less
than 3,000 rpm?
4.a Yes; replace the crankcase breather. Refer to section "Removal of the Crankcase Breather Assembly" .
6. Disconnect and inspect the engine crankcase breather oil separator speed sensor electrical connector. Is
there damage or corrosion present?
6.a Yes; replace the engine crankcase breather oil separator speed sensor and the pigtail.
8. Measure the voltage between pins 1 and 3 of the engine crankcase breather oil separator speed sensor
electrical connector harness side. Is the voltage between 4.5 to 5.5 volts?
9. Measure the voltage between pin 1 of the engine crankcase breather oil separator speed sensor electrical
connector harness side and ground. Is the voltage between 4.5 to 5.5 volts?
9.b No; repair the circuit between pin 1 of the engine crankcase breather oil separator speed sensor
11. Measure the resistance between pins 2 and 3 of the engine crankcase breather oil separator speed sensor
electrical connector harness side. Is the resistance more than five ohms?
electrical connector harness side and pin 49 of the MCM 120-pin electrical connector.
5
356.1 SPN 5488/FMI 3 – GHG17

Diesel Exhaust Fluid Line Heater 5 Circuit Failed High
SPN 5488/FMI 3
Description Line Heater 5 Circuit Failed High
Monitored Parameter Line Heater 5 Circuit
Dash Lamps MIL, CEL
5. Repeat Output Component Test. The ignition must be cycled between each test. Does the fault become
active?
5.b No, clear the fault and release the vehicle.
6. Disconnect the line heater / Dosing Unit harness connector.
heater 8-pin harness connector and pin 22 of the ACM 120-pin connector.
Dosing Unit
1 Dosing Unit Low side 28
2 Dosing Unit High side 33
3 Heating Low side 22
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
1
356.2 SPN 5488/FMI 4 – GHG17

Diesel Exhaust Fluid Line Heater 5 Circuit Failed Low
SPN 5488/FMI 4
Description Line Heater 5 Circuit Failed Low
Dash Lamps MIL, CEL

2. Disconnect the line heater/Dosing Unit 8-pin connector.
5. Measure the resistance between pin 3 on the harness side of the line heater 8-pin connector and ground.
5.a If the resistance is less than 10K ohms, repair the wire between pin 3 of the line heater 8-pin connector
5.b If the resistance is greater than 10K ohms, replace the Dosing Unit.
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
2
356.3 SPN 5488/FMI 5 – GHG17

Selective Catalyst Reduction Line Heater 5 Circuit Failed Open
SPN 5488/FMI 5
Description Selective Catalyst Reduction (SCR) Line Heater 5 Circuit
Failed Open
Monitored Parameter SCR Line Heater 5 Circuit
Dash Lamps MIL, CEL
Note : Diesel Exhaust Fluid (DEF) line heaters are internal of the DEF lines. The heater electrical connectors are
located near the DEF line couplings.
Line Heater 1 Doser To Tank DEF Line (Long-Line Extension Only)

Line Heater 2 Tank To Pump DEF Line
Line Heater 3 Pump To Doser DEF Line (Long-Line Extension Only)
Line Heater 4 Pump To Doser DEF Line
Line Heater 5 Doser To Tank DEF Line
Check as follows:
3
1. Disconnect line heater 5 harness connector. Refer to Original Equipment Manufacturer (OEM) literature for
and signs of moisture in the connector or wire damage near the connector.
2.a If signs of damage are present, repair as necessary. Using DiagnosticLink , perform Output
Component Test to verify repairs.
4. Measure the voltage between pin 2 on the line heater 5 harness side connector and battery ground.
4.a If the voltage is greater than 11.5V, Go to step 5.
4.b If the voltage is less than 11.5V, repair the wire between pin 2 on the harness side of the DEF line
heater connector and pin 39 of the Aftertreatment Control Module (ACM) 120-pin connector. Using
DiagnosticLink, perform Output Component Test to verify repairs.
7.a If signs of damage are present, repair as necessary. Using DiagnosticLink, perform Output Component
Test to verify repairs.
8. Measure the resistance between pin 1 on the line heater 5 harness side connector and pin 16 of the ACM
120-pin harness side connector.
8.a If the resistance is greater than 5 ohms, repair the open wire between pin 1 on the line heater 5
harness side connector and pin 16 of the ACM 120-pin harness side connector. Refer to Original
Equipment Manufacturer (OEM) literature for schematic information.
8.b If the resistance is less than 5 ohms, replace line heater 5. Refer to section "Removal of the Diesel Exhaust Fluid
Lines" .
4
356.1 SPN 5488/FMI 3 – GHG17

Diesel Exhaust Fluid Line Heater 5 Circuit Failed High
SPN 5488/FMI 3
Description Line Heater 5 Circuit Failed High
Dash Lamps MIL, CEL
5. Repeat Output Component Test. The ignition must be cycled between each test. Does the fault become
active?
5.b No, clear the fault and release the vehicle.
6. Disconnect the line heater / Dosing Unit harness connector.
heater 8-pin harness connector and pin 22 of the ACM 120-pin connector.
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
5
356.2 SPN 5488/FMI 4 – GHG17

Diesel Exhaust Fluid Line Heater 5 Circuit Failed Low
SPN 5488/FMI 4
Description Line Heater 5 Circuit Failed Low
Dash Lamps MIL, CEL

2. Disconnect the line heater/Dosing Unit 8-pin connector.
5. Measure the resistance between pin 3 on the harness side of the line heater 8-pin connector and ground.
5.a If the resistance is less than 10K ohms, repair the wire between pin 3 of the line heater 8-pin connector
5.b If the resistance is greater than 10K ohms, replace the Dosing Unit.
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
6
356.3 SPN 5488/FMI 5 – GHG17

Selective Catalyst Reduction Line Heater 5 Circuit Failed Open
SPN 5488/FMI 5
Description Selective Catalyst Reduction (SCR) Line Heater 5 Circuit
Failed Open
Monitored Parameter SCR Line Heater 5 Circuit
Dash Lamps MIL, CEL
Note : Diesel Exhaust Fluid (DEF) line heaters are internal of the DEF lines. The heater electrical connectors are
located near the DEF line couplings.
Line Heater 1 Doser To Tank DEF Line (Long-Line Extension Only)

Line Heater 2 Tank To Pump DEF Line
Line Heater 3 Pump To Doser DEF Line (Long-Line Extension Only)
Line Heater 4 Pump To Doser DEF Line
Line Heater 5 Doser To Tank DEF Line
Check as follows:
7
1. Disconnect line heater 5 harness connector. Refer to Original Equipment Manufacturer (OEM) literature for
2.a If signs of damage are present, repair as necessary. Using DiagnosticLink , perform Output
Component Test to verify repairs.
4. Measure the voltage between pin 2 on the line heater 5 harness side connector and battery ground.
4.a If the voltage is greater than 11.5V, Go to step 5.
4.b If the voltage is less than 11.5V, repair the wire between pin 2 on the harness side of the DEF line
heater connector and pin 39 of the Aftertreatment Control Module (ACM) 120-pin connector. Using
DiagnosticLink, perform Output Component Test to verify repairs.
7.a If signs of damage are present, repair as necessary. Using DiagnosticLink, perform Output Component
Test to verify repairs.
8. Measure the resistance between pin 1 on the line heater 5 harness side connector and pin 16 of the ACM
120-pin harness side connector.
8.a If the resistance is greater than 5 ohms, repair the open wire between pin 1 on the line heater 5
harness side connector and pin 16 of the ACM 120-pin harness side connector. Refer to Original
Equipment Manufacturer (OEM) literature for schematic information.
8.b If the resistance is less than 5 ohms, replace line heater 5. Refer to section "Removal of the Diesel Exhaust Fluid
Lines" .
8
357.1 SPN 5540/FMI 2 - GHG17

Fuel Temperature Signal Not Plausible
SPN 5540 /FMI 2

detects that the fuel temperature is more than plus or minus
20°C (36°F) from the expected temperature after the engine
has been turned off for eight hours.
Monitored Parameter Fuel Temperature
Typical Enabling Conditions Key ON, Engine OFF, battery voltage greater than 11 volts,
engine rpm zero, ambient temperature less than 40°C (104
°F) ,ignition off for no less than eight hours.
Dash Lamps MIL
operating temperature.
Possible causes:
• Reprogramming or time change to the CPC
• Usage of an external or aftermarket heating unit
• Damaged or corroded sensor connectors
• Failed sensor
Check as follows:
been changed?
4. Check for multiple fault codes. Are fault codes SPN 174/FMI 0, FMI 3, FMI 4 or FMI 17 present?
5. Monitor and record the fuel temperature.
WARNING
ENGINE EXHAUST
1
WARNING
PERSONAL INJURY

8. Monitor the fuel temperature. Has the temperature increased from the previously recorded value?
10. Disconnect and inspect the fuel temperature electrical connector. Is there damage or corrosion present?
10.b No; replace the fuel temperature sensor. Verify repair.
13. Put a suitable drain pan under the vehicle below the fuel temperature sensor.
14. Remove the fuel temperature sensor.
15. Let the fuel temperature sensor sit out for 20 minutes.
16. Reconnect the fuel temperature electrical connector while the fuel temperature sensor is still removed.
18. Compare the fuel temperature sensor reading to the ambient air temperature reading. Is the fuel
temperature within 10°C (18°F) of the ambient air temperature?
18.a Yes; the fault code may be caused by an external fuel heater. Go to step 19.
18.b No; replace the fuel temperature sensor. Go to step 19.
20. Reinstall the fuel temperature sensor.
2
357.1 SPN 5540/FMI 2 - GHG17

Fuel Temperature Signal Not Plausible
SPN 5540 /FMI 2

detects that the fuel temperature is more than plus or minus
20°C (36°F) from the expected temperature after the engine
has been turned off for eight hours.
Monitored Parameter Fuel Temperature
Typical Enabling Conditions Key ON, Engine OFF, battery voltage greater than 11 volts,
engine rpm zero, ambient temperature less than 40°C (104
°F) ,ignition off for no less than eight hours.
Dash Lamps MIL
operating temperature.
Possible causes:
• Reprogramming or time change to the CPC
• Usage of an external or aftermarket heating unit
• Damaged or corroded sensor connectors
• Failed sensor
Check as follows:
been changed?
4. Check for multiple fault codes. Are fault codes SPN 174/FMI 0, FMI 3, FMI 4 or FMI 17 present?
5. Monitor and record the fuel temperature.
WARNING
ENGINE EXHAUST
3
WARNING
PERSONAL INJURY

8. Monitor the fuel temperature. Has the temperature increased from the previously recorded value?
10.b No; replace the fuel temperature sensor. Verify repair.
13. Put a suitable drain pan under the vehicle below the fuel temperature sensor.
14. Remove the fuel temperature sensor.
15. Let the fuel temperature sensor sit out for 20 minutes.
16. Reconnect the fuel temperature electrical connector while the fuel temperature sensor is still removed.
18. Compare the fuel temperature sensor reading to the ambient air temperature reading. Is the fuel
temperature within 10°C (18°F) of the ambient air temperature?
18.a Yes; the fault code may be caused by an external fuel heater. Go to step 19.
18.b No; replace the fuel temperature sensor. Go to step 19.
20. Reinstall the fuel temperature sensor.
4
358.1 SPN 5569/FMI 3 - GHG17

Soot Sensor Printed Circuit Board Temperature 1 Signal Range High
SPN 5569/FMI 3
Description Soot Sensor detects an over-temperature
Monitored Parameter Soot Sensor Temperature
Typical Enabling Conditions Soot Sensor enabled
Dash Lamps MIL
Verification Verify repairs by using DiagnosticLink Soot Sensor Panel
inspection routine.
Check as follows:
Note : When the engine starts, soot sensor will cycle through three modes: 1) Protective heating of exhaust
(1472°F) to clean soot, and 3) measurement mode for duration of key cycle.
present?
damage found?
4.b No; replace the soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of the
2V2/2HH Soot Sensor". Verify repairs.
1
358.2 SPN 5569/FMI 4 - GHG17

Soot Sensor Printed Circuit Board Temperature 1 Signal Range Low
SPN 5569/FMI 4
Description Soot Sensor printed circuit board temperature low
Monitored Parameter Soot Sensor circuit board temperature
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
2
358.1 SPN 5569/FMI 3 - GHG17

SPN 5569/FMI 3
Description Soot Sensor detects an over-temperature
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
3
358.2 SPN 5569/FMI 4 - GHG17

SPN 5569/FMI 4
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
4
359.1 SPN 5571/FMI 7 - GHG17

Pressure Limiting Valve Staying Open
The pressure limiting valve will open when rail pressure is above 1150 bar. The Motor Control Module (MCM) will
command a lower rail pressure, trying to force the pressure limiting valve closed. If the pressure limiting valve
does not close, a fault code is generated. The condition that caused the Pressure Limiting Valve (PLV) to open
must be addressed.
SPN 5571/FMI 7
Description Pressure Limiting Valve, Failed to Close
Monitored Parameter Pressure Limiting Valve
Typical Enabling Conditions RP Closed Loop Control & RPM Greater than 0
Dash Lamps MIL,CEL
Check as follows:
1.a If additional fault codes are present with SPN 5571/FMI 7, service the additional fault codes first.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
1
WARNING
PRESSURIZED FUEL
test.
3. Using DiagnosticLink Standard, monitor fuel rail pressure at idle.

3.a If the fuel rail pressure is above 900 bar, check for a damaged needle return line and a damaged line
(fuel rail to fuel injector). Repair as necessary.
3.b If rail pressure is below 900 bar, Go to step 4.
WARNING
PERSONAL INJURY
4. Increase engine speed to 1800 rpm and check the fuel rail pressure.
4.a If rail pressure is above 900 bar, check for a damaged needle return line, a damaged amplifier return
line and a damaged line (fuel rail to fuel injector). Repair as necessary.
4.b If rail pressure is below 900 bar, replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-
Filter System" .
2
359.1 SPN 5571/FMI 7 - GHG17

Pressure Limiting Valve Staying Open
The pressure limiting valve will open when rail pressure is above 1150 bar. The Motor Control Module (MCM) will
command a lower rail pressure, trying to force the pressure limiting valve closed. If the pressure limiting valve
does not close, a fault code is generated. The condition that caused the Pressure Limiting Valve (PLV) to open
must be addressed.
SPN 5571/FMI 7
Description Pressure Limiting Valve, Failed to Close
Monitored Parameter Pressure Limiting Valve
Typical Enabling Conditions RP Closed Loop Control & RPM Greater than 0
Dash Lamps MIL,CEL
Check as follows:
1.a If additional fault codes are present with SPN 5571/FMI 7, service the additional fault codes first.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3
WARNING
PRESSURIZED FUEL
test.
3. Using DiagnosticLink Standard, monitor fuel rail pressure at idle.

3.a If the fuel rail pressure is above 900 bar, check for a damaged needle return line and a damaged line
(fuel rail to fuel injector). Repair as necessary.
3.b If rail pressure is below 900 bar, Go to step 4.
WARNING
PERSONAL INJURY
4. Increase engine speed to 1800 rpm and check the fuel rail pressure.
4.a If rail pressure is above 900 bar, check for a damaged needle return line, a damaged amplifier return
line and a damaged line (fuel rail to fuel injector). Repair as necessary.
4.b If rail pressure is below 900 bar, replace the PLV. Refer to section "Removal of the Pressure Limiting Valve - Two-
Filter System" .
4
360.1 SPN 5588/FMI 9 - GHG17

SPN 5588/FMI 9
Description The Fault Code Sets when the Motor Control Module (MCM)
Monitored Parameter MCM Communication from the EGR Valve Actuator
Dash Lamps MIL, CEL
Check as follows:
1. Check for low battery voltage fault codes. Is fault code SPN 520296/FMI 3 present?
1
damaged, corroded or spread pins?
5. Inspect the EGR valve actuator electrical connector harness side. Are there any damaged, corroded or
spread pins?
corroded pins?
12. Inspect the 120-pin MCM electrical connector harness side. Are there any damaged, corroded, or spread
pins?
2
360.1 SPN 5588/FMI 9 - GHG17

SPN 5588/FMI 9
Description The Fault Code Sets when the Motor Control Module (MCM)
Monitored Parameter MCM Communication from the EGR Valve Actuator
Dash Lamps MIL, CEL
Check as follows:
1. Check for low battery voltage fault codes. Is fault code SPN 520296/FMI 3 present?
3

spread pins?
corroded pins?
12. Inspect the 120-pin MCM electrical connector harness side. Are there any damaged, corroded, or spread
pins?
4
361.1 SPN 5741/FMI 4 - GHG17

Soot Sensor Inter-Digital Electrode Short Circuit
SPN 5741 / FMI 4

Description Soot Sensor Heater High Current Flow
Dash Lamps MIL
inspection routine.
Check as follows:
2. Using DiagnosticLink, check for any communication or voltage fault codes. Are any other fault codes
present?
3. Disconnect soot sensor harness connector.
4. Inspect the soot sensor and harness connector for signs of damaged, bent, spread, corroded or unseated
damage found?
4.b No; replace soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of the
1
361.2 SPN 5741/FMI 9 - GHG17

Soot Sensor Communication Error
SPN 5741/FMI 9
Description This fault code sets when the soot sensor feedback Controller
Area Network (CAN) signal fails.
Monitored Parameter Soot Sensor CAN Communication
Dash Lamps MIL
2
Check as follows:
3. Inspect the harness and connector for signs of damage, bent, spread, corroded or unseated (pushed out)
pins. Is any damage found?
4. Inspect the soot sensor wiring between the sensor probe and the sensor control unit. Is any damage
found?
4.a Yes; Replace the soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of
the 2V2/2HH Soot Sensor". Verify repairs.
3
5. Inspect the harness and connectors between the soot sensor and the Aftertreatment Control Module (ACM)
for signs of damage, chaffing, overheating, or corrosion. Is any damage found?
damage found?
8. Measure the resistance between pin 3 of the soot sensor connector, harness side and pin 44 of the ACM
120-pin connector, harness side. Is the resistance less than 5 ohms?
8.b No; repair the wire between pin 3 on the harness side of the soot sensor connector and pin 44 of the
ACM 120-pin connector. Verify repairs.
ACM 120-pin connector.
10. Measure the resistance between pin 3 of the soot sensor connector, harness side, and battery ground. Is
10.b No; repair the shorted wire between pin 3 on the harness side of the soot sensor connector and
ground. Verify repairs.
11. Measure the resistance between pin 4 of the soot sensor connector, harness side and battery ground. Is
12. Measure the resistance between pins 44 and 61 on the ACM 120-pin connector, component side. Is the
resistance between 50 and 70 ohms?
12.a Yes; replace the soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of the
2V2/2HH Soot Sensor. Verify repairs.
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
4
361.3 SPN 5741/FMI 12 - GHG17

Soot Sensor Inter-Digital Electrode Self-Diagnostic
SPN 5741/ FMI 12

Description Soot Sensor Heater Current Flow
Monitored Parameter Soot Sensor Heater Temperature
Dash Lamps MIL
Verification Verify repairs by using DiagnosticLink® Soot Sensor Panel
inspection routine.
Check as follows:
present?
damage found?
5
361.4 SPN 5741/FMI 13 - GHG17

SPN 5741/FMI 13
Description Soot Sensor Controller Area Network (CAN) Feedback Signal
Failure
Dash Lamps MIL, CEL
Verification Soot Sensor Inspection Routine
6
Check as follows:
1. Check the Aftertreatment Control Module (ACM) software level. Is the software level e7.57.5.0 or higher?
1.b No; connect to the server and update the ACM to the latest available on the server. Verify repairs.
3. Disconnect the soot sensor harness connector.
5. Inspect soot sensor wiring between the sensor probe and the sensor control unit. Is any damage found?
2V2/2HH Soot Sensor" . Verify repairs.
7

6. Inspect the harness and connectors between soot sensor and the Aftertreatment Control Module (ACM) for
signs of damage, chaffing, overheating, or corrosion. Is any damage found?
8. Measure the voltage between pins 1 and 2 of the soot sensor harness connector, harness side. Is the
voltage reading within .5 volts of battery voltage?
9. Measure the voltage between pin 1 of the soot sensor connector harness side and ground. Is the voltage
within .5 volts of battery voltage?
9.a Yes; repair the open circuit between pin 2 of the soot sensor connector and pin 96 of the ACM 120-pin
connector.
9.b No; repair the open circuit between pin 1 of the soot sensor connector and pin 66 of the ACM 120-pin
connector.
11. Measure the resistance between pins 3 and 4 of the soot sensor connector harness side. Is the resistance

12. Measure the resistance between pin 3 of the soot sensor connector harness side and ground. Is the
12.b No; repair the short to ground between pin 3 of the soot sensor connector and pin 44 of the ACM 120-
pin connector. Verify repair.
pin connector.
damage found?
resistance between 55 to 65 ohms?
repairs.
8
361.5 SPN 5741/FMI 16 - GHG17

Soot Sensor Data Valid But Above Normal Operating Range - Moderately Severe Level
SPN 5741/ FMI 16

Description Soot Sensor data is above normal range
Monitored Parameter Soot Sensor Inter-Digital Electrode (IDE)
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
9
361.6 SPN 5741/FMI 18 - GHG17

Soot Sensor Data Valid But Below Normal Operating Range - Moderately Severe Level
SPN 5741/ FMI 18

Description Soot Sensor data is below normal range
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
10
361.1 SPN 5741/FMI 4 - GHG17

Soot Sensor Inter-Digital Electrode Short Circuit
SPN 5741 / FMI 4

Description Soot Sensor Heater High Current Flow
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
11
361.2 SPN 5741/FMI 9 - GHG17

Soot Sensor Communication Error
SPN 5741/FMI 9
Description This fault code sets when the soot sensor feedback Controller
Area Network (CAN) signal fails.
Dash Lamps MIL
12
Check as follows:
4. Inspect the soot sensor wiring between the sensor probe and the sensor control unit. Is any damage
found?
4.a Yes; Replace the soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of
the 2V2/2HH Soot Sensor". Verify repairs.
13
5. Inspect the harness and connectors between the soot sensor and the Aftertreatment Control Module (ACM)
for signs of damage, chaffing, overheating, or corrosion. Is any damage found?
damage found?
ACM 120-pin connector. Verify repairs.
ACM 120-pin connector.
10. Measure the resistance between pin 3 of the soot sensor connector, harness side, and battery ground. Is
2V2/2HH Soot Sensor. Verify repairs.
For 2-BOX, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" . Verify repairs.
14
361.3 SPN 5741/FMI 12 - GHG17

Soot Sensor Inter-Digital Electrode Self-Diagnostic
SPN 5741/ FMI 12

Description Soot Sensor Heater Current Flow
Monitored Parameter Soot Sensor Heater Temperature
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
15
361.4 SPN 5741/FMI 13 - GHG17

SPN 5741/FMI 13
Description Soot Sensor Controller Area Network (CAN) Feedback Signal
Failure
Dash Lamps MIL, CEL
Verification Soot Sensor Inspection Routine
16
Check as follows:
1. Check the Aftertreatment Control Module (ACM) software level. Is the software level e7.57.5.0 or higher?
1.b No; connect to the server and update the ACM to the latest available on the server. Verify repairs.
5. Inspect soot sensor wiring between the sensor probe and the sensor control unit. Is any damage found?
17

6. Inspect the harness and connectors between soot sensor and the Aftertreatment Control Module (ACM) for
signs of damage, chaffing, overheating, or corrosion. Is any damage found?
8. Measure the voltage between pins 1 and 2 of the soot sensor harness connector, harness side. Is the
voltage reading within .5 volts of battery voltage?
9. Measure the voltage between pin 1 of the soot sensor connector harness side and ground. Is the voltage
within .5 volts of battery voltage?
9.a Yes; repair the open circuit between pin 2 of the soot sensor connector and pin 96 of the ACM 120-pin
connector.
9.b No; repair the open circuit between pin 1 of the soot sensor connector and pin 66 of the ACM 120-pin
connector.
11. Measure the resistance between pins 3 and 4 of the soot sensor connector harness side. Is the resistance

pin connector. Verify repair.
pin connector.
damage found?
resistance between 55 to 65 ohms?
repairs.
18
361.5 SPN 5741/FMI 16 - GHG17

Soot Sensor Data Valid But Above Normal Operating Range - Moderately Severe Level
SPN 5741/ FMI 16

Description Soot Sensor data is above normal range
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
19
361.6 SPN 5741/FMI 18 - GHG17

Soot Sensor Data Valid But Below Normal Operating Range - Moderately Severe Level
SPN 5741/ FMI 18

Description Soot Sensor data is below normal range
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
20
362.1 SPN 5747/FMI 12 - GHG17

Soot Sensor Heater Fault
SPN 5747/FMI 12
Description Soot Sensor heater temperature or voltage is out of range
Monitored Parameter Soot Sensor heater temperature or voltage
Typical Enabling Conditions Soot Sensor heater enabled
Dash Lamps MIL
Verification Verify repairs by using DiagnosticLink™ Soot Sensor Panel
inspection routine.
Check as follows:
present?
damage found?
1
362.1 SPN 5747/FMI 12 - GHG17

Soot Sensor Heater Fault
SPN 5747/FMI 12
Description Soot Sensor heater temperature or voltage is out of range
Monitored Parameter Soot Sensor heater temperature or voltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
2
363.1 SPN 5765/FMI 0 - GHG17

EGR temperature alert
SPN 5765/FMI 0
Description This fault code sets when the EGR actuator temperature is
greater than 134°C (275°F)
Monitored Parameter EGR temperature
Dash Lamps MIL, CEL
Verification Engine running
Check as follows:
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
• SPN 110/FMI 0
• SPN 110/FMI 16
• SPN 110/FMI 18
4. Inspect the EGR actuator coolant supply and return metal lines. Are the coolant lines pinched or kinked?
4.a Yes; replace the EGR coolant line.
5. Check for coolant leaks at the EGR actuator. Are there any leaks present?
6. Drain the coolant. Refer to Original Equipment Manufacturer (OEM) literature for coolant draining
procedures.
7. Remove the EGR actuator coolant lines.
1
WARNING
EYE INJURY
8. Use shop air to blow through the coolant fittings on the EGR actuator. Are there any restrictions present?
8.a Yes; clean the EGR coolant passage and flush the cooling system. Refer to OEM literature for cooling
system flushing procedures. Verify repair.
9. Use shop air to blow through the EGR actuator inlet coolant line. Are there any restrictions present?
9.a Yes; clean the EGR actuator inlet coolant line and flush the cooling system. Refer to OEM literature for
cooling system flushing procedures. Verify repair.
10. Use shop air to blow through the EGR actuator outlet coolant line. Are there any restrictions present?
10.a Yes; clean the EGR actuator outlet coolant line and flush the cooling system. Refer to OEM literature
for cooling system flushing procedures. Verify repair.
2
363.1 SPN 5765/FMI 0 - GHG17

EGR temperature alert
SPN 5765/FMI 0
Description This fault code sets when the EGR actuator temperature is
Monitored Parameter EGR temperature
Dash Lamps MIL, CEL
Verification Engine running
Check as follows:
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
• SPN 110/FMI 0
• SPN 110/FMI 16
• SPN 110/FMI 18
4. Inspect the EGR actuator coolant supply and return metal lines. Are the coolant lines pinched or kinked?
4.a Yes; replace the EGR coolant line.
5. Check for coolant leaks at the EGR actuator. Are there any leaks present?
3
6. Drain the coolant. Refer to Original Equipment Manufacturer (OEM) literature for coolant draining
procedures.
7. Remove the EGR actuator coolant lines.
WARNING
EYE INJURY
8. Use shop air to blow through the coolant fittings on the EGR actuator. Are there any restrictions present?
8.a Yes; clean the EGR coolant passage and flush the cooling system. Refer to OEM literature for cooling
system flushing procedures. Verify repair.
9. Use shop air to blow through the EGR actuator inlet coolant line. Are there any restrictions present?
9.a Yes; clean the EGR actuator inlet coolant line and flush the cooling system. Refer to OEM literature for
cooling system flushing procedures. Verify repair.
10. Use shop air to blow through the EGR actuator outlet coolant line. Are there any restrictions present?
10.a Yes; clean the EGR actuator outlet coolant line and flush the cooling system. Refer to OEM literature
for cooling system flushing procedures. Verify repair.
4
364.1 SPN 5841/FMI 14 - GHG17

Diesel Exhaust Fluid Quality Low
SPN 5841/FMI 14
Description Diesel Exhaust Fluid (DEF) Quality Low
Monitored Parameter DEF Quality
Typical Enabling Conditions Closed loop DEF dosing
Typical Duration Two hours
Dash Lamps None
Check as follows:
percentage between 31 to 34%?
2.b No; clean/flush the DEF tank, then Go to step 6. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
4. Unbolt the DEF Dosing Unit from the aftertreatment. Do not disconnect DEF hoses or electrical connector.
Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" .
5. Perform a DEF Quantity Test service routine and record the amount of DEF fluid level dispensed. Is the
dispensed DEF fluid level between 108 to 132 mL?
5.a Yes; reinstall DEF Dosing Unit. Go to step 6.
5.b No; replace DEF Dosing Unit. To verify repairs, Go to step 6.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
1
WARNING
HOT EXHAUST
. After the regen has completed, Go to step 7.
8. Perform an SCR Efficiency Test to clear fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
2
364.1 SPN 5841/FMI 14 - GHG17

Diesel Exhaust Fluid Quality Low
SPN 5841/FMI 14
Description Diesel Exhaust Fluid (DEF) Quality Low
Monitored Parameter DEF Quality
Typical Enabling Conditions Closed loop DEF dosing
Typical Duration Two hours
Dash Lamps None
Check as follows:
percentage between 31 to 34%?
2.b No; clean/flush the DEF tank, then Go to step 6. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
4. Unbolt the DEF Dosing Unit from the aftertreatment. Do not disconnect DEF hoses or electrical connector.
Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" .
5. Perform a DEF Quantity Test service routine and record the amount of DEF fluid level dispensed. Is the
dispensed DEF fluid level between 108 to 132 mL?
5.a Yes; reinstall DEF Dosing Unit. Go to step 6.
5.b No; replace DEF Dosing Unit. To verify repairs, Go to step 6.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3
WARNING
HOT EXHAUST
8. Perform an SCR Efficiency Test to clear fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
4
365.1 SPN 5927/FMI 2 - GHG17

Water Pump Limp Home Mode
This fault can be caused by:
• Coolant temperature in high
• Coolant temperature out
• Intake temperature high
• Engine protection mode
1.a If fault codes SPN 110/FMI (any) or SPN 1636/FMI (any) are also present, repair those faults first.
1.b If fault codes SPN 110/FMI (any) or SPN 1636/FMI (any) are not present, Go to step 2.
2. With engine cold, compare coolant inlet and coolant outlet temperatures. Are the temperatures within 15° C
(25° F) of each other?
2.b No; check coolant sensor resistance. Refer to chart for specifications, then replace sensor which is out
of range.
3. Check for coolant loss. Is coolant loss present?
3.a Yes; repair cause of coolant loss.
4. Check thermostat operation. Is the thermostat operating properly?
4.b No; replace thermostat and verify repair.
5. Check for blockage in radiator and charge air cooler. Was a blockage found in the radiator and/or charge
air cooler?
5.a Yes; repair cause of blockage and verify repair.
6. Check fan belt condition (slippage). Is the fan belt in good condition and not slipping?
6.b No; replace fan belt and verify repair.
7. Check for proper location of fan shroud. Is the fan shroud in the proper location?
7.b No; repair fan shroud and verify repair.
8. Check for proper radiator hose condition (no collapsed hoses). Are radiator hoses in proper working
condition?
8.b No; replace hoses as needed and verify repair.
9. Check for proper viscous fan operation. Is the fan operating properly?
9.b No; repair fan as necessary and verify repair.
1
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
10. Start engine and bring to operating temperature 85°C (185°F).

11. Does engine reach operating temperature 85°C (185°F)?
11.b No, service the engine cooling system thermostat. Refer to section "Removal of the Engine Coolant Thermostat and
Seal" .
12. Shut engine OFF (key OFF, engine OFF).

13. Disconnect inlet and outlet coolant sensors.
14. Inspect inlet and outlet coolant sensors harness connectors for bent, spread or corroded pins. Is damage
found?
15. Check coolant sensor resistance, refer to chart for specifications, replace sensor which is out of range.
Coolant Sensor Resistance Chart

Temp (°C) Temp (°F) Resistance ( Resistance ( Resistance Nominal Voltage Low Voltage High
) Nominal ) Low () High Voltage (V) (V) (V)
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
16. Clear faults and verify repairs.
2
365.2 SPN 5927/FMI 7 - GHG17

SPN 5927/FMI 7
Description This Code Logs When an Error Has Been Detected on the
Speed and Flow of the Cooling System
Monitored Parameter Water Pump Speed
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

• Water Pump Speed Less Than Commanded Threshold
• Coolant Temperature In High
• Coolant Temperature Out High
• Intake Temperature High
• Engine Protection Mode
3
Check as follows:
1. Check for multiple codes. Are there any other active cooling system faults?
1.a Yes; repair cooling system faults first.
2. With engine cold, compare coolant inlet and coolant outlet temperatures. Are the temperatures within 14°C
2.b No; check coolant sensor resistance. Refer to chart for specifications; replace sensor which is out of
range.

Temp (°C) Temp (°F) Resistance Resistance Resistance Nominal Voltage Low Voltage High
Nominal Low (ohms) High (ohms) Voltage (V) (V) (V)
(ohms)
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
4
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
4. Start engine and bring to operating temperature of 85°C (185°F).

5. Does engine reach operating temperature of 85°C (185°F)?
5.b No; service the engine cooling system thermostat. Refer to section "Removal of the Engine Coolant Thermostat and
Seal" .

9. Measure the resistance between pins 1 and 2 of the water pump speed sensor harness connector (engine
harness side). Is the resistance greater than 10K ohms?
9.b No; repair the short between pins 1 and 2 of the water pump harness connector and pins 107 and 50 of
10. Measure the resistance between pin 2 of the water pump speed sensor harness connector and pin 107 of
the MCM 120-pin connector. Is the resistance less than five ohms?
10.b No; repair the wire between pin 2 of the water pump speed sensor harness connector and pin 107 of
11.b No; repair the wire between pin 1 of the water pump speed sensor harness connector and pin 50 of the
12. Connect the MCM 120-pin connector.
14. Measure the voltage between pin 3 on the harness side of the water pump speed sensor harness
connector and ground. Is the voltage less than five volts?
14.a Yes; repair the open wire between pin 3 of the water pump speed sensor harness connector and pin 82
of the Motor Control Module (MCM) 120-pin connector.
5

15.a Yes; replace the water pump.
6
365.1 SPN 5927/FMI 2 - GHG17

Water Pump Limp Home Mode
• Coolant temperature in high
• Coolant temperature out
• Intake temperature high
• Engine protection mode
1.a If fault codes SPN 110/FMI (any) or SPN 1636/FMI (any) are also present, repair those faults first.
1.b If fault codes SPN 110/FMI (any) or SPN 1636/FMI (any) are not present, Go to step 2.
2. With engine cold, compare coolant inlet and coolant outlet temperatures. Are the temperatures within 15° C
(25° F) of each other?
2.b No; check coolant sensor resistance. Refer to chart for specifications, then replace sensor which is out
of range.
3. Check for coolant loss. Is coolant loss present?
3.a Yes; repair cause of coolant loss.
4. Check thermostat operation. Is the thermostat operating properly?
4.b No; replace thermostat and verify repair.
5. Check for blockage in radiator and charge air cooler. Was a blockage found in the radiator and/or charge
air cooler?
5.a Yes; repair cause of blockage and verify repair.
6. Check fan belt condition (slippage). Is the fan belt in good condition and not slipping?
6.b No; replace fan belt and verify repair.
7. Check for proper location of fan shroud. Is the fan shroud in the proper location?
7.b No; repair fan shroud and verify repair.
8. Check for proper radiator hose condition (no collapsed hoses). Are radiator hoses in proper working
condition?
8.b No; replace hoses as needed and verify repair.
9. Check for proper viscous fan operation. Is the fan operating properly?
9.b No; repair fan as necessary and verify repair.
7
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
10. Start engine and bring to operating temperature 85°C (185°F).

11. Does engine reach operating temperature 85°C (185°F)?
11.b No, service the engine cooling system thermostat. Refer to section "Removal of the Engine Coolant Thermostat and
Seal" .
12. Shut engine OFF (key OFF, engine OFF).

13. Disconnect inlet and outlet coolant sensors.
14. Inspect inlet and outlet coolant sensors harness connectors for bent, spread or corroded pins. Is damage
found?
15. Check coolant sensor resistance, refer to chart for specifications, replace sensor which is out of range.

Temp (°C) Temp (°F) Resistance ( Resistance ( Resistance Nominal Voltage Low Voltage High
) Nominal ) Low () High Voltage (V) (V) (V)
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
16. Clear faults and verify repairs.
8
365.2 SPN 5927/FMI 7 - EuroV

SPN 5927/FMI 7
Description This Code Logs When an Error Has Been Detected on the
Speed and Flow of the Cooling System
Monitored Parameter Water Pump Speed
Dash Lamps CEL
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

• Water Pump Speed Less Than Commanded Threshold
• Coolant Temperature In High
• Coolant Temperature Out High
• Intake Temperature High
• Engine Protection Mode
9
Check as follows:
1. Check for multiple codes. Are there any other active cooling system faults?
1.a Yes; repair cooling system faults first.
2. With engine cold, compare coolant inlet and coolant outlet temperatures. Are the temperatures within 14°C
2.b No; check coolant sensor resistance. Refer to chart for specifications; replace sensor which is out of
range.

Temp (°C) Temp (°F) Resistance Resistance Resistance Nominal Voltage Low Voltage High
Nominal Low (ohms) High (ohms) Voltage (V) (V) (V)
(ohms)
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
10
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
4. Start engine and bring to operating temperature of 85°C (185°F).

5. Does engine reach operating temperature of 85°C (185°F)?
5.b No; service the engine cooling system thermostat. Refer to section "Removal of the Engine Coolant Thermostat and
Seal" .

9. Measure the resistance between pins 1 and 2 of the water pump speed sensor harness connector (engine
harness side). Is the resistance greater than 10K ohms?
9.b No; repair the short between pins 1 and 2 of the water pump harness connector and pins 107 and 50 of
10.b No; repair the wire between pin 2 of the water pump speed sensor harness connector and pin 107 of
12. Connect the MCM 120-pin connector.
14. Measure the voltage between pin 3 on the harness side of the water pump speed sensor harness
connector and ground. Is the voltage less than five volts?
14.a Yes; repair the open wire between pin 3 of the water pump speed sensor harness connector and pin 82
of the Motor Control Module (MCM) 120-pin connector.
11

15.a Yes; replace the water pump.
12
366.1 SPN 7384/FMI 3 - GHG17

Injector Cylinder #1 Needle Control Valve, Abnormal Operation (MAX) Cold
SPN 7384/FMI 3
Description This code will set when the Needle solenoid current response
time does not meet requirement.
Monitored Parameter Injector Cylinder #1 Needle Control Valve Current
This mode cannot be seen through DiagnosticLink. This mode
is activated from a calculated value that includes a table value
(Charge Air Cooler Out vs. Coolant temperatures). Verification
will ensure all conditions are met.
Typical Duration 5 sec
Dash Lamps MIL, CEL
Engine Reaction 25% Derate, DPF Inhibit Regeneration
Verification Let the engine cold soak to room temperature. Start engine
and warm up to operating temperature (or 65°C (149°F))
Check as follows:
• SPN 168/FMI any
1
• SPN 723/FMI any

1.a Yes, repair fault with the highest priority listed above. Verify repairs.
connector seal for damage (signs of water or oil intrusion). Was water or oil intrusion, bent or spread pins
found?
Note : DO NOT touch the metal ohmmeter leads with your hands when taking measurements.

2
7.a Yes; replace the front fuel injector harness.

of wire damage. Were signs of damage are found?
3

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


4
366.2 SPN 7384/FMI 4 - GHG17

Injector Cylinder #1 Needle Control Valve, Abnormal Operation (MIN) Cold
SPN 7384/FMI 4
Engine is running in cold mode.
Dash Lamps MIL, CEL
Check as follows:
1. Follow troubleshooting procedure for SPN 7384/FMI 3. Refer to section "SPN 7384/FMI 3 - GHG17" .
5
366.1 SPN 7384/FMI 3 - GHG17

SPN 7384/FMI 3
Dash Lamps MIL, CEL
Check as follows:
6

• SPN 168/FMI any
• SPN 723/FMI any
found?

7

of wire damage. Were signs of damage are found?
8

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


9
366.2 SPN 7384/FMI 4 - GHG17

SPN 7384/FMI 4
Dash Lamps MIL, CEL
Check as follows:
10
367.1 SPN 7385/FMI 3 - GHG17

SPN 7385/FMI 3
Dash Lamps MIL, CEL
Check as follows:
1. Are any of the following faults present?
1
• SPN 168/FMI any

• SPN 723/FMI any
found?

2

of wire damage. Were signs of damage found?
3

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


12.b No; Refer to section "Removal of the Motor Control Module" .
4
367.2 SPN 7385/FMI 4 - GHG17

SPN 7385/FMI 4
Dash Lamps MIL, CEL
Check as follows:
5
367.1 SPN 7385/FMI 3 - GHG17

SPN 7385/FMI 3
Dash Lamps MIL, CEL
Check as follows:
6

• SPN 168/FMI any
• SPN 723/FMI any
found?

7

8

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


9
367.2 SPN 7385/FMI 4 - GHG17

SPN 7385/FMI 4
Dash Lamps MIL, CEL
Check as follows:
10
368.1 SPN 7386/FMI 3 - GHG17

SPN 7386/FMI 3
Dash Lamps MIL, CEL
Check as follows:
1
• SPN 168/FMI any

• SPN 723/FMI any
found?

2

3

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


4
368.2 SPN 7386/FMI 4 - GHG17

SPN 7386/FMI 4
Dash Lamps MIL, CEL
Check as follows:
5
368.1 SPN 7386/FMI 3 - GHG17

SPN 7386/FMI 3
Dash Lamps MIL, CEL
Check as follows:
6

• SPN 168/FMI any
• SPN 723/FMI any
found?

7

8

1 25 1 and ground
2 26 2 and ground
3 22 3 and ground
4 24 4 and ground


9
368.2 SPN 7386/FMI 4 - GHG17

SPN 7386/FMI 4
Dash Lamps MIL, CEL
Check as follows:
10
369.1 SPN 7387/FMI 3 - GHG17

SPN 7387/FMI 3
Dash Lamps MIL, CEL
Check as follows:
1

• SPN 168/FMI any
• SPN 723/FMI any
found?
Injector #4 Needle 1.3 - 2.5* greater than 100k* greater than100k* greater than100k*

6. Remove the rear fuel injector harness from the engine.
2
Injector #4 Needle 2.0 or less* greater than 100k* greater than100k* greater than100k*
7.a Yes; replace the rear fuel injector harness.

9.a Yes; repair as necessary. Verify repairs
3

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground


4
369.2 SPN 7387/FMI 4 - GHG17

SPN 7387/FMI 4
Dash Lamps MIL, CEL
Check as follows:
5
370.1 SPN 7388/FMI 3 - GHG17

SPN 7388/FMI 3
Dash Lamps MIL, CEL
Check as follows:
1
• SPN 168/FMI any

• SPN 723/FMI any
found?

2

3

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground


4
370.2 SPN 7388/FMI 4 - GHG17

SPN 7388/FMI 4
Dash Lamps MIL, CEL
Check as follows:
5
370.1 SPN 7388/FMI 3 - GHG17

SPN 7388/FMI 3
Dash Lamps MIL, CEL
Check as follows:
6

• SPN 168/FMI any
• SPN 723/FMI any
found?

7

8

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground


9
370.2 SPN 7388/FMI 4 - GHG17

SPN 7388/FMI 4
Dash Lamps MIL, CEL
Check as follows:
10
371.1 SPN 7389/FMI 3 - GHG17

SPN 7389/FMI 3
Dash Lamps MIL, CEL
Check as follows:
1
• SPN 168/FMI any

• SPN 723/FMI any
found?

2

3

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground


4
371.2 SPN 7389/FMI 4 - GHG17

SPN 7389/FMI 4
Dash Lamps MIL, CEL
Engine Reaction 25% Derate, DPF Inhibit Regeneration, EGR Valve Shut, Limit
DEF Dosing
Check as follows:
1. Follow troubleshooting procedure for SPN 7389/FMI 3. Refer to section "SPN 7389/FMI 3 - GHG17 " .
5
371.1 SPN 7389/FMI 3 - GHG17

SPN 7389/FMI 3
Dash Lamps MIL, CEL
Check as follows:
6

• SPN 168/FMI any
• SPN 723/FMI any
found?

7

8

1 19 1 and ground
2 16 2 and ground
3 20 3 and ground
4 18 4 and ground


9
371.2 SPN 7389/FMI 4 - GHG17

SPN 7389/FMI 4
Dash Lamps MIL, CEL
Engine Reaction 25% Derate, DPF Inhibit Regeneration, EGR Valve Shut, Limit
DEF Dosing
Check as follows:
1. Follow troubleshooting procedure for SPN 7389/FMI 3. Refer to section "SPN 7389/FMI 3 - GHG17 " .
10
SPN 520199 (IPPC) (GHG17)
372.1 SPN 520199/FMI 19 - GHG17

Gyroscope Network Data Error
SPN 520199/FMI 19
Description This Code Sets When the Integrated Predictive Powertrain
Control (IPPC) Module Receives Invalid Network Data from
the Gyroscope
Monitored Parameter Gyroscope
Execution Frequency 2 Seconds
Dash Lamps None
Check as follows:
1. Replace the Integrated Predictive Powertrain Control (IPPC) module. Refer to OEM literature. Verify repair.
1
373.1 SPN 520200/FMI 6 - GHG17

Powertrain Controller Area Network Common Circuit Error
SPN 520200/FMI 6
Description This Fault Code Sets when the Integrated Predictive
Powertrain Control (IPPC) Module Detects that the Powertrain
Controller Area Network (PT-CAN) Circuit is Shorted to Power
or Ground
Monitored Parameter PT-CAN
Dash Lamps None
1
Check as follows:
2. Remove and inspect the IPPC electrical connector. Are there any spread or damaged pins?
2.a Yes; repair the pins as necessary. Verify repair.
3. Measure the resistance between pins 13 and 15 of the IPPC electrical connector. Is the resistance between
55 and 65 ohms?
3.a Yes; refer to OEM literature and replace the IPPC module.
3.b No; repair the PT CAN circuit. Verify repair.
2
SPN 520203 (CPC3) (GHG17)
375.1 SPN 520203/FMI 3 - GHG17

Accelerator Pedal Sensor 1 Supply Short to Battery
Check as follows:
damage found?

Function CPC3 Cavity Pedal Connector Pin Comments Pedal
Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
5.5 volts?
4.a Yes; repair the short to battery power between pin C of the accelerator pedal sensor harness connector
4.b No; replace the accelerator pedal.
1
375.2 SPN 520203/FMI 4 - GHG17

Accelerator Pedal Sensor 1 Supply Short to Ground
Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
4.a Yes; replace the accelerator pedal.
4.b No; repair the circuit between pin C of the accelerator pedal sensor harness connector and pin 15 of
2
374.1 SPN 520203/FMI 6 - GHG17

Measurement-Controller Area Network Common Circuit Error
SPN 520203/FMI 6
Powertrain Control (IPPC) Module Detects that the
Measurement Controller Area Network (CAN) Circuit is
Shorted to Power or Ground. Note: The Measurement CAN is
Used for Engineering Purposes
Monitored Parameter Measurement CAN
Dash Lamps None
Check as follows:
1. Remove and inspect the 15 pin Integrated Predictive Powertrain Control (IPPC) module electrical
connector. Are there spread or damaged pins?
2. Are wires present in cavities 10, 11, and 12?
2.a Yes; remove the circuits from the connector cavities. Verify repair.
1
2.b No; replace the IPPC module. Refer to OEM literature. Verify repair.
2
374.1 SPN 520203/FMI 6 - GHG17

Measurement-Controller Area Network Common Circuit Error
SPN 520203/FMI 6
Powertrain Control (IPPC) Module Detects that the
Measurement Controller Area Network (CAN) Circuit is
Shorted to Power or Ground. Note: The Measurement CAN is
Used for Engineering Purposes
Monitored Parameter Measurement CAN
Dash Lamps None
Check as follows:
1. Remove and inspect the 15 pin Integrated Predictive Powertrain Control (IPPC) module electrical
connector. Are there spread or damaged pins?
3

2. Are wires present in cavities 10, 11, and 12?
2.a Yes; remove the circuits from the connector cavities. Verify repair.
2.b No; replace the IPPC module. Refer to OEM literature. Verify repair.
4
376.1 SPN 520204/FMI 5 - GHG17

SPN 520204/FMI 5
Description Common Powertrain Controller (CPC3) Ground Circuit Open,
Connector 5, Pin 6
Monitored Parameter CPC3 Battery Ground
Dash Lamps CEL
This fault indicates an open circuit to pin 6 of the CPC3 connector #5.
1. Connect DiagnosticLink® 8.08 or higher.
5. Inspect the harness connector for bent, spread or corroded pins. Is there any pin damage?
6. Measure the resistance between pin 6 of the CPC3 connector #5 and ground. Is the resistance less than
three ohms?
6.a Yes; replace the CPC3 connector.
6.b No; restore ground to pin 6 of the CPC3 connector #5. Refer to EZWiring/Vehicle Sub-
System/GROUND) section for detailed schematic information.
1
376.1 SPN 520204/FMI 5 - GHG17

SPN 520204/FMI 5
Connector 5, Pin 6
Dash Lamps CEL
three ohms?
2
SPN 520204 (CPC3) (GHG17)
376.1 SPN 520204/FMI 5 - GHG17

SPN 520204/FMI 5
Connector 5, Pin 6
Dash Lamps CEL
three ohms?
3
377.1 SPN 520205/FMI 3 - GHG17

Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
4. Measure the voltage between pin D of the AP harness connector and ground. Is the voltage greater than
5.5 volts?
4.a Yes; repair the short to battery power between pin D of the accelerator pedal sensor harness connector
1
377.2 SPN 520205/FMI 4 - GHG17

damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
4.b No; repair the circuit between pin D of the accelerator pedal sensor harness connector and pin 21 of
2
SPN 520205 (CPC3) (GHG17)
377.1 SPN 520205/FMI 3 - GHG17

Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
5.5 volts?
3
377.2 SPN 520205/FMI 4 - GHG17

damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
4
378.1 SPN 520208/FMI 19 - GHG17

PID General Checksum Error
SPN 520208/FMI 19
Description PID general checksum error
Monitored Parameter Internal Integrated Predictive Powertrain Control (IPPC)
Software
Dash Lamps None
Verification Ignition on
Check as follows:
2. Reprogram the IPPC. Does the fault return?
2.a Yes; replace the IPPC module. Refer to the Original Equipment Manufacturer (OEM) literature.
1
378.1 SPN 520208/FMI 19 - GHG17

PID General Checksum Error
SPN 520208/FMI 19
Description PID general checksum error
Software
Dash Lamps None
Verification Ignition on
Check as follows:
2. Reprogram the IPPC. Does the fault return?
2.a Yes; replace the IPPC module. Refer to the Original Equipment Manufacturer (OEM) literature.
2
379.1 SPN 520210/FMI 19 - GHG17

Check Map Failed
SPN 520210/FMI 19
Description This Fault Code Sets When The Internal Integrated Predictive
Powertrain Control (IPPC) Module Is Unable To Read The
Map Software
Software
Dash Lamps None
Check as follows:
1
380.1 SPN 520211/FMI 2 - GHG17

SPN 520211/FMI 2
Description This Fault Code Sets When the Integrated Predictive
Powertrain Control (IPPC) Module Receives Erratic, Incorrect,
or Intermittent Data From the Common Powertrain Control
(CPC) Module During Initial Activation
Monitored Parameters PT-CAN
Execution Frequency Two Seconds
Dash Lamps None
Check as follows:
1. Check other modules for fault codes. Are there Powertrain Controller Area Network (PT- CAN)
communication fault codes present in any other modules?
1.a Yes; repair the powertrain PT-CAN communication faults first.
2. Use DiagnosticLink to reprogram the CPC using the latest server information.
4. Close DiagnosticLink and disconnect the PC to vehicle interface/communication device from the 9-pin
connector.
1
5. Cycle the ignition in the following sequence:

• Ignition OFF for 60 seconds
• Ignition ON for 60 seconds
6. Reconnect the PC to vehicle interface/communication device to the 9-pin connector and open
DiagnosticLink.
7. Turn the ignition ON (key ON, engine OFF) and wait 10 seconds.
8.a Yes; replace the IPPC module. Refer to OEM literature. Verify repair.
2
380.1 SPN 520211/FMI 2 - GHG17

SPN 520211/FMI 2
Description This Fault Code Sets When the Integrated Predictive
Powertrain Control (IPPC) Module Receives Erratic, Incorrect,
or Intermittent Data From the Common Powertrain Control
(CPC) Module During Initial Activation
Monitored Parameters PT-CAN
Execution Frequency Two Seconds
Dash Lamps None
Check as follows:
1. Check other modules for fault codes. Are there Powertrain Controller Area Network (PT- CAN)
communication fault codes present in any other modules?
1.a Yes; repair the powertrain PT-CAN communication faults first.
2. Use DiagnosticLink to reprogram the CPC using the latest server information.
3

4. Close DiagnosticLink and disconnect the PC to vehicle interface/communication device from the 9-pin
connector.
5. Cycle the ignition in the following sequence:
6. Reconnect the PC to vehicle interface/communication device to the 9-pin connector and open
DiagnosticLink.
7. Turn the ignition ON (key ON, engine OFF) and wait 10 seconds.
8.a Yes; replace the IPPC module. Refer to OEM literature. Verify repair.
4
381.1 SPN 520212/FMI 11 - GHG17

SW Watchdog Error
SPN 520212/FMI 11
Description This Fault Code Sets When There is an Internal Error with the
Integrated Predictive Powertrain Control (IPPC) Software
Monitored Parameter IPPC Software
Dash Lamps None
1
381.1 SPN 520212/FMI 11 - GHG17

SW Watchdog Error
SPN 520212/FMI 11
Integrated Predictive Powertrain Control (IPPC) Software
Monitored Parameter IPPC Software
Dash Lamps None
2
382.1 SPN 520213/FMI 11 - GHG17

Hardware Watchdog Error
SPN 520213/FMI 11
Integrated Predictive Powertrain Control (IPPC) Hardware
Monitored Parameter IPPC Hardware
Dash Lamps None
1
383.1 SPN 520215/FMI 4 - GHG17

Global Positioning System Antenna Main Line Short To Battery Plus
SPN 520215/FMI 4
Powertrain Control (IPPC) Module Detects that the Global
Positioning System (GPS) Antenna Circuit is Shorted to
Power
Monitored Parameters GPS Antenna
Dash Lamps None
Check as follows:
Note : When the GPS antenna wire is disconnected, fault code 520215/FMI 5 will set. This fault code can be
erased using DiagnosticLink after the GPS antenna has been reinstalled.
3. Disconnect the GPS antenna from the Integrated Predictive Powertrain Control (IPPC) module.
1

5.a Yes; replace the IPPC module. Refer to the Original Equipment Manufacturer (OEM) service literature.
7. Reconnect the GPS antenna harness back to the IPPC module.
8. Disconnect the GPS antenna harness from the GPS antenna pigtail.
10.a Yes; replace the GPS antenna harness. Refer to OEM service literature.
10.b No; replace the GPS antenna. Refer to OEM service literature.
2
383.2 SPN 520215/FMI 5 - GHG17

Global Positioning System Antenna Main Line Open
SPN 520215/FMI 5
Powertrain Control (IPPC) Module Detects that there is an
Open Circuit in the Global Positioning System (GPS) Antenna
Circuit
Monitored Parameters GPS Antenna Circuit
Dash Lamps None
Check as follows:
2. Inspect the GPS antenna harness connector at the IPPC module. Is the GPS antenna harness connector
properly connected to the IPPC connector?
2.b No; repair as necessary. Verify repair.
3. Inspect the GPS antenna harness connector at the GPS antenna pigtail. Is the GPS antenna harness
connector properly connected to the GPS antenna pigtail connector?
3

4. Remove the GPS antenna from the vehicle.
5. Connect the GPS antenna pigtail into the IPPC GPS antenna port.
7.a Yes; replace the GPS antenna. Refer to Original Equipment Manufacturer (OEM) service literature.
7.b No; replace the GPS antenna harness. Refer to OEM service literature.
4
383.3 SPN 520215/FMI 6 - GHG17

Global Positioning System Antenna Main Line Short To Ground
SPN 520215/FMI 6
Ground
Dash Lamps None
Check as follows:
Note : When the GPS antenna wire is disconnected, fault code SPN 520215/FMI 5 will set. This fault code can be
5

5.a Yes; replace the IPPC module. Refer to Original Equipment Manufacturer (OEM) service literature.
9.a Yes; replace the GPS antenna harness. Refer to the OEM service literature.
9.b No; replace the GPS antenna. Refer to the OEM service literature.
6
383.1 SPN 520215/FMI 4 - GHG17

Global Positioning System Antenna Main Line Short To Battery Plus
SPN 520215/FMI 4
Power
Monitored Parameters GPS Antenna
Dash Lamps None
Check as follows:
Note : When the GPS antenna wire is disconnected, fault code 520215/FMI 5 will set. This fault code can be
7
5.a Yes; replace the IPPC module. Refer to the Original Equipment Manufacturer (OEM) service literature.
7. Reconnect the GPS antenna harness back to the IPPC module.
10.a Yes; replace the GPS antenna harness. Refer to OEM service literature.
10.b No; replace the GPS antenna. Refer to OEM service literature.
8
383.2 SPN 520215/FMI 5 - GHG17

Global Positioning System Antenna Main Line Open
SPN 520215/FMI 5
Open Circuit in the Global Positioning System (GPS) Antenna
Circuit
Dash Lamps None
Check as follows:
2. Inspect the GPS antenna harness connector at the IPPC module. Is the GPS antenna harness connector
properly connected to the IPPC connector?
3. Inspect the GPS antenna harness connector at the GPS antenna pigtail. Is the GPS antenna harness
connector properly connected to the GPS antenna pigtail connector?
9

4. Remove the GPS antenna from the vehicle.
5. Connect the GPS antenna pigtail into the IPPC GPS antenna port.
7.a Yes; replace the GPS antenna. Refer to Original Equipment Manufacturer (OEM) service literature.
7.b No; replace the GPS antenna harness. Refer to OEM service literature.
10
383.3 SPN 520215/FMI 6 - GHG17

Global Positioning System Antenna Main Line Short To Ground
SPN 520215/FMI 6
Ground
Dash Lamps None
Check as follows:
Note : When the GPS antenna wire is disconnected, fault code SPN 520215/FMI 5 will set. This fault code can be
11

5.a Yes; replace the IPPC module. Refer to Original Equipment Manufacturer (OEM) service literature.
9.a Yes; replace the GPS antenna harness. Refer to the OEM service literature.
9.b No; replace the GPS antenna. Refer to the OEM service literature.
12
384.1 SPN 520217/FMI 11 - GHG17

Application Error
SPN 520217/FMI 11
Description This Fault Code Sets when There is an Internal Application
Error in the Integrated Predictive Powertrain Control (IPPC)
Module Software
Monitored Parameters Internal IPPC Application
Dash Lamps None
Check as follows:
1
384.1 SPN 520217/FMI 11 - GHG17

Application Error
SPN 520217/FMI 11
Description This Fault Code Sets when There is an Internal Application
Error in the Integrated Predictive Powertrain Control (IPPC)
Module Software
Monitored Parameters Internal IPPC Application
Dash Lamps None
Check as follows:
2
385.1 SPN 520219/FMI 13 - GHG17

Driving Mode in the Common Powertrain Controller and Integrated Predictive Powertrain Control Not Plausible
SPN 520219/FMI 13
Description This Fault Code Sets when the Driving/Transmission Mode in
the Integrated Predictive Powertrain Control (IPPC) Module
Does Not Match the Driving/Transmission Mode in the
Common Powertrain Control (CPC) Module
Monitored Parameter Transmission Mode
Typical Enabling Conditions Cruise Control Enabled
Dash Lamps None
Verification Road Test With Cruise Control Enabled
Note : When a new IPPC module is installed, this fault code will be active until the parameter is set correctly in the
CPC.
2. Refer to the Application and Installation (A&I) manual and verify that the parameters are set correctly in the
Common Powertrain Controller (CPC), refer to “DDC-SVC-MAN-0127”. Are the parameters set correctly?
2.a Yes; refer to Original Equipment Manufacturer (OEM) literature and replace the IPPC module. Verify
repair.
2.b No; change the CPC parameters as necessary and road test the vehicle.
1
SPN 520228 (CPC3) (GHG17)
386.1 SPN 520228/FMI 3 - GHG17

Accelerator Pedal Sensor 1 Supply Pin 2/15 - Short to Battery
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
5.5 volts?
4.a Yes; repair the short to battery power between pin C of the accelerator pedal sensor harness connector
1
386.2 SPN 520228/FMI 4 - GHG17

Accelerator Pedal Sensor 1 Supply Pin 2-20 Short to Ground
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
4.b No; repair the circuit between pin C of the accelerator pedal sensor harness connector and pin 15 of
2
388.1 SPN 520229/FMI 3 - GHG17

Accelerator Pedal Sensor 2 Supply Pin 2-21 Short to Battery
Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
5.5 volts?
1
388.2 SPN 520229/FMI 4 - GHG17

Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
2
SPN 520229 (CPC3) (GHG17)
388.1 SPN 520229/FMI 3 - GHG17

Accelerator Pedal Sensor 2 Supply Pin 2-21 Short to Battery
Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
5.5 volts?
3
388.2 SPN 520229/FMI 4 - GHG17

Check as follows:
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
APS2 2/4 F SENSOR 2
and 5.5 volts?
4
387.1 SPN 520229/FMI 3 - GHG17

Ignition Status Not Plausible
SPN 520229/FMI 3
Description This Fault Code Sets when the Ignition Power to the
Integrated Predictive Powertrain Control (IPPC) Module Does
Not Match the Ignition Status in the Common Powertrain
Controller (CPC)
Monitored Parameter Ignition Power
Dash Lamps None
1
Check as follows:
1. Disconnect the Integrated Predictive Powertrain Control (IPPC) electrical connector.
3. Measure the voltage between pin 2 of the IPPC 15-pin connector, harness side, and ground. Is the voltage
between 10.5 volts and 12.5 volts?
3.a Yes; replace the IPPC module. Refer to Original Equipment Manufacturer (OEM) literature. Verify
repair.
3.b No; repair the ignition power circuit. Refer to the OEM literature for the IPPC wiring diagrams.
2
389.1 SPN 520230/FMI 5 - GHG17

Powertrain - Controller Area Network Open
SPN 520230/FMI 5
Open in the Powertrain Controller Area Network (CAN) Circuit
Monitored Parameter PT CAN
Dash Lamps None
1
Front Looking into the Pins on the Harness
2
3
Check as follows:
4
3. Check for fault codes in the other modules. Are there any powertrain CAN fault codes also present in the
other modules?
3.a Yes; diagnose the other fault codes first. Refer to section "SPN 625/FMI 9 – GHG17" .
5. Disconnect and inspect the IPPC 15-pin connector. Are there any spread or damaged pins?
6. Measure the resistance between pin 13 and pin 15 of the IPPC electrical connector, harness side. Is the
6.a Yes; refer to Original Equipment Manufacturer (OEM) literature and replace the IPPC module.
6.b No; repair the Powertrain CAN circuit. Verify repair.
5
389.1 SPN 520230/FMI 5 - GHG17

Powertrain - Controller Area Network Open
SPN 520230/FMI 5
Open in the Powertrain Controller Area Network (CAN) Circuit
Monitored Parameter PT CAN
Dash Lamps None
6
Front Looking into the Pins on the Harness
7
8
Check as follows:
9
3. Check for fault codes in the other modules. Are there any powertrain CAN fault codes also present in the
other modules?
3.a Yes; diagnose the other fault codes first. Refer to section "SPN 625/FMI 9 – GHG17" .
5. Disconnect and inspect the IPPC 15-pin connector. Are there any spread or damaged pins?
6. Measure the resistance between pin 13 and pin 15 of the IPPC electrical connector, harness side. Is the
6.a Yes; refer to Original Equipment Manufacturer (OEM) literature and replace the IPPC module.
6.b No; repair the Powertrain CAN circuit. Verify repair.
10
390.1 SPN 520232/FMI 9 - GHG17

NOx Mass Signal Not Available via Controller Area Network
1. Has the Aftertreatment Control Module (ACM)/Motor Control Module (MCM)/Common Powertrain Controller
(CPC) been recently reprogrammed?
1.a Yes; clear fault codes if they do not become active, release vehicle.
4.a Yes; follow entire SPN 625/FMI 9 procedure for further PT Controller Area Network (CAN)
troubleshooting. Refer to section "SPN 625/FMI 9 – GHG17" .
1
SPN 520232 (ACM) (GHG17)
390.1 SPN 520232/FMI 9 - GHG17

NOx Mass Signal Not Available via Controller Area Network
1. Has the Aftertreatment Control Module (ACM)/Motor Control Module (MCM)/Common Powertrain Controller
(CPC) been recently reprogrammed?
1.a Yes; clear fault codes if they do not become active, release vehicle.
4.a Yes; follow entire SPN 625/FMI 9 procedure for further PT Controller Area Network (CAN)
troubleshooting. Refer to section "SPN 625/FMI 9 – GHG17" .
2
391.1 SPN 520253/FMI 14 - GHG17

Software Reset Detected Due to an Error in Engine Speed Plausibility
This fault may be caused by an external fuel source or torque out-of-bounds. Check injectors, alternative fuel
sources or add-on devices that may be requesting torque modifications.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2. Using DiagnosticLink .
3. Check the ISB Values. Refer to section "Idle Speed Balance Test" . Are there any cylinders above 70% or below -
70%?
3.a Yes; Follow repair procedures and Refer to section "Idle Speed Balance Test" and verify repairs. Refer to section
"Verify Repairs" .
3.b If any value is less than +70, the fault may be intermittent. Obtain information from customer on driving
habits, recent repairs, number of occurrences when fault code set, or situations when the code
occurred. Try to retest engine within these parameters. If no problem found, Go to step 4.
4. Clear faults and reevaluate the vehicle. Does the fault return?
4.a Yes; Reprogram Motor Control Module (MCM) with the latest software release.
1
391.2 SPN 520253/FMI 31 - GHG17

Software Reset Due to Internal Monitoring. Reprogram MCM with the latest software release.
2
SPN 520253 (MCM) (GHG17)
391.1 SPN 520253/FMI 14 - GHG17

Software Reset Detected Due to an Error in Engine Speed Plausibility
This fault may be caused by an external fuel source or torque out-of-bounds. Check injectors, alternative fuel
sources or add-on devices that may be requesting torque modifications.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
2. Using DiagnosticLink .
3. Check the ISB Values. Refer to section "Idle Speed Balance Test" . Are there any cylinders above 70% or below -
70%?
3.a Yes; Follow repair procedures and Refer to section "Idle Speed Balance Test" and verify repairs. Refer to section
"Verify Repairs" .
3.b If any value is less than +70, the fault may be intermittent. Obtain information from customer on driving
habits, recent repairs, number of occurrences when fault code set, or situations when the code
occurred. Try to retest engine within these parameters. If no problem found, Go to step 4.
4. Clear faults and reevaluate the vehicle. Does the fault return?
4.a Yes; Reprogram Motor Control Module (MCM) with the latest software release.
3
391.2 SPN 520253/FMI 31 - GHG17

Software Reset Due to Internal Monitoring. Reprogram MCM with the latest software release.
4
392.1 SPN 520261/FMI 31 – GHG17

Speed Limitation Fault
SPN 520261/FMI 31
Description Speed Limitation Fault Due to Powertrain Monitoring Control
Typical Duration Zero Seconds
Dash Lamps None
Engine Reaction Engine idle speed limited to 950 rpm
Verification Engine at idle, raise the engine speed above 950 rpm
Check as follows:
2. Is communication to the Motor Control Module (MCM) possible?
2.a Yes; reprogram the MCM with the latest software release. Go to step 3.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3. Start the engine and raise the idle speed above 950 rpm . Is SPN 520261/FMI 31 active?
3.b No; testing is complete . Release the vehicle.
1
SPN 520261 (MCM) (GHG17)
392.1 SPN 520261/FMI 31 – GHG17

Speed Limitation Fault
SPN 520261/FMI 31
Description Speed Limitation Fault Due to Powertrain Monitoring Control
Dash Lamps None
Engine Reaction Engine idle speed limited to 950 rpm
Verification Engine at idle, raise the engine speed above 950 rpm
Check as follows:
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
3. Start the engine and raise the idle speed above 950 rpm . Is SPN 520261/FMI 31 active?
3.b No; testing is complete . Release the vehicle.
2
393.1 SPN 520268/FMI 16 - GHG17

SPN 520268/FMI 16
Description Fuel Rail Pressure Low
Typical Enabling Conditions Closed Loop & Actual Rail pressure 200 bar (2900 psi) Lower
Than Desired Rail Pressure
Dash Lamps MIL
Complete the troubleshooting for SPN 157/FMI 16. Refer to section "SPN 157/FMI 16 - GHG17" Refer to section
"SPN 157/FMI 16 - GHG17" .
1
393.2 SPN 520268/FMI 18 - GHG17

SPN 520268/FMI 18
Typical Enabling Conditions Closed Loop & Actual Rail Pressure 200 Bar (2900 psi)
Higher than Desired Rail Pressure
Dash Lamps MIL
Complete the troubleshooting for SPN 157/FMI 18. Refer to section "SPN 157/FMI 18 - GHG17" Refer to section
"SPN 157/FMI 18 - GHG17" .
2
393.1 SPN 520268/FMI 16 - GHG17

SPN 520268/FMI 16
Typical Enabling Conditions Torque Within 20% of the Torque and Within 375 rpm of Initial
157/16 Fault
Monitor Sequence This Monitor Sets Simultaneously with 157/16, and Remains
Active Until Monitor Passes In Similar Operating Conditions to
the Initial 157/16 Fault
Dash Lamps MIL
Verification Use Freeze-Frame Data to Determine the Speed and Load
Conditions when the Original 157/16 Code Set. Road Test
Vehicle and Operate in Similar Speed and Load Conditions.
Verify that 157/16 and 520268/16 Codes are No Longer
Active
Complete the troubleshooting for SPN 157/FMI 16. .
3
393.2 SPN 520268/FMI 18 - GHG17

SPN 520268/FMI 18
157/18 Fault
Dash Lamps MIL
Active
4
SPN 520268 (MCM) (GHG17)
393.1 SPN 520268/FMI 16 - GHG17

SPN 520268/FMI 16
157/16 Fault
Dash Lamps MIL
Active
5
393.2 SPN 520268/FMI 18 - GHG17

SPN 520268/FMI 18
157/18 Fault
Dash Lamps MIL
Active
6
394.1 SPN 520280/FMI 7 - GHG17

Mismatch in Jake Brake Request Controller Area Network Matrix Between Motor Control Module and Common
Powertrain Controller
Reprogram Motor Control Module (MCM) and Common Powertrain Controller (CPC) with the latest software
release.
1
SPN 520280 (MCM) (GHG17)
394.1 SPN 520280/FMI 7 - GHG17

Mismatch in Jake Brake Request Controller Area Network Matrix Between Motor Control Module and Common
Powertrain Controller
release.
2
395.1 SPN 520281/FMI 7 – GHG17

Mismatch in Controller Area Network matrix between MCM and CPC. Reprogram MCM and CPC with the latest
software release.
1
SPN 520281 (MCM) (GHG17)
395.1 SPN 520281/FMI 7 – GHG17

Mismatch in Controller Area Network matrix between MCM and CPC. Reprogram MCM and CPC with the latest
software release.
2
396.1 SPN 520282/FMI 7 - GHG17

Mismatch in Jake Brake® Solenoid Request Controller Area Network Matrix between Motor Control Module and
Common Powertrain Controller
release.
1
SPN 520282 (MCM) (GHG17)
396.1 SPN 520282/FMI 7 - GHG17

Mismatch in Jake Brake® Solenoid Request Controller Area Network Matrix between Motor Control Module and
Common Powertrain Controller
release.
2
397.1 SPN 520286/FMI 31 - GHG17

Software Reset Detected, Case A
SPN 520286/FMI 31
Description This Code Logs Due to a Software Reset Caused by Internal
Monitoring
Monitored Parameter MCM
Typical Duration None Seconds
Dash Lamps None
Engine Reaction Engine Speed Limited to Idle Speed
Verification Engine At Idle, Raise the Engine Speed Above 1150 rpm
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Start the engine and raise the idle speed above 1150 rpm. Is SPN 520286/FMI 31 active?
3.b No; testing is complete. Release the vehicle.
1
SPN 520286 (MCM) (GHG17)
397.1 SPN 520286/FMI 31 - GHG17

Software Reset Detected, Case A
SPN 520286/FMI 31
Description This Code Logs Due to a Software Reset Caused by Internal
Monitoring
Typical Duration None Seconds
Dash Lamps None
Engine Reaction Engine Speed Limited to Idle Speed
Verification Engine At Idle, Raise the Engine Speed Above 1150 rpm
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Start the engine and raise the idle speed above 1150 rpm. Is SPN 520286/FMI 31 active?
2
398.1 SPN 520287/FMI 7 - GHG17

MCM Hardware Reset
SPN 520287/FMI 7
Description Software Reset due to Hardware Issue in the Motor Control
Module (MCM)
Dash Lamps None
Engine Reaction Intermittent Loss Of Communication
Check as follows:
2. Check the extended fault data for SPN 520287/FMI 7. Does SPN 520287/FMI 7 have more than one
occurrence?
2.b No; reprogram the MCM with the latest software release.
1
398.2 SPN 520287/FMI 13 - GHG17

SPN 520287/FMI 13
Description Software Reset due to Internal Monitoring
Dash Lamps None
Check as follows:
3. Turn the key to the ON position, engine OFF. Is SPN 520287/FMI 13 active?
2
398.3 SPN 520287/FMI 14 - GHG17

SPN 520287/FMI 14
Description This Fault Usually Occurs After Reprogramming the Motor
Control Module (MCM). After Reprogramming, All Fault Codes
Must be Cleared.
Dash Lamps None
Use DiagnosticLink Professional to set Engine Serial Number/Vehicle Identification Number (ESN/VIN)
command. This command changes the ESN/VIN in the electronic control modules when they are replaced, or
when the engine is exchanged.
3
SPN 520287 (MCM) (GHG17)
398.1 SPN 520287/FMI 7 - GHG17

MCM Hardware Reset
SPN 520287/FMI 7
Description Software Reset due to Hardware Issue in the Motor Control
Module (MCM)
Dash Lamps None
Engine Reaction Intermittent Loss Of Communication
Check as follows:
2. Check the extended fault data for SPN 520287/FMI 7. Does SPN 520287/FMI 7 have more than one
occurrence?
2.b No; reprogram the MCM with the latest software release.
4
398.2 SPN 520287/FMI 13 - GHG17

SPN 520287/FMI 13
Description Software Reset due to Internal Monitoring
Dash Lamps None
Check as follows:
3. Turn the key to the ON position, engine OFF. Is SPN 520287/FMI 13 active?
5
398.3 SPN 520287/FMI 14 - GHG17

SPN 520287/FMI 14
Description This Fault Usually Occurs After Reprogramming the Motor
Control Module (MCM). After Reprogramming, All Fault Codes
Must be Cleared.
Dash Lamps None
Use DiagnosticLink Professional to set Engine Serial Number/Vehicle Identification Number (ESN/VIN)
command. This command changes the ESN/VIN in the electronic control modules when they are replaced, or
when the engine is exchanged.
6
399.1 SPN 520296/FMI 3 - GHG17

Exhaust Gas Recirculation Valve Actuator, Low Supply Voltage
SPN 520296/FMI 3
Description Exhaust Gas Recirculation (EGR) Valve Actuator, Low Supply
Voltage
Monitored Parameter EGR Valve Actuator Voltage
Typical Enabling Conditions EGR Valve Actuator internal self test at start up.
Dash Lamps MIL, CEL

1.a If SPN 3510/FMI 4 is also present, troubleshoot SPN 3510/FMI 4 first.
2. Disconnect the EGR valve connector.
4. Measure the voltage between pins 1 and 2 of the EGR valve actuator connector (engine harness side).
4.a If the voltage is greater than 11 volts, Go to step 6.
5. Measure the voltage between pin 1 of the EGR valve actuator connector and ground (engine harness side).
5.a If the voltage is less than 11 volts, repair wire between pin 1 of the EGR valve actuator connector
harness and pin 62 of the Motor Control Module (MCM) 120-pin connector.
5.b If the voltage is greater than 11 volts, repair wire between pin 2 of the EGR valve actuator connector
(engine harness side) and pin 67 of the MCM 120-pin connector.
6. Check Charging System and Starting System for proper operation. Refer to OEM procedures for testing.
6.a If problem is present, repair as necessary. Verify repairs.
6.b If no problems are present, Go to step 7.
7. Clear codes, cycle the ignition ON and monitor SRA3 status using DiagnosticLink .
7.a If SRA3 status is "0" or "OK", clear the codes and release the vehicle.
7.b If SRA3 status is not "0" or "OK", contact the Detroit™ Customer Support Center at 800-445-1980.
1
399.2 SPN 520296/FMI 31 - GHG17

SPN 520296/FMI 31
Position Does Not Reach the Commanded Position Within a
Calibrated Time.
Dash Lamps MIL, CEL
Check as follows:
2.b No; install the components correctly (replace any clamps that need readjustment), and use
DiagnosticLink to perform the EGR Slow Learn routine. Verify repair.
3. Verify the orientation of the pull rod. Is the "S" stamped on the pull rod facing toward the EGR actuator and
the "V" stamped on the pull rod facing toward the EGR valve?
repair.
move?
missing?
move?
end stop?
2

3
SPN 520296 (MCM) (GHG17)
399.1 SPN 520296/FMI 3 - GHG17

Exhaust Gas Recirculation Valve Actuator, Low Supply Voltage
SPN 520296/FMI 3
Description Exhaust Gas Recirculation (EGR) Valve Actuator, Low Supply
Voltage
Monitored Parameter EGR Valve Actuator Voltage
Typical Enabling Conditions EGR Valve Actuator internal self test at start up.
Dash Lamps MIL, CEL

1.a If SPN 3510/FMI 4 is also present, troubleshoot SPN 3510/FMI 4 first.
2. Disconnect the EGR valve connector.
4. Measure the voltage between pins 1 and 2 of the EGR valve actuator connector (engine harness side).
4.a If the voltage is greater than 11 volts, Go to step 6.
5. Measure the voltage between pin 1 of the EGR valve actuator connector and ground (engine harness side).
5.a If the voltage is less than 11 volts, repair wire between pin 1 of the EGR valve actuator connector
harness and pin 62 of the Motor Control Module (MCM) 120-pin connector.
5.b If the voltage is greater than 11 volts, repair wire between pin 2 of the EGR valve actuator connector
(engine harness side) and pin 67 of the MCM 120-pin connector.
6. Check Charging System and Starting System for proper operation. Refer to OEM procedures for testing.
6.a If problem is present, repair as necessary. Verify repairs.
6.b If no problems are present, Go to step 7.
7. Clear codes, cycle the ignition ON and monitor SRA3 status using DiagnosticLink .
7.a If SRA3 status is "0" or "OK", clear the codes and release the vehicle.
7.b If SRA3 status is not "0" or "OK", contact the Detroit™ Customer Support Center at 800-445-1980.
4
399.2 SPN 520296/FMI 31 - GHG17

SPN 520296/FMI 31
Position Does Not Reach the Commanded Position Within a
Calibrated Time.
Dash Lamps MIL, CEL
Check as follows:
2.b No; install the components correctly (replace any clamps that need readjustment), and use
DiagnosticLink to perform the EGR Slow Learn routine. Verify repair.
3. Verify the orientation of the pull rod. Is the "S" stamped on the pull rod facing toward the EGR actuator and
the "V" stamped on the pull rod facing toward the EGR valve?
repair.
move?
missing?
move?
end stop?
5

6
400.1 SPN 520321/FMI 31- GHG17

Internal MCM Error
SPN 520321/FMI 31
Description Internal MCM Error Detected
Dash Lamps CEL
Verification Key On
3. Is SPN 520321/FMI 31 still active?
1
SPN 520321 (MCM) (GHG17)
400.1 SPN 520321/FMI 31- GHG17

Internal MCM Error
SPN 520321/FMI 31
Description Internal MCM Error Detected
Dash Lamps CEL
Verification Key On
3. Is SPN 520321/FMI 31 still active?
2
401.1 SPN 520322/FMI 31 - GHG17

No Match of Camshaft and Crankshaft Signals - engine cold
SPN 520322/FMI 31
Description This fault code sets when the Camshaft signal is 6 degrees
different from the crankshaft signal for 50 counts.
Engine Idle
Engine coolant temperature less than (87°C)188 °F
Dash Lamps MIL, CEL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 723 FMI 3, FMI 4, SPN 636 FMI 3 or FMI 4 also
present?
4. Has the camshafts recently been removed from the engine?
5. Verify the camshaft timing. Is the camshaft timing correct?
5.b No; correct the camshaft timing. Verify repair.
6. Disconnect and inspect the camshaft position sensor connector. Is there damage, corrosion or fretting
present?
7. Remove and inspect the camshaft position sensor. Is the camshaft position sensor damaged?
7.a Yes; replace the camshaft position sensor.
8. Check the cam gear tone wheel for damage. Is the cam gear tone wheel damaged?
8.a Yes; replace the camshaft.
8.b No; replace the camshaft position sensor. Verify repair.
1
SPN 520322 (MCM) (GHG17)
401.1 SPN 520322/FMI 31 - GHG17

No Match of Camshaft and Crankshaft Signals - engine cold
SPN 520322/FMI 31
Description This fault code sets when the Camshaft signal is 6 degrees
different from the crankshaft signal for 50 counts.
Engine Idle
Engine coolant temperature less than (87°C)188 °F
Dash Lamps MIL, CEL
Check as follows:
3. Check for multiple fault codes. Are fault codes SPN 723 FMI 3, FMI 4, SPN 636 FMI 3 or FMI 4 also
present?
4. Has the camshafts recently been removed from the engine?
5. Verify the camshaft timing. Is the camshaft timing correct?
5.b No; correct the camshaft timing. Verify repair.
6. Disconnect and inspect the camshaft position sensor connector. Is there damage, corrosion or fretting
present?
7. Remove and inspect the camshaft position sensor. Is the camshaft position sensor damaged?
7.a Yes; replace the camshaft position sensor.
8. Check the cam gear tone wheel for damage. Is the cam gear tone wheel damaged?
8.a Yes; replace the camshaft.
8.b No; replace the camshaft position sensor. Verify repair.
2
402.1 SPN 520323/FMI 3 - GHG17

High Side Digital Output Supply Voltage Circuit Failed High
SPN 520323/FMI 3
Description High Side Digital Output Supply Voltage Circuit Failed High
Dash Lamps MIL, CEL

2. Disconnect the Diesel Exhaust Fluid (DEF) Dosing Unit harness connector.
1
3. Inspect Dosing Unit harness connector for bent, spread or corroded pins. Was any damage found?
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
5. Measure the voltage between pins 2 and 7 on the harness side of the DEF dosing unit connector. Is the
5.b No; repair the short to battery voltage between pin 2 on the harness side of the DEF Dosing Unit
harness connector and pin 33 of the ACM 120-pin connector.
6. Measure the voltage between pin 2 on the harness side of the DEF dosing unit harness connector and
engine ground.
6.a If voltage is less than 11.5 volts, repair the wire between pin 1 on the harness side of the DEF Dosing
Unit harness connector and pin 28 of the ACM 120-pin connector.
6.b If voltage is greater than 11.5 volts, repair the short to battery voltage between pin 2 on the harness
side of the DEF Dosing Unit harness connector and pin 33 of the ACM 120-pin connector.
2
402.2 SPN 520323/FMI 4 - GHG17

High Side Digital Output Supply Voltage Circuit Failed Low
SPN 520323/FMI 4
Description High Side Digital Output Supply Voltage Circuit Failed Low
Dash Lamps MIL, CEL

3
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
5. Measure the resistance between pins 2 and 7 on the harness side of the DEF Dosing Unit harness
connector. Is the resistance greater than 10k ohms?
5.b No; repair the short between pins 2 and 7 on the harness side of the DEF Dosing Unit.
6. Measure the resistance between pin 2 on the harness side of the DEF Dosing Unit harness connector and
engine ground. Is the resistance greater than 10k ohms?
6.a Yes; repair the short to ground between pin 1 on the harness side of the DEF Dosing Unit harness
6.b No; repair the short to ground between pin 2 on the harness side of the DEF Dosing Unit and pin 33 of
4
SPN 520323 (ACM) (GHG17)
402.1 SPN 520323/FMI 3 - GHG17

High Side Digital Output Supply Voltage Circuit Failed High
SPN 520323/FMI 3
Description High Side Digital Output Supply Voltage Circuit Failed High
Dash Lamps MIL, CEL
5

Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
5. Measure the voltage between pins 2 and 7 on the harness side of the DEF dosing unit connector. Is the
5.b No; repair the short to battery voltage between pin 2 on the harness side of the DEF Dosing Unit
harness connector and pin 33 of the ACM 120-pin connector.
6. Measure the voltage between pin 2 on the harness side of the DEF dosing unit harness connector and
engine ground.
6.a If voltage is less than 11.5 volts, repair the wire between pin 1 on the harness side of the DEF Dosing
Unit harness connector and pin 28 of the ACM 120-pin connector.
6.b If voltage is greater than 11.5 volts, repair the short to battery voltage between pin 2 on the harness
side of the DEF Dosing Unit harness connector and pin 33 of the ACM 120-pin connector.
6
402.2 SPN 520323/FMI 4 - GHG17

High Side Digital Output Supply Voltage Circuit Failed Low
SPN 520323/FMI 4
Description High Side Digital Output Supply Voltage Circuit Failed Low
Dash Lamps MIL, CEL

7
Dosing Unit
4 Heating Supply 3
6 Not Used Not Used
7 Sensor Ground 99
5. Measure the resistance between pins 2 and 7 on the harness side of the DEF Dosing Unit harness
connector. Is the resistance greater than 10k ohms?
5.b No; repair the short between pins 2 and 7 on the harness side of the DEF Dosing Unit.
6. Measure the resistance between pin 2 on the harness side of the DEF Dosing Unit harness connector and
engine ground. Is the resistance greater than 10k ohms?
6.a Yes; repair the short to ground between pin 1 on the harness side of the DEF Dosing Unit harness
6.b No; repair the short to ground between pin 2 on the harness side of the DEF Dosing Unit and pin 33 of
8
SPN 520328 (ACM) (GHG17)
403.1 SPN 520328/FMI 7 – GHG17

Diesel Exhaust Fluid System has Been Over-pressurized
SPN 520328/FMI 7
Diesel Exhaust Fluid (DEF) Pressure Relief Valve Stuck
Description Closed
Monitored Parameter DEF Pressure
When Service Routine Is Enabled and During In-Use Checks
Typical Enabling Conditions under Non-DEF Dosing Conditions
Service Tool and During In-Use Checks under Non-DEF
Execution Frequency Dosing Conditions
Dash Lamps None

Check as follows:
3.a If other fault codes are active, in addition to SPN 520328/FMI 7, troubleshoot the other faults first.
4. Replace Pressure Relief Valve (PRV). Refer to section "Removal of the Diesel Exhaust Fluid Pump Pressure Relief Valve" .
Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine to prime the
system and verify repairs.
1
SPN 520329 (ACM) (GHG17)
404.1 SPN 520329/FMI 31 - GHG17

DEF flow quantity below normal
SPN 520329/FMI 31
Description Diesel Exhaust Fluid (DEF) pump speed low
Monitored Parameter DEF pump speed
Typical Enabling Conditions DEF pump enabled and cannot operate above a DEF pump
speed threshold
Monitor Sequence DEF pump is enabled
Dash Lamps CEL
ADS) Self-check

Check as follows:
1.b No; replace the DEF pump. Refer to section "Removal of the Diesel Exhaust Fluid Pump Module" . Verify repair.
1
405.1 SPN 520332/FMI 17 – GHG17

Diesel Oxidation Catalyst Inlet Temperature Out of Range Low Preventing HC Dosing
The fault indicates that the High Idle Regen (HIR) was aborted due to the Diesel Oxidation Catalyst (DOC) inlet
temperature not reaching the minimum of 270°C (518°F) to initiate dosing during an HIR .
SPN 520332/FMI 17
Monitored Parameter Exhaust temperature
Dash Lamps MIL

1. Are any other faults present?
1.a Yes; troubleshoot and repair them first.
2. Inspect the following areas for possible issues:
• Intake Throttle Valve – perform intake throttle service routine to see if commanded position can be
achieved
• Exhaust leaks
• Intake manifold leaks
• Charge Air Cooler (CAC) leaks
• Jake Brake® operation
• Thermostat
3. Compare Diesel Oxidation Filter (DOC) inlet temperature to the DOC outlet temperature and the Diesel
Particulate Filter (DPF) outlet temperature sensors with the key ON, engine OFF. Both sensors should read
within 25°C (77°F) . Is any problem found?
3.a Yes; perform repairs as needed.
4. Disconnect the DOC inlet temperature sensor.
5. Inspect the DOC inlet temperature sensor harness connector for bent, spread or corroded pins.
5.b If no pin damage is found, replace the DOC inlet temperature sensor.
1
SPN 520332 (ACM) (GHG17)
405.1 SPN 520332/FMI 17 – GHG17

Diesel Oxidation Catalyst Inlet Temperature Out of Range Low Preventing HC Dosing
The fault indicates that the High Idle Regen (HIR) was aborted due to the Diesel Oxidation Catalyst (DOC) inlet
temperature not reaching the minimum of 270°C (518°F) to initiate dosing during an HIR .
SPN 520332/FMI 17
Monitored Parameter Exhaust temperature
Dash Lamps MIL

1. Are any other faults present?
1.a Yes; troubleshoot and repair them first.
2. Inspect the following areas for possible issues:
• Intake Throttle Valve – perform intake throttle service routine to see if commanded position can be
achieved
• Exhaust leaks
• Intake manifold leaks
• Charge Air Cooler (CAC) leaks
• Jake Brake® operation
• Thermostat
3. Compare Diesel Oxidation Filter (DOC) inlet temperature to the DOC outlet temperature and the Diesel
Particulate Filter (DPF) outlet temperature sensors with the key ON, engine OFF. Both sensors should read
within 25°C (77°F) . Is any problem found?
3.a Yes; perform repairs as needed.
4. Disconnect the DOC inlet temperature sensor.
5. Inspect the DOC inlet temperature sensor harness connector for bent, spread or corroded pins.
5.b If no pin damage is found, replace the DOC inlet temperature sensor.
2
SPN 520348 (ACM) (GHG17)
406.1 SPN 520348/FMI 14 - GHG17

Soot Sensor Tube Clogged / Defect
SPN 520348/FMI 14
Description Soot Sensor blockage or tampering.
Monitored Parameter Soot Sensor Protection Tube Temperature
Dash Lamps MIL, CEL
Verification Verify repairs by road test with loaded trailer for 30 minutes.
Check as follows:
Note : When the engine starts, Soot Sensor will cycle through three modes: protective heating of exhaust
temperature dew point 210°C (410°F) to allow moisture to evaporate, heater active regeneration 800°C (1472°F)
to clean soot, and measurement mode for duration of key cycle.
2. Using DiagnosticLink , check for multiple fault codes. Are any other fault codes present?
4. Inspect soot sensor for tampering, damage and proper mounting. Is soot sensor damaged or loose?
5. Remove Soot Sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor".
WARNING
EYE INJURY
6. Inspect the soot sensor for deposits restricting the exhaust gas flow through its protection tube. Is the
protection tube plugged or excessive soot found?
6.a Yes; diagnose and repair the source of soot. Clean soot sensor protection tube using compressed air.
Go to step 7.
6.b No; replace Soot Sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs by
using DiagnosticLink Soot Sensor Panel inspection routine.
7. Road test to verify cleaning procedure. Does the fault code return?
7.a Yes; replace Soot Sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs by
1
SPN 520349 (ACM) (GHG17)
407.1 SPN 520349/FMI 14 - GHG17

SPN 520349/FMI 14
Description Soot Sensor Detects Elevated Soot Accumulation
Monitored Parameter Soot Sensor Current Measurement
Dash Lamps MIL
Verification Verify Repairs Using DiagnosticLink Soot Sensor Panel
inspection Routine
Check as follows:
Note : When the engine starts, soot sensor will cycle through three modes: protective heating of exhaust
2.a Yes; repair those fault codes first. Other fault codes may result in excessive soot build-up.
3. Remove the soot sensor. Refer to section "Removal of the Soot Sensor" .
4. Inspect soot sensor for excessive soot. Soot evidence can be a slight existence of black film in the tip and
around the edges and can be identified by wiping with a light colored cloth. Is excessive soot present?
4.a Yes; wipe clean the soot sensor's protection tube and reinstall the soot sensor. Refer to section "Installation
of the Soot Sensor" . Go to step 5.

5. This fault has set due to a failed DPF. Replace the DPF. Refer to section "Removal of the 1-BOX™ Diesel Particulate
Filter" . Clean all remaining soot. Go to step 6.
6. Reset the ash accumulation. Verify repair.

7. Remove the DPF and inspect the outlet face of the DPF substrate for contamination. Refer to section "Removal
of the 1-BOX™ Diesel Particulate Filter" . Is soot present on the outlet face of the DPF?
1
Clean DPF Excessive Soot Presence
7.a Yes; replace the DPF. Clean all remaining soot. Reset the ash accumulation. Go to step 8.
7.b No; clean all remaining soot and replace soot sensor. Refer to section "Installation of the Soot Sensor" . Verify
repairs.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
8. Reinstall the soot sensor. Refer to section "Installation of the Soot Sensor" .
9. Clear fault codes. Perform a parked regeneration; reset the ash accumulators. Refer to section "Performing a
Parked Regeneration - GHG17" .
10. Using DiagnosticLink, perform soot sensor inspection routine to verify repairs. Does the routine pass?
10.b No; replace soot sensor. Refer to section "Removal of the Soot Sensor" . Verify repairs.
2
SPN 520349 (ACM) (GHG17)
407.1 SPN 520349/FMI 14 - GHG17

SPN 520349/FMI 14
Description Soot Sensor Detects Elevated Soot Accumulation
Monitored Parameter Soot Sensor Current Measurement
Dash Lamps MIL
Verification Verify Repairs Using DiagnosticLink Soot Sensor Panel
inspection Routine
Check as follows:
2.a Yes; repair those fault codes first. Other fault codes may result in excessive soot build-up.
3. Remove the soot sensor. Refer to section "Removal of the Soot Sensor" .
4. Inspect soot sensor for excessive soot. Soot evidence can be a slight existence of black film in the tip and
around the edges and can be identified by wiping with a light colored cloth. Is excessive soot present?
4.a Yes; wipe clean the soot sensor's protection tube and reinstall the soot sensor. Refer to section "Installation
of the Soot Sensor" . Go to step 5.

5. This fault has set due to a failed DPF. Replace the DPF. Refer to section "Removal of the 1-BOX™ Diesel Particulate
Filter" . Clean all remaining soot. Go to step 6.
6. Reset the ash accumulation. Verify repair.

7. Remove the DPF and inspect the outlet face of the DPF substrate for contamination. Refer to section "Removal
of the 1-BOX™ Diesel Particulate Filter" . Is soot present on the outlet face of the DPF?
3
Clean DPF Excessive Soot Presence
7.a Yes; replace the DPF. Clean all remaining soot. Reset the ash accumulation. Go to step 8.
7.b No; clean all remaining soot and replace soot sensor. Refer to section "Installation of the Soot Sensor" . Verify
repairs.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
WARNING
HOT EXHAUST
8. Reinstall the soot sensor. Refer to section "Installation of the Soot Sensor" .
9. Clear fault codes. Perform a parked regeneration; reset the ash accumulators. Refer to section "Performing a
Parked Regeneration - GHG17" .
10. Using DiagnosticLink, perform soot sensor inspection routine to verify repairs. Does the routine pass?
10.b No; replace soot sensor. Refer to section "Removal of the Soot Sensor" . Verify repairs.
4
SPN 520352 (ACM) (GHG17)
408.1 SPN 520352/FMI 3 - GHG17

Supply Voltage Difference Between ACM and Soot Sensor
SPN 520352 / FMI 3

Description Supply Voltage Signals not equal between ACM and soot
sensor when heater is on
Monitored Parameter Soot Sensor voltage supply
Dash Lamps MIL
Verification Key Cycle - Engine Idle two minutes.
1
Check as follows:
1. Turn the ignition key ON (key ON, engine OFF).
present?
2
6. Inspect soot sensor wiring from Soot Sensor Control Unit (SCU) to sensor probe. Is any damage found?
6.a Yes; replace soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section "Removal of the
8. Measure the voltage between soot sensor connector pins 1 and 2, harness side. Is the voltage within 0.5 V
of the battery voltage?
9. Measure the voltage between soot sensor connector pin 1, harness side and battery ground. Is the voltage
within 0.5 V of the battery voltage?
9.a Yes; repair the open wire between pin 2 on the harness side of the soot sensor connector and pin 96 of
the ACM 120-pin connector. Verify repairs.
damage found?
13.b No; repair the open wire between pin 1 on the harness side of the soot sensor connector and pin 66 of
15. Measure the resistance between pin 2 on the harness side of the soot sensor connector and pin 96 of the
ACM 120-pin connector. Is the resistance less than 5 ohms?
17. Measure the voltage between pins 66 and 96 of the ACM 120-pin connector . Is the voltage within 0.5 V of
the battery voltage?
17.a Yes; replace soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section"Removal of the
For Two-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .Verify repairs.
3
SPN 520352 (ACM) (GHG17)
408.1 SPN 520352/FMI 3 - GHG17

Supply Voltage Difference Between ACM and Soot Sensor
SPN 520352 / FMI 3

Description Supply Voltage Signals not equal between ACM and soot
sensor when heater is on
Dash Lamps MIL
4
Check as follows:
present?
5
6. Inspect soot sensor wiring from Soot Sensor Control Unit (SCU) to sensor probe. Is any damage found?
8. Measure the voltage between soot sensor connector pins 1 and 2, harness side. Is the voltage within 0.5 V
of the battery voltage?
9. Measure the voltage between soot sensor connector pin 1, harness side and battery ground. Is the voltage
within 0.5 V of the battery voltage?
9.a Yes; repair the open wire between pin 2 on the harness side of the soot sensor connector and pin 96 of
damage found?
17. Measure the voltage between pins 66 and 96 of the ACM 120-pin connector . Is the voltage within 0.5 V of
17.a Yes; replace soot sensor. Refer to section "Removal of the Soot Sensor" or Refer to section"Removal of the
For Two-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" .Verify repairs.
6
409.1 SPN 520353/FMI 17 - GHG17

Soot Sensor Temperature Rationality Failure - Cold Start
SPN 520353/FMI 17
Description Soot sensor temperature and select catalyst reduction
temperature sensors do not match when cold
Monitored Parameter Soot Sensor Temperature, SCR Outlet Temperature
Dash Lamps MIL, CEL
Verification Key cycle; perform DiagnosticLink Soot Sensor Panel
inspection routine.
Check as follows:
1. Turn the ignition key ON (Key ON, Engine OFF).
damage found?
4.b No; reconnect soot sensor. Go to step 5.
5. Using DiagnosticLink, monitor the listed Aftertreatment Device (ATD) temperatures:
• Diesel Particulate Filter (DPF) Outlet
• Selective Catalyst Reduction (SCR) Inlet
• SCR Outlet
• Soot temperature
6. Is the SCR outlet temperature sensor reading similar to temperature values of the others? For example: if
the other temperature readings are approx 25°C (77°F) and SCR outlet temperature reading is 0°C (32°F)
or 50°C (122°F), that would be the suspect sensor.
6.a Yes; replace soot sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs by
1
SPN 520353 (ACM) (GHG17)
409.1 SPN 520353/FMI 17 - GHG17

Soot Sensor Temperature Rationality Failure - Cold Start
SPN 520353/FMI 17
Description Soot sensor temperature and select catalyst reduction
temperature sensors do not match when cold
Monitored Parameter Soot Sensor Temperature, SCR Outlet Temperature
Dash Lamps MIL, CEL
Verification Key cycle; perform DiagnosticLink Soot Sensor Panel
inspection routine.
Check as follows:
damage found?
4.b No; reconnect soot sensor. Go to step 5.
5. Using DiagnosticLink, monitor the listed Aftertreatment Device (ATD) temperatures:
• Diesel Particulate Filter (DPF) Outlet
• Selective Catalyst Reduction (SCR) Inlet
• SCR Outlet
• Soot temperature
6. Is the SCR outlet temperature sensor reading similar to temperature values of the others? For example: if
the other temperature readings are approx 25°C (77°F) and SCR outlet temperature reading is 0°C (32°F)
or 50°C (122°F), that would be the suspect sensor.
6.a Yes; replace soot sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs by
2
410.1 SPN 520357/FMI 2 - GHG17

Soot Sensor Printed Circuit Board Temperature Rationality Fault
SPN 520357/FMI 2
Description This Fault Code Sets when Soot Sensor Control Unit Detects
an Over-temperature
Dash Lamps MIL
Verification Verify Repairs By Using DiagnosticLink Soot Sensor Panel
Inspection Routine
Check as follows:
temperature dew point 210°C (410°F) to allow moisture to evaporate; 2) Heater active regeneration 800°C
(1472°F) to clean soot; and 3) Measurement mode for duration of key cycle.
present?
damage found?
1
410.2 SPN 520357/FMI 15 - GHG17

Soot Sensor Printed Circuit Board Temperature High
SPN 520357/FMI 15
Description Soot Sensor Detects A Circuit Board Over-Temperature
Dash Lamps MIL
Inspection Routine
Check as follows:
present?
damage found?
2
SPN 520357 (ACM) (GHG17)
410.1 SPN 520357/FMI 2 - GHG17

Soot Sensor Printed Circuit Board Temperature Rationality Fault
SPN 520357/FMI 2
Description This Fault Code Sets when Soot Sensor Control Unit Detects
an Over-temperature
Dash Lamps MIL
Inspection Routine
Check as follows:
present?
damage found?
3
410.2 SPN 520357/FMI 15 - GHG17

Soot Sensor Printed Circuit Board Temperature High
SPN 520357/FMI 15
Description Soot Sensor Detects A Circuit Board Over-Temperature
Dash Lamps MIL
Inspection Routine
Check as follows:
present?
damage found?
4
411.1 SPN 520358/FMI 3 - GHG17

SPN 520358 / FMI 3

Description Soot Sensor printed circuit board temperature high
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
1
411.2 SPN 520358/FMI 4 - GHG17

SPN 520358 / FMI 4

Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
2
SPN 520358 (ACM) (GHG17)
411.1 SPN 520358/FMI 3 - GHG17

SPN 520358 / FMI 3

Description Soot Sensor printed circuit board temperature high
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
3
411.2 SPN 520358/FMI 4 - GHG17

SPN 520358 / FMI 4

Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
4
412.1 SPN 520359/FMI 3 - GHG17

Soot Sensor Heater Short Circuit to Battery
SPN 520359 / FMI 3

Description Higher than expected heater circuit voltage
Monitored Parameter Soot Sensor heater
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
1
412.2 SPN 520359/FMI 4 - GHG17

Soot Sensor Heater Short Circuit to Ground
SPN 520359 / FMI 4

Description Lower than expected heater circuit voltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
2
412.3 SPN 520359/FMI 5 - GHG17

Soot Sensor Heater Open Load
SPN 520359/FMI 5
Description Lower than expected heater current
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
3
412.4 SPN 520359/FMI 12 - GHG17

Soot Sensor Heater Printed Circuit Board Component Failure
SPN 520359 / FMI 12

Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
4
SPN 520359 (ACM) (GHG17)
412.1 SPN 520359/FMI 3 - GHG17

Soot Sensor Heater Short Circuit to Battery
SPN 520359 / FMI 3

Description Higher than expected heater circuit voltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
5
412.2 SPN 520359/FMI 4 - GHG17

Soot Sensor Heater Short Circuit to Ground
SPN 520359 / FMI 4

Description Lower than expected heater circuit voltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
6
412.3 SPN 520359/FMI 5 - GHG17

Soot Sensor Heater Open Load
SPN 520359/FMI 5
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
7
412.4 SPN 520359/FMI 12 - GHG17

Soot Sensor Heater Printed Circuit Board Component Failure
SPN 520359 / FMI 12

Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
8
413.1 SPN 520360/FMI 3 - GHG17

Soot Sensor Inter-Digital Electrode Positive Short Circuit to Battery Diagnostic
SPN 520360 / FMI 3

Description Soot Sensor inter-digital electrode (IDE) overvoltage
Monitored Parameter Soot Sensor IDE current
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
1
413.2 SPN 520360/FMI 4 - GHG17

Soot Sensor Inter-Digital Electrode Positive Short Circuit to Ground Diagnostic
SPN 520360/FMI 4
Description Soot Sensor inter-digital electrode (IDE) short to ground
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
2
413.3 SPN 520360/FMI 15 - GHG17

Soot Sensor Inter-Digital Electrode Positive Signal Range High Diagnostic
SPN 520360 / FMI 15

Description Soot Sensor inter-digital electrode (IDE) detects an
overvoltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
3
SPN 520360 (ACM) (GHG17)
413.1 SPN 520360/FMI 3 - GHG17

Soot Sensor Inter-Digital Electrode Positive Short Circuit to Battery Diagnostic
SPN 520360 / FMI 3

Description Soot Sensor inter-digital electrode (IDE) overvoltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
4
413.2 SPN 520360/FMI 4 - GHG17

Soot Sensor Inter-Digital Electrode Positive Short Circuit to Ground Diagnostic
SPN 520360/FMI 4
Description Soot Sensor inter-digital electrode (IDE) short to ground
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
5
413.3 SPN 520360/FMI 15 - GHG17

Soot Sensor Inter-Digital Electrode Positive Signal Range High Diagnostic
SPN 520360 / FMI 15

Description Soot Sensor inter-digital electrode (IDE) detects an
overvoltage
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
6
414.1 SPN 520361/FMI 2 - GHG17

Soot Sensor Temperature Rationality Signal Range Low
SPN 520361/FMI 2
Description Soot Sensor Temperature out of range Low
Dash Lamps MIL, CEL
inspection routine.
Check as follows:
2. Using DiagnosticLink®, check for any communication or voltage fault codes. Are any other fault codes
present?
damage found?
4.b No; Replace soot sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs.
1
414.2 SPN 520361/FMI 16 - GHG17

Soot Sensor Temperature High
SPN 520361/FMI 16
Description Higher Than Expected Heater Current For Soot Sensor
Temperature
Monitored Parameter Soot Sensor Heater Current and Temperature Signals
Typical Enabling Conditions Soot Sensor Heater Enabled
Dash Lamps MIL
inspection routine.
Check as follows:
(1472°F) to clean soot; and 3) Measurement mode for the duration of the key cycle.
present?
damage found?
2
414.3 SPN 520361/FMI 18 - GHG17

Soot Sensor Temperature Low
SPN 520361/FMI 18
Description Lower than expected Soot Sensor temperature
Monitored Parameter Soot Sensor temperature signal
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
3
SPN 520361 (ACM) (GHG17)
414.1 SPN 520361/FMI 2 - GHG17

Soot Sensor Temperature Rationality Signal Range Low
SPN 520361/FMI 2
Description Soot Sensor Temperature out of range Low
Dash Lamps MIL, CEL
inspection routine.
Check as follows:
2. Using DiagnosticLink®, check for any communication or voltage fault codes. Are any other fault codes
present?
damage found?
4.b No; Replace soot sensor. Refer to section "Removal of the 2V2/2HH Soot Sensor". Verify repairs.
4
414.2 SPN 520361/FMI 16 - GHG17

Soot Sensor Temperature High
SPN 520361/FMI 16
Description Higher Than Expected Heater Current For Soot Sensor
Temperature
Monitored Parameter Soot Sensor Heater Current and Temperature Signals
Typical Enabling Conditions Soot Sensor Heater Enabled
Dash Lamps MIL
inspection routine.
Check as follows:
(1472°F) to clean soot; and 3) Measurement mode for the duration of the key cycle.
present?
damage found?
5
414.3 SPN 520361/FMI 18 - GHG17

Soot Sensor Temperature Low
SPN 520361/FMI 18
Description Lower than expected Soot Sensor temperature
Monitored Parameter Soot Sensor temperature signal
Dash Lamps MIL
inspection routine.
Check as follows:
present?
damage found?
6
415.1 SPN 520362/FMI 3 - GHG17

Soot Sensor Supply Line Voltage Above Normal, Or Shorted To High Source
SPN 520362 / FMI 3

Description This Fault sets when Supply Voltage is Above Normal with the
ignition ON Or Shorted To voltage with ignition OFF.
Dash Lamps MIL
Verification Key Cycle - Engine Idle two minutes
1
Check as follows:
present?
2
Note : No voltage should be present at soot sensor with ignition key off.
6. Measure the voltage between soot sensor harness connector pins 1 and 2. Is there any voltage present?
6.a Yes; repair the short to power wire between pin 1 on the harness side of the soot sensor connector and
pin 66 on the ACM. Verify repairs.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7. Start the engine and run at 900 rpm.

8. Measure the voltage between soot sensor harness connector pins 1and 2. Is the voltage greater than
15.5V?
8.a Yes; inspect and repair charging system. Refer to the Original Equipment Manufacturer (OEM) service
literature.
3
415.2 SPN 520362/FMI 4 - GHG17

Soot Sensor Supply Line Signal Range Low
SPN 520362/FMI 4
Description Soot senor supply voltage below normal
Monitored Parameter soot sensor voltage supply
Typical Enabling Conditions soot sensor enabled
Dash Lamps MIL
4
Check as follows:
present?
5
6. Is this a Two-box aftertreatment system?

7. Disconnect the harness between the ACM and Soot sensor. For a 2V2 disconnect the 47-way and for a
2HH disconnect the 14-way. Inspect the harness connectors for signs of damage, bent, spread, corroded or
unseated (pushed out) pins. Was any damage found?
8. Reconnect the harness between the soot sensor and ACM.
10. Measure the voltage between soot sensor harness connector pins 1 and 2. Is the voltage within 0.5V of the
battery voltage?
11. Measure the voltage between soot sensor harness connector pin 1 and battery ground. Is the voltage within
0.5V of the battery voltage?
11.a Yes; repair the open wire between pin 2 on the harness side of the Soot Sensor connector and pin 96
of the ACM 120-pin connector. Verify repairs.
damage found?
16. Measure the resistance between pin 1 on the harness side of the soot sensor connector and battery
18. Measure the voltage between pins 66 and 96 of the ACM 120-pin connector. Is the voltage within 0.5V of
For Two-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" Verify repairs.
6
SPN 520362 (ACM) (GHG17)
415.1 SPN 520362/FMI 3 - GHG17

Soot Sensor Supply Line Voltage Above Normal, Or Shorted To High Source
SPN 520362 / FMI 3

Description This Fault sets when Supply Voltage is Above Normal with the
ignition ON Or Shorted To voltage with ignition OFF.
Dash Lamps MIL
Verification Key Cycle - Engine Idle two minutes
7
Check as follows:
present?
8
Note : No voltage should be present at soot sensor with ignition key off.
6. Measure the voltage between soot sensor harness connector pins 1 and 2. Is there any voltage present?
6.a Yes; repair the short to power wire between pin 1 on the harness side of the soot sensor connector and
pin 66 on the ACM. Verify repairs.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7. Start the engine and run at 900 rpm.

8. Measure the voltage between soot sensor harness connector pins 1and 2. Is the voltage greater than
15.5V?
8.a Yes; inspect and repair charging system. Refer to the Original Equipment Manufacturer (OEM) service
literature.
9
415.2 SPN 520362/FMI 4 - GHG17

Soot Sensor Supply Line Signal Range Low
SPN 520362/FMI 4
Description Soot senor supply voltage below normal
Monitored Parameter soot sensor voltage supply
Typical Enabling Conditions soot sensor enabled
Dash Lamps MIL
10
Check as follows:
present?
11
6. Is this a Two-box aftertreatment system?

7. Disconnect the harness between the ACM and Soot sensor. For a 2V2 disconnect the 47-way and for a
2HH disconnect the 14-way. Inspect the harness connectors for signs of damage, bent, spread, corroded or
unseated (pushed out) pins. Was any damage found?
8. Reconnect the harness between the soot sensor and ACM.
10. Measure the voltage between soot sensor harness connector pins 1 and 2. Is the voltage within 0.5V of the
battery voltage?
11. Measure the voltage between soot sensor harness connector pin 1 and battery ground. Is the voltage within
0.5V of the battery voltage?
11.a Yes; repair the open wire between pin 2 on the harness side of the Soot Sensor connector and pin 96
of the ACM 120-pin connector. Verify repairs.
damage found?
16. Measure the resistance between pin 1 on the harness side of the soot sensor connector and battery
18. Measure the voltage between pins 66 and 96 of the ACM 120-pin connector. Is the voltage within 0.5V of
For Two-Box, Refer to section "Removal of the Two-BOX (2V2) Aftertreatment Control Module" Verify repairs.
12
416.1 SPN 520363/FMI 3 - GHG17

SPN 520363/FMI 5
Dash Lamps MIL, CEL
Check as follows:
damage found?
1
416.2 SPN 520363/FMI 5 - GHG17

SPN 520363/FMI 5
Description This Codes Sets When There is an Open on the SCR Inlet
Dash Lamps MIL, CEL
Check as follows:
damage found?
2
SPN 520363 (ACM) (GHG17)
416.1 SPN 520363/FMI 3 - GHG17

SPN 520363/FMI 5
Dash Lamps MIL, CEL
Check as follows:
damage found?
3
416.2 SPN 520363/FMI 5 - GHG17

SPN 520363/FMI 5
Description This Codes Sets When There is an Open on the SCR Inlet
Dash Lamps MIL, CEL
Check as follows:
damage found?
4
417.1 SPN 520364/FMI 3 - GHG17

SPN 520364/FMI 3
Inlet NOx Circuit Between the Sensor and the ECU
Dash Lamps MIL, CEL
Check as follows:
damage found?
1
SPN 520364 (ACM) (GHG17)
417.1 SPN 520364/FMI 3 - GHG17

SPN 520364/FMI 3
Inlet NOx Circuit Between the Sensor and the ECU
Dash Lamps MIL, CEL
Check as follows:
damage found?
2
SPN 520365 (ACM) (GHG17)
418.1 SPN 520365/FMI 3 - GHG17

SPN 520365/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" .
1
418.2 SPN 520365/FMI 5 - GHG17

SPN 520365/FMI 5
Outlet Circuit Between the Sensor and the ECU
Dash Lamps MIL, CEL
Check as follows:
damage found?
2
SPN 520366 (ACM) (GHG17)
419.1 SPN 520366/FMI 3 - GHG17

SPN 520366/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST

1
419.2 SPN 520366/FMI 5 - GHG17

SPN 520366/FMI 5
Description This Code Sets When There is an Open on the SCR Outlet
Dash Lamps MIL, CEL

damage found?
WARNING
HOT EXHAUST

2
420.1 SPN 520367/FMI 3 - GHG17

SPN 520367/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST

For Two-BOX, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" .
1
420.2 SPN 520367/FMI 5 - GHG17

SPN 520367/FMI 5
Description This Code Sets When There is an Open on the SCR NOx
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST

2
SPN 520367 (ACM) (GHG17)
420.1 SPN 520367/FMI 3 - GHG17

SPN 520367/FMI 3
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST

3
420.2 SPN 520367/FMI 5 - GHG17

SPN 520367/FMI 5
Description This Code Sets When There is an Open on the SCR NOx
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST

4
421.1 SPN 520368/FMI 14 - GHG17

SPN 520368/FMI 14
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST
3. No; replace the SCR Outlet NOx sensor.

1
421.2 SPN 520368/FMI 31 - GHG17

SPN 520368/FMI 31
Dash Lamps MIL, CEL
Engine Reaction 10 % Derate
Check as follows:
damage found?
WARNING
HOT EXHAUST

2
SPN 520368 (ACM) (GHG17)
421.1 SPN 520368/FMI 14 - GHG17

SPN 520368/FMI 14
Dash Lamps MIL, CEL
Check as follows:
damage found?
WARNING
HOT EXHAUST
3. No; replace the SCR Outlet NOx sensor.

3
421.2 SPN 520368/FMI 31 - GHG17

SPN 520368/FMI 31
Dash Lamps MIL, CEL
Engine Reaction 10 % Derate
Check as follows:
damage found?
WARNING
HOT EXHAUST

4
422.1 SPN 520371/FMI 16 - GHG17

SPN 520371/FMI 16
Description The Fault Indicates High Diesel Exhaust Fluid (DEF) Delivery
Dash Lamps None
Check as follows:
2.b No; clean/flush the DEF tank. Go to step 4. Refer to section "Flushing of the Diesel Exhaust Fluid System" .
3. Unbolt DEF dosing unit from aftertreatment. Do not disconnect DEF hoses or electrical connector. Refer to
4. Perform DEF Quantity Test service routine and record the amount of DEF dispensed. Is the dispensed DEF
fluid level between 108 and 132 mL?
4.b No; replace the DEF dosing unit. To verify repairs, Go to step 8. Refer to section "Installation of the Diesel Exhaust
Fluid Dosing Unit " .
5. Reinstall the DEF dosing unit to the aftertreatment, using a new gasket and bolts. Refer to section "Installation of
the Diesel Exhaust Fluid Dosing Unit " . Go to step 6.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
1
6. Start the engine. Using DiagnosticLink, run the NOx Sensor Verification test located in the drop-down menu
7. Did the NOx Sensor Verification test pass?

7.b No; replace the Inlet NOx sensor. Go to step 8.
8. Turn the ignition OFF and allow for all modules to power down, then turn the ignition back ON. Go to step 9.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2
WARNING
HOT EXHAUST
9. Start the engine and perform a Parked SCR Efficiency test to clear the fault code. Refer to section "GHG17
3
422.1 SPN 520371/FMI 16 - GHG17

SPN 520371/FMI 16
Dash Lamps None
Check as follows:
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
4

WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5
WARNING
HOT EXHAUST
6
SPN 520371 (ACM) (GHG17)
422.1 SPN 520371/FMI 16 - GHG17

SPN 520371/FMI 16
Dash Lamps None
Check as follows:
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
7
WARNING
HOT EXHAUST

WARNING
PERSONAL INJURY
8
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
9
423.1 SPN 520372/FMI 14 - GHG17

SPN 520372/FMI 14
Description The Fault Indicates Low Diesel Exhaust Fluid (DEF) Delivery
Dash Lamps None
Check as follows:
2.b No; clean/flush the DEF tank. Go to step 4. Refer to section "Flushing of the Diesel Exhaust Fluid System" . Verify
repair.
3. Remove the DEF dosing unit. Do not disconnect the DEF lines or electrical connector. Refer to section "Removal
of the Diesel Exhaust Fluid Dosing Unit" .
4.b No; replace the DEF dosing unit. To verify repairs, Refer to section "Removal of the Diesel Exhaust Fluid Dosing
Unit" . Go to step 10.
5. Install the DEF dosing unit. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " . Go to step 6.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
1
under Actions / Aftertreatment. .

For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go to step 8.
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Inlet NOx Sensor" . Go to step 8.
8. Start the engine. Run the NOx Sensor Verification panel a second time to verify both sensors are now
reading correctly.
9.b No; replace the outlet NOx sensor.
For 1-Box™, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" . Go to step 10.
For Two-Box, Refer to section "Removal of the Selective Catalytic Reduction Outlet NOx Sensor" . Go to step 10.
WARNING
PERSONAL INJURY
2
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
11. Perform a Parked SCR Efficiency test to clear fault and verify repairs. Refer to section "GHG17 Perform Parked SCR
Efficiency Test" .
3
423.2 SPN 520372/FMI 16 - GHG17

Selective Catalyst Reduction Closed Loop Control at Maximum Limit
SPN 520372/FMI 16
Description The Fault Indicates High DEF Delivery
Dash Lamps MIL
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005
3. Check for multiple fault codes. Are any of the following faults present: SPN 4331/FMI 15, SPN 3216/FMI
16, SPN 520372/FMI 14 or SPN 5841/FMI 14?
5. Unbolt the DEF Dosing Unit from the aftertreatment device. Do not disconnect DEF lines or electrical
connector. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" .
6.b No; replace the DEF Dosing Unit. To verify repairs, Go to step 10. Refer to section "Installation of the Diesel
Exhaust Fluid Dosing Unit " .
7. Install the DEF Dosing Unit. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " .
4
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
10. Perform a Parked SCR Efficiency test to clear fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
5
423.1 SPN 520372/FMI 14 - GHG17

SPN 520372/FMI 14
Dash Lamps None
Check as follows:
repair.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
6

reading correctly.
WARNING
PERSONAL INJURY
7
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Efficiency Test" .
8
423.2 SPN 520372/FMI 16 - GHG17

SPN 520372/FMI 16
Description The Fault Indicates High DEF Delivery
Dash Lamps MIL
Check as follows:

DD15, DD16,DD13 1-Box 7.56.6.0 ZGS 005
DD13 Two-Box 2V2 7.56.6.0 ZGS 004
DD13 EvoBus 7.56.6.0 ZGS 005
3. Check for multiple fault codes. Are any of the following faults present: SPN 4331/FMI 15, SPN 3216/FMI
16, SPN 520372/FMI 14 or SPN 5841/FMI 14?
5. Unbolt the DEF Dosing Unit from the aftertreatment device. Do not disconnect DEF lines or electrical
connector. Refer to section "Removal of the Diesel Exhaust Fluid Dosing Unit" .
6.b No; replace the DEF Dosing Unit. To verify repairs, Go to step 10. Refer to section "Installation of the Diesel
Exhaust Fluid Dosing Unit " .
7. Install the DEF Dosing Unit. Refer to section "Installation of the Diesel Exhaust Fluid Dosing Unit " .
9
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
10. Perform a Parked SCR Efficiency test to clear fault. Refer to section "GHG17 Perform Parked SCR Efficiency Test" .
10
423.1 SPN 520372/FMI 14 - GHG17

SPN 520372/FMI 14
Dash Lamps None
Check as follows:
repair.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
11

reading correctly.
WARNING
PERSONAL INJURY
12
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Efficiency Test" .
13
423.2 SPN 520372/FMI 16 - GHG17

SPN 520372/FMI 16
(ACM) detects that there is a DEF dosing fault. An additional
fault code should set identifying the dosing system fault.
Monitored Parameter NOx Conversion Efficiency, DEF dosing, DEF pump
revolutions.
Dash Lamps MIL
Verification Perform a parked regeneration, turn the ignition off for five
minutes, then perform a parked SCR Efficiency Test.
Check as follows:
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Note : If another dosing system fault code is not present with this fault code, the vehicle will need to run until the
fault monitor can run to identify the fault.
3. Check the ACM software level. Is ACM software level 7.57.4 or higher?
3.b No; update the ACM using the latest server information and Go to step 4.
4. Is the ACM fuel map ZGS 002 or higher?
5. Check for fault codes. Are there any other DEF dosing, fuel system or engine air management fault codes
present?
5.a Yes; diagnose the other fault code(s).
14
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5.b No; perform a parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17" . Once the
parked regeneration has completed, turn the ignition OFF for five minutes to allow the modules to
disconnect. Turn the ignition ON, start the engine and run the SCR Efficiency Test. Refer to section "GHG17
Perform Parked SCR Efficiency Test" . Diagnose the DEF dosing system fault code that sets.
15
SPN 520372 (ACM) (GHG17)
423.1 SPN 520372/FMI 14 - GHG17

SPN 520372/FMI 14
Dash Lamps None
Check as follows:
repair.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
16
WARNING
HOT EXHAUST

reading correctly.
17
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Efficiency Test" .
18
423.2 SPN 520372/FMI 16 - GHG17

SPN 520372/FMI 16
(ACM) detects that there is a DEF dosing fault. An additional
fault code should set identifying the dosing system fault.
Monitored Parameter NOx Conversion Efficiency, DEF dosing, DEF pump
revolutions.
Dash Lamps MIL
Verification Perform a parked regeneration, turn the ignition off for five
minutes, then perform a parked SCR Efficiency Test.
Check as follows:
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
Note : If another dosing system fault code is not present with this fault code, the vehicle will need to run until the
fault monitor can run to identify the fault.
3. Check the ACM software level. Is ACM software level 7.57.4 or higher?
4. Is the ACM fuel map ZGS 002 or higher?
5. Check for fault codes. Are there any other DEF dosing, fuel system or engine air management fault codes
present?
5.a Yes; diagnose the other fault code(s).
19
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5.b No; perform a parked regeneration. Refer to section "Performing a Parked Regeneration - GHG17" . Once the
parked regeneration has completed, turn the ignition OFF for five minutes to allow the modules to
disconnect. Turn the ignition ON, start the engine and run the SCR Efficiency Test. Refer to section "GHG17
Perform Parked SCR Efficiency Test" . Diagnose the DEF dosing system fault code that sets.
20
424.1 SPN 520378/FMI 0 - GHG17

Aftertreatment Temperature not plausible
SPN 520378/FMI 0
Description This fault sets when more than one aftertreatment
temperature sensor drifts greater than 70°C (126°F ).
Monitored Parameter Diesel Oxidation Catalyst (DOC) Inlet/Outlet Temperature vs.
Diesel Particulate Filter (DPF) outlet vs. Selective Catalyst
Reduction (SCR) Outlet Temperature
Typical Enabling Conditions Ignition off 8-Hour then cycled on for 60 seconds, Battery
voltage above 10.98 V
Execution Frequency Once Per 8-Hour Cold Soak
Dash Lamps MIL, AWL
Check as follows:
1.a If SPN 3242/FMI 3/4, SPN 3250/FMI 3/4, SPN 3246/FMI 3/4 or SPN4363/FMI 3/4 is also present,
repair those faults first.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Compare DOC inlet/outlet temperature, DPF outlet temperature and SCR outlet temperature.
5. Replace the two temperature sensors that are drifted more than 25°C (45°F) compared to the other
aftertreatment temperature sensor.
1
SPN 520378 (ACM) (GHG17)
424.1 SPN 520378/FMI 0 - GHG17

Aftertreatment Temperature not plausible
SPN 520378/FMI 0
Description This fault sets when more than one aftertreatment
temperature sensor drifts greater than 70°C (126°F ).
Monitored Parameter Diesel Oxidation Catalyst (DOC) Inlet/Outlet Temperature vs.
Diesel Particulate Filter (DPF) outlet vs. Selective Catalyst
Reduction (SCR) Outlet Temperature
Typical Enabling Conditions Ignition off 8-Hour then cycled on for 60 seconds, Battery
voltage above 10.98 V
Execution Frequency Once Per 8-Hour Cold Soak
Dash Lamps MIL, AWL
Check as follows:
1.a If SPN 3242/FMI 3/4, SPN 3250/FMI 3/4, SPN 3246/FMI 3/4 or SPN4363/FMI 3/4 is also present,
repair those faults first.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY

4. Compare DOC inlet/outlet temperature, DPF outlet temperature and SCR outlet temperature.
5. Replace the two temperature sensors that are drifted more than 25°C (45°F) compared to the other
aftertreatment temperature sensor.
2
425.1 SPN 520381/FMI 2 - GHG17

DOC Inlet Temperature Not Plausible
SPN 520381/FMI 2
Description This fault sets if DOC inlet temperature is 70°C (126°F) higher
Monitored Parameter Diesel Oxidation Catalyst (DOC) Inlet Temperature versus all
Dash Lamps MIL
Check as follows:
4. Disconnect and inspect the DOC inlet temperature sensor electrical connector, harness side.
5.b No; replace the DOC inlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .Verify repair.
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" . Verify repair.
1
SPN 520381 (ACM) (GHG17)
425.1 SPN 520381/FMI 2 - GHG17

DOC Inlet Temperature Not Plausible
SPN 520381/FMI 2
Description This fault sets if DOC inlet temperature is 70°C (126°F) higher
Monitored Parameter Diesel Oxidation Catalyst (DOC) Inlet Temperature versus all
Dash Lamps MIL
Check as follows:
4. Disconnect and inspect the DOC inlet temperature sensor electrical connector, harness side.
5.b No; replace the DOC inlet temperature sensor.
For 1-BOX™, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" .Verify repair.
For Two-Box, Refer to section "Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor" . Verify repair.
2
426.1 SPN 521001/FMI 14

Check as follows:
1. Has the vehicle's Transmission Control Module (TCM), Aftertreatment Control Module (ACM), Motor
Control Module (MCM), or Common Powertrain Controller (CPC) been recently programmed?
1.a Yes; verify correct software levels are present.
4. Are there any other active transmission-related faults also present other than SPN 521001/FMI 14 or SPN
521002/FMI 14?
4.a Yes; repair other transmission faults first.
5. Are there any chassis-side Anti-lock Brake System (ABS) faults present?
5.a Yes; refer to OEM literature for ABS diagnostics.
6. Are there any CAN/J1939 communication faults present?
7. Is the vehicle experiencing any drivability complaints related to Transmission Symptom Diagnostics?
7.a Yes; complete the appropriate Symptom Diagnostic section
8. Under instrumentation "Transmission" tab, does the clutch and transmission learned values display
"learned values available"?
8.b No; under the Actions drop-down menu "Transmission Selection," perform the "Transmission Learn
Procedure."
9. In DiagnosticLink, ensure auto-connect to J1708 and J1939 devices is enabled. If the unit can be driven,
obtain a driving log file. If the unit cannot be driven, attempt to duplicate the complaint or complete an
Engine Idle Gear/Split/Range test going through all gears. Obtain DDEC Reports, and contact Software
Support at the Detroit™ Customer Support Center at 855-253-0428 for further transmission assistance.
1
SPN 521001 (CPC3) (GHG17)
426.1 SPN 521001/FMI 14

Check as follows:
4. Are there any other active transmission-related faults also present other than SPN 521001/FMI 14 or SPN
521002/FMI 14?
7.a Yes; complete the appropriate Symptom Diagnostic section
8. Under instrumentation "Transmission" tab, does the clutch and transmission learned values display
"learned values available"?
8.b No; under the Actions drop-down menu "Transmission Selection," perform the "Transmission Learn
Procedure."
Engine Idle Gear/Split/Range test going through all gears. Obtain DDEC Reports, and contact Software
Support at the Detroit™ Customer Support Center at 855-253-0428 for further transmission assistance.
2
427.1 SPN 521002/FMI 14

DT12 Automatic Mode not Available
4. Are there any other active transmission related faults also present other than SPN 521002/FMI 14 or SPN
521001/FMI 14?
7.a Yes; complete the appropriate Symptom Diagnostic section.
8. Under instrumentation "transmission" tab, does the clutch and transmission learned values display "learned
values available"?
8.b No; under the Actions dropdown menu "Transmission Selection," perform the "Transmission Learn
Procedure."
engine idle Gear/Split/Range test going through all gears, obtain DDEC Reports, and contact the Detroit™
Customer Support Center at 855-253-0428 for further transmission assistance.
1
SPN 521002 (CPC3) (GHG17)
427.1 SPN 521002/FMI 14

DT12 Automatic Mode not Available
521001/FMI 14?
values available"?
Procedure."
engine idle Gear/Split/Range test going through all gears, obtain DDEC Reports, and contact the Detroit™
Customer Support Center at 855-253-0428 for further transmission assistance.
2
428.1 SPN 521003/FMI 14 - GHG17

This fault indicates the CPC3 has detected inconsistent ABS input signals and has disabled eCoast during this
condition.
1. Connect DiagnosticLink 8.0 or higher to all Powertrain and Chassis modules on the vehicle. Are there any
ABS speed sensor or communication faults present on any modules (active/inactive)?
1.b No; road test the vehicle. If fault does not become active, release the truck. If fault becomes active,
repeat step 1.
1
428.1 SPN 521003/FMI 14 - GHG17

condition.
repeat step 1.
2
SPN 521003 (CPC3) (GHG17)
428.1 SPN 521003/FMI 14 - GHG17

condition.
repeat step 1.
3
429.1 SPN 521004/FMI 14

This Fault Indicates CPC3 Has Detected an Incompatible or Missing Dataset
1. Connect DiagnosticLink® 8.07 SP2 or higher.
3. Under the "Identification" heading, "Common" tab, verify a shift map part number is present in the CPC3. Is
a shift map part number present?
3.a No; program the CPC3 to the latest server setting.
4. Under the "Identification" heading, "Common" tab, verify the correct transmission type is set under the TCM
heading, based on the metal identification plate on the lower left rear of the transmission. Is the
transmission type set correctly?
4.a No; under the "Actions" tab, "Transmission" heading, select "TCM replacement" and reset the
transmission type accordingly. After reset, perform a Transmission/Clutch Relearn.
5. Reprogram the CPC3/MCM/ACM/TCM to the latest server configuration.
1
429.1 SPN 521004/FMI 14

2
SPN 521004 (CPC3) (GHG17)
429.1 SPN 521004/FMI 14

3
430.1 SPN 521005/FMI 14 - GHG17

Check as follows:
1. Compare CPC3 parameters to OEM settings and adjust as necessary.
1
SPN 521005 (CPC3) (GHG17)
430.1 SPN 521005/FMI 14 - GHG17

Check as follows:
1. Compare CPC3 parameters to OEM settings and adjust as necessary.
2
431.1 SPN 521005/FMI 3 - GHG17

SPN 521005/FMI 3
Description Internal Power Supply Voltage Failed High
Monitored Parameter Internal Power Supply Voltage
Dash Lamps None
Check as follows:
WARNING
ENGINE EXHAUST
3.b No; this fault may have set due to a low MCM voltage while cranking or when the ignition has been left
on. No further diagnostics or repairs are necessary. Erase the fault code and release the vehicle.
1
431.2 SPN 521005/FMI 4 - GHG17

SPN 521005/FMI 4
Description Internal Power Supply Voltage Failed Low
Dash Lamps None
Check as follows:
WARNING
ENGINE EXHAUST
3. 3. Is fault code SPN 521005/FMI 4 active?
2
SPN 521005 (MCM) (GHG17)
431.1 SPN 521005/FMI 3 - GHG17

SPN 521005/FMI 3
Description Internal Power Supply Voltage Failed High
Dash Lamps None
Check as follows:
WARNING
ENGINE EXHAUST
3
431.2 SPN 521005/FMI 4 - GHG17

SPN 521005/FMI 4
Description Internal Power Supply Voltage Failed Low
Dash Lamps None
Check as follows:
WARNING
ENGINE EXHAUST
3. 3. Is fault code SPN 521005/FMI 4 active?
4
432.1 SPN 521006/FMI 14 - GHG17

Check as follows:
This fault indicates an internal failure of the DT12 shift stalk lever. Replace the shift stalk lever.
1
SPN 521006 (CPC3) (GHG17)
432.1 SPN 521006/FMI 14 - GHG17

Check as follows:
2
433.1 SPN 521007/FMI 14 - GHG17

1
SPN 521007 (CPC3) (GHG17)
433.1 SPN 521007/FMI 14 - GHG17

2
434.1 SPN 521008/FMI 14 - GHG17

This fault indicates the DT12 shift stalk lever is incorrectly configured. Reprogram CPC3 to OEM settings.
1
SPN 521008 (CPC3) (GHG17)
434.1 SPN 521008/FMI 14 - GHG17

This fault indicates the DT12 shift stalk lever is incorrectly configured. Reprogram CPC3 to OEM settings.
2
435.1 SPN 521012/FMI 1 - GHG17

Intake Deviation Low
SPN 521012/FMI 1
Description Intake Manifold Pressure Too Low
Monitored Parameter
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps MIL
Verification At operating temperature of 71°C (160°F). Drive at highway
minutes.
Check as follows:
1
1.a If the air intake system leaks or restrictions are found, repair as necessary. Verify repairs.
depending on the intake air temperature. Is the intake manifold pressure within the tolerance range of
barometric pressure indicated below?

-40°C to 10°C (-40°F to 50°F) +/- 8.6 kPa (1.25 psi)
10°C to 110°C (50°F to 230°F) +/- 5.6 kPa (0.81 psi)
110°C to 130°C (230°F to 266°F) +/- 8.6 kPa (1.25 psi)


6. Inspect intake manifold pressure/temperature sensor connector for bent, spread or corroded pins.
6.a If damage is found, repair the intake manifold pressure/temperature sensor connector as necessary.
Verify repairs.
6.b If no damage is found, replace the intake manifold pressure/temperature sensor. Refer to section "Removal
of the Intake Pressure/Temperature Sensor" .
2
SPN 521012 (MCM) (GHG17)
435.1 SPN 521012/FMI 1 - GHG17

Intake Deviation Low
SPN 521012/FMI 1
Description Intake Manifold Pressure Too Low
Monitored Parameter
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps MIL
Verification At operating temperature of 71°C (160°F). Drive at highway
minutes.
3
Check as follows:
1.a If the air intake system leaks or restrictions are found, repair as necessary. Verify repairs.
depending on the intake air temperature. Is the intake manifold pressure within the tolerance range of
barometric pressure indicated below?

-40°C to 10°C (-40°F to 50°F) +/- 8.6 kPa (1.25 psi)
10°C to 110°C (50°F to 230°F) +/- 5.6 kPa (0.81 psi)
110°C to 130°C (230°F to 266°F) +/- 8.6 kPa (1.25 psi)


6. Inspect intake manifold pressure/temperature sensor connector for bent, spread or corroded pins.
6.a If damage is found, repair the intake manifold pressure/temperature sensor connector as necessary.
Verify repairs.
6.b If no damage is found, replace the intake manifold pressure/temperature sensor. Refer to section "Removal
of the Intake Pressure/Temperature Sensor" .
4
436.1 SPN 521013/FMI 31 - GHG17

SPN 521013/FMI 31
Description Symmetric Injection Mode Expected
Monitored Parameter Injector Duration Ratio
Typical Enabling Conditions Injector Duration Ratio greater than 0.5
Monitor Sequence Engine Load greater than 20% and less than 100%, Engine
Speed Gradient less than or equal to 200 rpm
Execution Frequency Five Seconds, Two Times in one Drive Cycle
Typical Duration
Dash Lamps MIL
Verification

• SPN 651/FMI any
• SPN 652/FMI any
• SPN 653/FMI any
• SPN 654/FMI any
• SPN 655/FMI any
• SPN 656/FMI any
1.a Yes; troubleshoot that fault code first.
2. Disconnect both injector harness 14-pin connectors. Inspect the fuel injector harness 14-pin connector for
bent or spread pins; inspect the connector seal for damage (signs of water or oil intrusion). Was an issue
found?
2.a Yes; repair as needed. Clear fault and release to customer.
2.b No; clear fault and release to customer.
1
SPN 521013 (MCM) (GHG17)
436.1 SPN 521013/FMI 31 - GHG17

SPN 521013/FMI 31
Description Symmetric Injection Mode Expected
Monitored Parameter Injector Duration Ratio
Typical Enabling Conditions Injector Duration Ratio greater than 0.5
Monitor Sequence Engine Load greater than 20% and less than 100%, Engine
Speed Gradient less than or equal to 200 rpm
Execution Frequency Five Seconds, Two Times in one Drive Cycle
Typical Duration
Dash Lamps MIL
Verification

• SPN 651/FMI any
• SPN 652/FMI any
• SPN 653/FMI any
• SPN 654/FMI any
• SPN 655/FMI any
• SPN 656/FMI any
1.a Yes; troubleshoot that fault code first.
2. Disconnect both injector harness 14-pin connectors. Inspect the fuel injector harness 14-pin connector for
bent or spread pins; inspect the connector seal for damage (signs of water or oil intrusion). Was an issue
found?
2.a Yes; repair as needed. Clear fault and release to customer.
2.b No; clear fault and release to customer.
2
437.1 SPN 521014/FMI 19 - GHG17


2 LIN 3/47 LIN COM
Check as follows:
steps.
11.5 and 12 volts?
connector.
connector.
connector.
1
SPN 521014 (CPC3) (GHG17)
437.1 SPN 521014/FMI 19 - GHG17


2 LIN 3/47 LIN COM
Check as follows:
steps.
11.5 and 12 volts?
connector.
connector.
connector.
2
438.1 SPN 521015/FMI 12 - GHG17

This fault indicates and internal failure of the DT12 shift stalk lever. Replace the shift stalk lever.
1
SPN 521015 (CPC3) (GHG17)
438.1 SPN 521015/FMI 12 - GHG17

This fault indicates and internal failure of the DT12 shift stalk lever. Replace the shift stalk lever.
2
439.1 SPN 521018/FMI 0 - GHG17

Group 1 Sensors Not Plausible
SPN 521018/FMI 0
Description This Fault Code Sets when One or More Sensors from Group
2 and One or More Sensors from Group 3 are Not Within an
Expected Range After an 8 Hour Cold Soak.
Monitored Parameter
Fuel Temp
Engine Oil temp
Coolant In
Coolant Out
Compressor Inlet
Charge Air Cooler Outlet
Intake Temp
Ambient Air Temp
Typical Enabling Conditions Key ON, Engine OFF, Battery Voltage Greater than 11 Volts,
(104°F), Ignition Off for No Less than 8 Hours.
Execution Frequency Once Per Cold Cycle
Dash Lamps MIL
Oil Temperature is Within 20°C (36°F) of the Engine Coolant
Outlet Temperature.
Possible causes:
been changed?
4.b No; Update the MCM software using the latest server information. Perform the repair verification. If the
fault code returns, Go to step 5.
• SPN 100/FMI 3 or FMI 4
1

6. Monitor and record the following readings:
• engine oil temperature
• fuel temperature
• compressor inlet temperature
• intake air temperature
• coolant inlet temperature
• coolant outlet temperature
• charge air cooler outlet temperature
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

9. Monitor and record the following readings again:
10. Have the values increased from the recorded values in step 5?
11. Compare the sensor readings in the chart below. Are any of the sensors out of the allowable range?
2
Sensor Range Sensor

Oil temperature Coolant outlet temperature
Ambient Air Temperature Compressor inlet temperature
Compressor inlet temperature Ambient air temperature
Intake temperature Intercooler outlet temperature
Coolant inlet temp Coolant outlet temperature
Coolant outlet temp Coolant inlet temperature
CAC outlet temp Intercooler inlet temperature

11.b No; the fault code may have been set due to an external heating unit.
12. Disconnect and inspect the sensor electrical connector of the faulty sensors. Is there damage, corrosion or
fretting present?
12.b No; replace the sensors that are out of range. Verify repair.
3
SPN 521018 (MCM) (GHG17)
439.1 SPN 521018/FMI 0 - GHG17

SPN 521018/FMI 0
Description This Fault Code Sets when One or More Sensors from Group
2 and One or More Sensors from Group 3 are Not Within an
Expected Range After an 8 Hour Cold Soak.
Monitored Parameter
Fuel Temp
Engine Oil temp
Coolant In
Coolant Out
Compressor Inlet
Intake Temp
Ambient Air Temp
Typical Enabling Conditions Key ON, Engine OFF, Battery Voltage Greater than 11 Volts,
(104°F), Ignition Off for No Less than 8 Hours.
Execution Frequency Once Per Cold Cycle
Dash Lamps MIL
Oil Temperature is Within 20°C (36°F) of the Engine Coolant
Outlet Temperature.
Possible causes:
been changed?
4.b No; Update the MCM software using the latest server information. Perform the repair verification. If the
fault code returns, Go to step 5.
4

WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

5
Sensor Range Sensor

Oil temperature Coolant outlet temperature
Ambient Air Temperature Compressor inlet temperature
Compressor inlet temperature Ambient air temperature
Intake temperature Intercooler outlet temperature
Coolant inlet temp Coolant outlet temperature
Coolant outlet temp Coolant inlet temperature
CAC outlet temp Intercooler inlet temperature

fretting present?
6
440.1 SPN 521019/FMI 0 - GHG17

SPN 521019/FMI 0
Description This fault code sets when 2 or more sensors from group 2 are
not within an expected range after an 8 hour cold soak.
Monitored Parameter
Coolant In
Coolant Out
Intake Temp
Engine Oil Temp
(104°F), ignition off for no less than 8 hours.
Execution Frequency Once per cold cycle
Dash Lamps MIL
temperature.
Possible causes:
been changed?
1
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

Sensor Range Sensor

Coolant inlet temperature Coolant outlet temperature
Coolant outlet temp Coolant inlet temp
Oil temp Coolant outlet temp
Intake air temperature CAC outlet temp

fretting present?
2
SPN 521019 (MCM) (GHG17)
440.1 SPN 521019/FMI 0 - GHG17

SPN 521019/FMI 0
Monitored Parameter
Coolant In
Coolant Out
Intake Temp
Engine Oil Temp
Dash Lamps MIL
temperature.
Possible causes:
been changed?
3
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

Sensor Range Sensor

Coolant inlet temperature Coolant outlet temperature
Coolant outlet temp Coolant inlet temp
Oil temp Coolant outlet temp
Intake air temperature CAC outlet temp

fretting present?
4
441.1 SPN 521020/FMI 0 - GHG17

SPN 521020/FMI 0
Monitored Parameter
Fuel Temp
Compressor Inlet
Ambient Air Temp
Dash Lamps MIL
Engine Reaction 25% derate, regen disabled, EGR valve shut and SCR dosing
is disabled
temperature.
Possible causes:
been changed?

• Fuel temperature
• Compressor inlet temperature
• CAC outlet temperature
1
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

10. Compare the sensor readings in the chart below. Then, Go to step 11.
Sensor Range Sensor

Fuel temperature Compare to ambient temperature after
greater than 10°C (18°F) the fuel temp sensor has been removed
for 20 minutes.
Compressor inlet temp Ambient air temp
CAC outlet temp Intake air temp
Ambient air temperature Intercooler air temperature
fretting present?
2
SPN 521020 (MCM) (GHG17)
441.1 SPN 521020/FMI 0 - GHG17

SPN 521020/FMI 0
Monitored Parameter
Fuel Temp
Compressor Inlet
Ambient Air Temp
Dash Lamps MIL
Engine Reaction 25% derate, regen disabled, EGR valve shut and SCR dosing
is disabled
temperature.
Possible causes:
been changed?

3
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST

10. Compare the sensor readings in the chart below. Then, Go to step 11.
Sensor Range Sensor

Fuel temperature Compare to ambient temperature after
greater than 10°C (18°F) the fuel temp sensor has been removed
for 20 minutes.
Compressor inlet temp Ambient air temp
CAC outlet temp Intake air temp
Ambient air temperature Intercooler air temperature
fretting present?
4
SPN 521027 (MCM) (GHG17)
442.1 SPN 521027/FMI 9 - GHG17

EGR Valve Actuator No Longer Communicating On MCM CAN3
SPN 521027 /FMI 9

Description Lost Communication With Exhaust Gas Recirculation Control
Module, CAN Bus is Ok
Monitored Parameter EGR Valve Actuator
Dash Lamps MIL, CEL
Verification Turn the Ignition OFF, Wait Five Minutes, Turn the Ignition ON
and Recheck for the Fault.
Check as follows:
1. Check for low battery voltage fault codes. Are there any battery voltage fault codes present?
1

spread pins?
11. Disconnect and inspect the MCM 120-pin electrical connector components side. Are there any damaged or
corroded pins?
12. Inspect the MCM 120-pin electrical connector harness side. Are there any damaged, corroded, or spread
pins?
74 of the MCM 120-pin electrical connector harness side. Is the resistance less than five ohms?
harness side and pin 74 of the MCM 120-pin electrical connector harness side.
75 of the MCM 120-pin electrical connector harness side. Is the resistance less than five ohms?
harness side and pin 75 of the MCM 120-pin electrical connector harness side.
2
443.1 SPN 521039/FMI 16 - GHG17

EGR Controller Effort Exceeds Limits Low - High EGR flow
SPN 521039/FMI 16
Exhaust Gas Recirculation (EGR) flow and the commanded
EGR flow is higher than a calibrated threshold.
Typical Enabling Conditions Desired EGR Mass Flow Greater Than .08, EGR In Closed-
Loop Control, CAC Outlet Temperature Greater Than 0°C
(32°F), Engine Speed 1080 to 2500 rpm, Engine Torque 200
to 2500 N·M (148 to 1894 lb·ft), Coolant Temperature Greater
Than 65°C (149°F), Ambient Temperature Greater Than -8°C
(17.6°F) Ambient, Barometric Pressure Greater Than 755
mbar (11 psi).
Monitor Sequence none
Typical Duration 20
Dash Lamps MIL, CEL
than 65°C (149°F) ensure ambient temperature greater than -
8°C (17.6°F) ambient and ambient barometric pressure
greater than 755 mbar (11 psi). Desired EGR mass flow
greater than .08, EGR in closed-loop control, CAC outlet
temperature greater than 0°C (32°F), engine speed 1080 to
2500 rpm, engine torque 200 to 2500 N·m (148 to 1894 lb·ft)
Check as follows:
• SPN 411/FMI 2
• SPN 411/FMI 3
• SPN 411/FMI 4
• SPN 411/FMI 13
• SPN 1636/FMI 3
• SPN 1636/FMI 4
• SPN 1636/FMI 14
• SPN 2791/FMI 2
• SPN 2791/FMI 7
• SPN 2791/FMI 9
• SPN 2791/FMI 11
• SPN 2791/FMI 12
• SPN 2791/FMI 13
• SPN 2791/FMI 14
• SPN 2791/FMI 16
• SPN 2791/FMI 18
• SPN 2791/FMI 31
• SPN 3563/FMI 3
1
• SPN 3563/FMI 4
• SPN 3563/FMI 10
4. Check the Diesel Particulate Filter (DPF) Zone; is the DPF zone zero?
4.b No; perform a parked regeneration . Recheck for the fault code, if fault code SPN 521039 FMI 18
returns Go to step 5.
5. Monitor the EGR delta pressure voltage with the ignition ON (key ON, engine OFF). Is the voltage between
0.55 and 0.83 volts?
7. Disconnect and inspect the EGR delta pressure sensor electrical connector. Is there damage, corrosion or
fretting present?
7.a Yes; replace the delta pressure sensor and the pigtail.
8. Remove and inspect the EGR delta pressure sensor ports. Is there a restriction or contamination present?
8.a Yes; clean the delta pressure sensor and clean the ports in the venturi pipe.
9. Reconnect the EGR delta pressure sensor connector while the sensor is still removed from the venturi pipe.
11.b No; replace the delta pressure sensor.
pressure within 68.9 mbar (1 psi) of the barometric pressure for your area?
Intake Manifold Pressure sensor reading within 103.4 mbar (1.5 psi) of the barometric pressure reading?
16.b No; replace the intake manifold temperature sensor.
2
17. Remove the EGR delta pressure sensor and inspect the ports. Is there a restriction or contamination
present?
19.a Yes; replace the delta P sensor.
3
443.2 SPN 521039/FMI 18 - GHG17

EGR Controller Effort Exceeds Limits High - Low EGR flow
SPN 521039/FMI 18
EGR flow is lower than a calibrated threshold.
mbar (11 psi).
Typical Duration 20
Dash Lamps MIL, CEL
Check as follows:
• SPN 411/FMI 2
• SPN 411/FMI 3
• SPN 411/FMI 4
• SPN 411/FMI 13
• SPN 1636/FMI 3
• SPN 1636/FMI 4
• SPN 1636/FMI 14
• SPN 2791/FMI 2
• SPN 2791/FMI 7
• SPN 2791/FMI 9
• SPN 2791/FMI 11
• SPN 2791/FMI 12
• SPN 2791/FMI 13
• SPN 2791/FMI 14
• SPN 2791/FMI 16
• SPN 2791/FMI 18
• SPN 2791/FMI 31
• SPN 3563/FMI 3
4
• SPN 3563/FMI 4
• SPN 3563/FMI 10
4.b No; perform a parked regeneration. Recheck for the fault code, if fault code SPN 521039/FMI 18
WARNING
ELECTRICAL SHOCK
usage.
fretting present?
present?
5
WARNING
ELECTRICAL SHOCK
usage.
14.a Yes repair as necessary.

WARNING
ELECTRICAL SHOCK
usage.

present?
WARNING
ELECTRICAL SHOCK
usage.

18.b No; replace the delta P sensor.
6
SPN 521039 (MCM) (GHG17)
443.1 SPN 521039/FMI 16 - GHG17

EGR Controller Effort Exceeds Limits Low - High EGR flow
SPN 521039/FMI 16
EGR flow is higher than a calibrated threshold.
mbar (11 psi).
Typical Duration 20
Dash Lamps MIL, CEL
Check as follows:
• SPN 411/FMI 2
• SPN 411/FMI 3
• SPN 411/FMI 4
• SPN 411/FMI 13
• SPN 1636/FMI 3
• SPN 1636/FMI 4
• SPN 1636/FMI 14
• SPN 2791/FMI 2
• SPN 2791/FMI 7
• SPN 2791/FMI 9
• SPN 2791/FMI 11
• SPN 2791/FMI 12
• SPN 2791/FMI 13
• SPN 2791/FMI 14
• SPN 2791/FMI 16
7
• SPN 2791/FMI 18
• SPN 2791/FMI 31
• SPN 3563/FMI 3
• SPN 3563/FMI 4
• SPN 3563/FMI 10
4.b No; perform a parked regeneration . Recheck for the fault code, if fault code SPN 521039 FMI 18
fretting present?
8. Remove and inspect the EGR delta pressure sensor ports. Is there a restriction or contamination present?
8
present?
19.a Yes; replace the delta P sensor.
9
443.2 SPN 521039/FMI 18 - GHG17

EGR Controller Effort Exceeds Limits High - Low EGR flow
SPN 521039/FMI 18
EGR flow is lower than a calibrated threshold.
mbar (11 psi).
Typical Duration 20
Dash Lamps MIL, CEL
Check as follows:
• SPN 411/FMI 2
• SPN 411/FMI 3
• SPN 411/FMI 4
• SPN 411/FMI 13
• SPN 1636/FMI 3
• SPN 1636/FMI 4
• SPN 1636/FMI 14
• SPN 2791/FMI 2
• SPN 2791/FMI 7
• SPN 2791/FMI 9
• SPN 2791/FMI 11
• SPN 2791/FMI 12
• SPN 2791/FMI 13
• SPN 2791/FMI 14
• SPN 2791/FMI 16
• SPN 2791/FMI 18
• SPN 2791/FMI 31
• SPN 3563/FMI 3
10
• SPN 3563/FMI 4
• SPN 3563/FMI 10
4.b No; perform a parked regeneration. Recheck for the fault code, if fault code SPN 521039/FMI 18
WARNING
ELECTRICAL SHOCK
usage.
fretting present?
present?
11
WARNING
ELECTRICAL SHOCK
usage.
14.a Yes repair as necessary.

WARNING
ELECTRICAL SHOCK
usage.

present?
WARNING
ELECTRICAL SHOCK
usage.

18.b No; replace the delta P sensor.
12
444.1 SPN 521049/FMI 31 - GHG17

SPN 521049/FMI 31
Description This Code Sets When There is a Code Present for the Diesel
Exhaust Fluid (DEF) Tank Level, DEF Dosing Unit, DEF
Pump, NOx Sensors, Blocked DEF Line, DEF Quality, NOx
Efficiency, Selective Catalyst Reduction (SCR) Harness
and/or SCR Sensor.
Monitored Parameter SCR and Diesel Particulate Filter (DPF) Sensors
Dash Lamps DEF Lamp
Verification High Idle Regeneration followed by a Parked SCR Efficiency
Test
Check as follows:
1. Connect DiagnosticLink
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
3. Check for other emission-related fault codes. Are there any Selective Catalyst Reduction (SCR) or Diesel
Particulate Filter (DPF) related fault codes present?
1
3.a Yes; diagnose and repair the emission-related fault codes first. Verify repair.
3.b No; perform a high idle regeneration. When the engine returns to idle, turn the ignition OFF and wait for
all the modules to power down (usually about one minute). Turn the ignition ON (key ON, engine OFF)
and wait one minute, then start the engine and run a Parked SCR efficiency test. Use DiagnosticLink to
clear the code.
2
SPN 521049 (MCM) (GHG17)
444.1 SPN 521049/FMI 31 - GHG17

SPN 521049/FMI 31
Description This Code Sets When There is a Code Present for the Diesel
Exhaust Fluid (DEF) Tank Level, DEF Dosing Unit, DEF
Pump, NOx Sensors, Blocked DEF Line, DEF Quality, NOx
Efficiency, Selective Catalyst Reduction (SCR) Harness
and/or SCR Sensor.
Dash Lamps DEF Lamp
Test
Check as follows:
1. Connect DiagnosticLink
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3
WARNING
HOT EXHAUST
clear the code.
4
445.1 SPN 521050/FMI 14 - GHG17

Check as follows:
1. Disconnect DiagnosticLink from the 9-pin connector. If tool is connected, the fault will not clear. Turn
the ignition OFF; wait until ICUC display goes blank (this ensures all modules have gone offline and may
take a few minutes).
2. Turn ignition ON (key ON, engine OFF). Wait one minute and then connect DiagnosticLink. Verify fault is no
longer active.
1
SPN 521050 (CPC3) (GHG17)
445.1 SPN 521050/FMI 14 - GHG17

Check as follows:
1. Disconnect DiagnosticLink from the 9-pin connector. If tool is connected, the fault will not clear. Turn
the ignition OFF; wait until ICUC display goes blank (this ensures all modules have gone offline and may
2. Turn ignition ON (key ON, engine OFF). Wait one minute and then connect DiagnosticLink. Verify fault is no
longer active.
2
446.1 SPN 521050/FMI 31 - GHG17

SPN 521050/FMI 31
Description This Code Sets After SPN 521049/FMI 31 is Present and the
Speed Limit has Been Reduced to 55 mph.
Dash Lamps SEL Lamp
Engine Reaction 40% Derate, Vehicle Speed Limited to Five mph
Test
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
1
and wait one minutes, then start the engine and run a Parked SCR efficiency test. Use DiagnosticLink
to clear the code.
2
SPN 521050 (MCM) (GHG17)
446.1 SPN 521050/FMI 31 - GHG17

SPN 521050/FMI 31
Description This Code Sets After SPN 521049/FMI 31 is Present and the
Speed Limit has Been Reduced to 55 mph.
Dash Lamps SEL Lamp
Engine Reaction 40% Derate, Vehicle Speed Limited to Five mph
Test
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
3
and wait one minutes, then start the engine and run a Parked SCR efficiency test. Use DiagnosticLink
to clear the code.
4
447.1 SPN 521052/FMI 31 - GHG17

SPN 521052/FMI 31
Description This Code Sets When SPN 521050/FMI 31 has Been Present
for One Hour of Idle Time, the Vehicle has Been Restarted or
Six Gallons of Fuel has Been Used.
Dash Lamps CEL Lamp
Engine Reaction 55 mph Speed Limit, Progressive Derate From 25% to 40%
Test
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
1
clear the code.
2
SPN 521052 (MCM) (GHG17)
447.1 SPN 521052/FMI 31 - GHG17

SPN 521052/FMI 31
Description This Code Sets When SPN 521050/FMI 31 has Been Present
for One Hour of Idle Time, the Vehicle has Been Restarted or
Six Gallons of Fuel has Been Used.
Dash Lamps CEL Lamp
Engine Reaction 55 mph Speed Limit, Progressive Derate From 25% to 40%
Test
Check as follows:
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
WARNING
HOT EXHAUST
3
clear the code.
4
448.1 SPN 521054/FMI 14 - GHG17

Check as follows:
1. Disconnect DiagnosticLink from the 9-pin connector (if tool is connected, fault will not clear) . Turn the
ignition OFF and wait until ICUC display goes blank (this ensures all modules have gone offline and may
2. Turn ignition ON (key ON, engine OFF), wait one minute, and then connect DiagnosticLink. Verify fault is
no longer active.
4. If fault is active after above steps, reprogram MCM to latest settings.
1
SPN 521054 (CPC3) (GHG17)
448.1 SPN 521054/FMI 14 - GHG17

Check as follows:
1. Disconnect DiagnosticLink from the 9-pin connector (if tool is connected, fault will not clear) . Turn the
ignition OFF and wait until ICUC display goes blank (this ensures all modules have gone offline and may
2. Turn ignition ON (key ON, engine OFF), wait one minute, and then connect DiagnosticLink. Verify fault is
no longer active.
4. If fault is active after above steps, reprogram MCM to latest settings.
2
449.1 SPN 521058/FMI 13 - GHG17

SPN 521058/FMI 13
Description This fault code sets when the vehicle speed is not transmitted
from the CPC to the MCM.
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are any of the following fault codes present in the CPC?
• SPN 84/FMI 3
• SPN 84/FMI 4
• SPN 84/FMI 5
• SPN 84/FMI 9
• SPN 84/FMI 10
• SPN 84/FMI 11
• SPN 84/FMI 13
• SPN 84/FMI 14
• SPN 84/FMI 19
• SPN 84/FMI 20
• SPN 84/FMI 21
• SPN 625/FMI 9
4. Verify the VSS parameters are configured correctly for the vehicle application.
5. Install a test CPC. Does fault code SPN 521058/FMI 13 become active?
1
449.2 SPN 521058/FMI 14 - GHG17

Check as follows:
1. Compare the below CPC3 parameters to OEM settings and adjust as necessary.
• Grp 227 Single (1) or Dual (2) Wheel on Drive Axle
• Grp 50 PTO Mode Governor Type
• Grp 233 Rear Axle Ratio
• Grp 228 Engine Torque/Power Selection
2
SPN 521058 (MCM) (GHG17)
449.1 SPN 521058/FMI 13 - GHG17

SPN 521058/FMI 13
Description This fault code sets when the vehicle speed is not transmitted
from the CPC to the MCM.
Dash Lamps MIL
Check as follows:
3. Check for multiple fault codes. Are any of the following fault codes present in the CPC?
• SPN 84/FMI 3
• SPN 84/FMI 4
• SPN 84/FMI 5
• SPN 84/FMI 9
• SPN 84/FMI 10
• SPN 84/FMI 11
• SPN 84/FMI 13
• SPN 84/FMI 14
• SPN 84/FMI 19
• SPN 84/FMI 20
• SPN 84/FMI 21
• SPN 625/FMI 9
4. Verify the VSS parameters are configured correctly for the vehicle application.
5. Install a test CPC. Does fault code SPN 521058/FMI 13 become active?
3
449.2 SPN 521058/FMI 14 - GHG17

Check as follows:
1. Compare the below CPC3 parameters to OEM settings and adjust as necessary.
• Grp 227 Single (1) or Dual (2) Wheel on Drive Axle
• Grp 50 PTO Mode Governor Type
• Grp 233 Rear Axle Ratio
• Grp 228 Engine Torque/Power Selection
4
SPN 522204 (CPC3) (GHG17)
450.1 SPN 522204/FMI 14 - GHG17

Check as follows:
1. Reprogram CPC3 to latest software level. Does the fault go inactive?
1.b No; replace CPC3 and then reprogram to latest software level.
1
451.1 SPN 522222/FMI 2 - GHG17

CPC Internal - EEPROM Checksum Error
This fault indicates the CPC3evo has detected an internal EEPROM checksum error. This fault generally occurs
after a programming event. Using DiagnosticLink 8.08 or higher reprogram the CPC3evo module to latest
settings.
1
451.2 SPN 522222/FMI 13 - GHG17

Check as follows:
1. This fault indicates the CPC3evo has detected an internal EEPROM Data verification. This fault generally
occurs after a programming event. Using DiagnosticLink® 8.08 or higher reprogram the CPC3evo module
to latest settings.
2
SPN 522222 (CPC3) (GHG17)
451.1 SPN 522222/FMI 2 - GHG17

CPC Internal - EEPROM Checksum Error
This fault indicates the CPC3evo has detected an internal EEPROM checksum error. This fault generally occurs
after a programming event. Using DiagnosticLink 8.08 or higher reprogram the CPC3evo module to latest
settings.
3
451.2 SPN 522222/FMI 13 - GHG17

Check as follows:
1. This fault indicates the CPC3evo has detected an internal EEPROM Data verification. This fault generally
occurs after a programming event. Using DiagnosticLink® 8.08 or higher reprogram the CPC3evo module
to latest settings.
4
452.1 SPN 523597/FMI 3 - GHG17

Shift Stalk Pin 3-34 Short to Battery
Check as follows:
1. Disconnect right shift stalk connector.
2. Inspect harness connector for bent, spread, or corroded pins. Is pin damage present?
2.a Yes; repair harness between shift stalk and CPC3 connector #3.
2.b No; repair short to battery power between right shift stalk connector and pin 34 of the CPC3 connector
#3. Refer to Original Equipment Manufacturer (OEM) wiring schematics for harness layout.
1
452.2 SPN 523597/FMI 4 - GHG17

Shift Stalk Pin 3-34 Short to Ground
Check as follows:
2.b No, repair short to ground between right shift stalk connector and pin 34 of the CPC3 connector #3.
2
SPN 523597 (CPC3) (GHG17)
452.1 SPN 523597/FMI 3 - GHG17

Shift Stalk Pin 3-34 Short to Battery
Check as follows:
2.b No; repair short to battery power between right shift stalk connector and pin 34 of the CPC3 connector
#3. Refer to Original Equipment Manufacturer (OEM) wiring schematics for harness layout.
3
452.2 SPN 523597/FMI 4 - GHG17

Shift Stalk Pin 3-34 Short to Ground
Check as follows:
2.b No, repair short to ground between right shift stalk connector and pin 34 of the CPC3 connector #3.
4
453.1 SPN 524200/FMI 3 - GHG17

This fault indicates there is an internal error failure in the CPC3. Replace the CPC3. After replacement, reprogram
the module to latest server configuration.
1
SPN 524200 (CPC3) (GHG17)
453.1 SPN 524200/FMI 3 - GHG17

This fault indicates there is an internal error failure in the CPC3. Replace the CPC3. After replacement, reprogram
the module to latest server configuration.
2
454.1 SPN 524204/FMI 5 - GHG17

CPC3 Ground Circuit Pin 5/6 Open
Check as follows:
2.b No; restore ground connection to pin 6 of connector #5. Refer to EZ Wiring module 283 for harness
layout.
1
SPN 524204 (CPC3) (GHG17)
454.1 SPN 524204/FMI 5 - GHG17

Check as follows:
2.b No; restore ground connection to pin 6 of connector #5. Refer to EZ Wiring module 283 for harness
layout.
2
455.1 SPN 524205/FMI 14 - GHG17

This fault indicates there is an internal PMC error failure in the CPC3. Replace the CPC3. After replacement,
reprogram the module to latest server configuration.
1
SPN 524205 (CPC3) (GHG17)
455.1 SPN 524205/FMI 14 - GHG17

This fault indicates there is an internal PMC error failure in the CPC3. Replace the CPC3. After replacement,
reprogram the module to latest server configuration.
2
456.1 SPN 524206/FMI 5 - GHG17

Check as follows:
2.b No; restore ground connection to pin 8 of connector #5. Refer to Original Equipment Manufacturer
(OEM) wiring schematics for harness layout.
1
456.2 SPN 524206/FMI 12 - GHG17

This fault indicates internal temperature error failure in the CPC3. Replace the CPC3. After replacement,
reprogram the module to the latest server configuration.
2
SPN 524206 (CPC3) (GHG17)
456.1 SPN 524206/FMI 5 - GHG17

Check as follows:
2.b No; restore ground connection to pin 8 of connector #5. Refer to Original Equipment Manufacturer
(OEM) wiring schematics for harness layout.
3
456.2 SPN 524206/FMI 12 - GHG17

This fault indicates internal temperature error failure in the CPC3. Replace the CPC3. After replacement,
reprogram the module to the latest server configuration.
4
457.1 SPN 524207/FMI 12 - GHG17

Check as follows:
steps.
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
6.a Yes; repair the short to power between pin A of the AP harness connector and pin 3 of the CPC3
any damage present?
1

Verify repair.
than 10K ohms?
connector #2.
12. Measure the resistance between pin A of the AP harness connector and pin 3 of the CPC3 connector #2. Is
12.b No; repair the circuit between pin A of the AP harness connector and pin 3 of the CPC3 connector#2.
Verify repair.
than 10K ohms?
13.b No; repair the shorted circuit between pin A of the AP harness connector and pin 3 of the CPC3
connector #2.
2
SPN 524207 (CPC3) (GHG17)
457.1 SPN 524207/FMI 12 - GHG17

Check as follows:
steps.
damage found?

Harness
Connector
Body
APS1 2/3 A SENSOR 1
above is
the front
side
looking
into the
pins on the
Harness
Connector.
Connector
and Seal
(P/N:
12066317)
Terminal
Female
(P/N:
12103881)
6.a Yes; repair the short to power between pin A of the AP harness connector and pin 3 of the CPC3
any damage present?
3

Verify repair.
than 10K ohms?
connector #2.
12. Measure the resistance between pin A of the AP harness connector and pin 3 of the CPC3 connector #2. Is
12.b No; repair the circuit between pin A of the AP harness connector and pin 3 of the CPC3 connector#2.
Verify repair.
than 10K ohms?
13.b No; repair the shorted circuit between pin A of the AP harness connector and pin 3 of the CPC3
connector #2.
4
SPN 524208 (CPC3) (GHG17)
458.1 SPN 524208/FMI 14 - GHG17

Accelerator Pedal - Idle Position Not Detected
This is an information-only fault code; a silent fault code that displays a message in the instrument cluster
indicating that the accelerator pedal was pressed at the time of engine start. No action is required: this is
information only.
1
459.1 SPN 524213/FMI 14 - GHG17

This is an information-only fault which means the transmission has been placed in dyno mode. Connect
DiagnosticLink® 8.04 SP2, or higher, and under the Actions/Transmission tab, deactivate dyno mode.
1
SPN 524213 (CPC3) (GHG17)
459.1 SPN 524213/FMI 14 - GHG17

This is an information-only fault which means the transmission has been placed in dyno mode. Connect
DiagnosticLink® 8.04 SP2, or higher, and under the Actions/Transmission tab, deactivate dyno mode.
2
460.1 SPN 524275/FMI 19 - GHG17

RCM Message Not Received or Stopped Arriving
SPN 524275/FMI 19
Description Retarder Control Module (RCM) messages are missing
Monitored Parameter CPC 001/091 RCM Diagnosis Source Address
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps
Verification CPC 001/091 should not be configured.
Check as follows:
Controller (CPC) parameter set is wrong.
configuration?
1
SPN 524275 (CPC) (GHG17)
460.1 SPN 524275/FMI 19 - GHG17

RCM Message Not Received or Stopped Arriving
SPN 524275/FMI 19
Description Retarder Control Module (RCM) messages are missing
Monitored Parameter CPC 001/091 RCM Diagnosis Source Address
Monitor Sequence
Execution Frequency
Typical Duration
Dash Lamps
Verification CPC 001/091 should not be configured.
Check as follows:
Controller (CPC) parameter set is wrong.
configuration?
2
461.1 SPN 524276/FMI 13 - GHG17

SPN 524276/FMI 13
Description Common Powertrain Controller (CPC) Configuration
Mismatched
Monitored Parameter CPC PGR002/024 GVC Emission Standard Conf
Dash Lamps CEL
configuration?
2.b No; reprogram the CPC with the correct the information as necessary. To verify repair, Go to step 3.
1
SPN 524276 (CPC) (GHG17)
461.1 SPN 524276/FMI 13 - GHG17

SPN 524276/FMI 13
Description Common Powertrain Controller (CPC) Configuration
Mismatched
Monitored Parameter CPC PGR002/024 GVC Emission Standard Conf
Dash Lamps CEL
configuration?
2.b No; reprogram the CPC with the correct the information as necessary. To verify repair, Go to step 3.
2
462.1 SPN 524277/FMI 13 - GHG17

SPN 524277/FMI 13
Description This Code is not Configured for NAFTA Applications; if this
Code is Active, CPC Configuration is Incorrect
Monitored Parameter CPC PGR042
Execution Frequency Nonet
Dash Lamps CEL
1
462.2 SPN 524277/FMI 14 - GHG17

SPN 524277/FMI 14
Dash Lamps CEL
2
462.3 SPN 524277/FMI 19 - GHG17

SPN 524277/FMI 19
Description This Code is not Configured for NAFTA Applications; if This
Dash Lamps CEL
3
SPN 524277 (CPC) (GHG17)
462.1 SPN 524277/FMI 13 - GHG17

SPN 524277/FMI 13
Execution Frequency Nonet
Dash Lamps CEL
4
462.2 SPN 524277/FMI 14 - GHG17

SPN 524277/FMI 14
Dash Lamps CEL
5
462.3 SPN 524277/FMI 19 - GHG17

SPN 524277/FMI 19
Description This Code is not Configured for NAFTA Applications; if This
Dash Lamps CEL
6
463.1 SPN 524278/FMI 13 - GHG17

SPN 524278/FMI 13
Description Accelerator Pedal Signal Missing
Monitored Parameter Accelerator Pedal
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
1
463.2 SPN 524278/FMI 14 - GHG17

SPN 524278/FMI 14
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
2
463.3 SPN 524278/FMI 15 - GHG17

SPN 524278/FMI 15
Description Accelerator Pedal Signal Error
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
3
SPN 524278 (CPC) (GHG17)
463.1 SPN 524278/FMI 13 - GHG17

SPN 524278/FMI 13
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
4
463.2 SPN 524278/FMI 14 - GHG17

SPN 524278/FMI 14
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
5
463.3 SPN 524278/FMI 15 - GHG17

SPN 524278/FMI 15
Description Accelerator Pedal Signal Error
Dash Lamps CEL
WARNING
ENGINE EXHAUST
Check as follows:
configuration?
6
464.1 SPN 524279/FMI 2 - GHG17

SPN 524279/FMI 2
Description This Code is not Configured for NAFTA Applications. If This
Code is Active, Common Powertrain Controller (CPC)
Configuration is Incorrect
Dash Lamps CEL
Check as follows:
1
464.2 SPN 524279/FMI 3 - GHG17

SPN 524279/FMI 3
Description This Code is Not Configured for NAFTA Applications; If this
Dash Lamps CEL
Check as follows:
configuration?
2
464.3 SPN 524279/FMI 4 - GHG17

SPN 524279/FMI 4
Description This Code is not Configured For NAFTA Applications. If This
Dash Lamps CEL
Check as follows:
configuration?
3
464.4 SPN 524279/FMI 11 - GHG17

SPN 524279/FMI 11
Description This Code is not Configured for NAFTA Applications. If this
Dash Lamps CEL
Check as follows:
configuration?
4
464.5 SPN 524279/FMI 18 - GHG17

SPN 524279/FMI 18
Dash Lamps CEL
Check as follows:
configuration?
5
SPN 524279 (CPC) (GHG17)
464.1 SPN 524279/FMI 2 - GHG17

SPN 524279/FMI 2
Description This Code is not Configured for NAFTA Applications. If This
Dash Lamps CEL
Check as follows:
6
464.2 SPN 524279/FMI 3 - GHG17

SPN 524279/FMI 3
Description This Code is Not Configured for NAFTA Applications; If this
Dash Lamps CEL
Check as follows:
configuration?
7
464.3 SPN 524279/FMI 4 - GHG17

SPN 524279/FMI 4
Description This Code is not Configured For NAFTA Applications. If This
Dash Lamps CEL
Check as follows:
configuration?
8
464.4 SPN 524279/FMI 11 - GHG17

SPN 524279/FMI 11
Dash Lamps CEL
Check as follows:
configuration?
9
464.5 SPN 524279/FMI 18 - GHG17

SPN 524279/FMI 18
Dash Lamps CEL
Check as follows:
configuration?
10
465.1 SPN 524280/FMI 2 - GHG17

SPN 524280/FMI 2
Description Idle Validation Switch Inputs Reversed
Monitored Parameter Idle Validation Switch Input
Dash Lamps MIL
Verification Ignition Key Cycled On
1. Verify that the vehicle is equipped with an Idle Validation Switch. Is the vehicle equipped with a remote
accelerator pedal?
2. Has the Common Powertrain Controller (CPC) been reprogrammed recently?
2.a Yes; verify the configuration of the CPC against the server information or the Application and
Installation Manual. Correct the information as necessary. Verify repair.
3. Reprogram the CPC using the information from the server. Is SPN 524280/FMI 2 still present?
1

4. Disconnect the Idle Validation Switch. Go to step 5.
5. Is SPN 524280/FMI 2 still present?
5.b No; refer to OEM procedures to diagnose either a short in the Idle Validation Switch or incorrect wiring.
6. Reprogram the CPC. Is SPN 524280/FMI 2 still present?
2
465.2 SPN 524280/FMI 3 - GHG17

SPN 524280/FMI 3
Description Idle Validation Switch 1 Open Circuit
Monitored Parameter VCC1
Dash Lamps MIL
accelerator pedal?
3

4. Measure the resistance between pin 8 of the CPC connector #1 and the Idle Validation Switch. Is the
4.a Yes; refer to OEM procedures to diagnose the open in the Idle Validation Switch.
4.b No; repair the open between pin 8 of the CPC connector #1 and the Idle Validation Switch.
4
465.3 SPN 524280/FMI 4 - GHG17

SPN 524280/FMI 4
Description Idle Validation Switch 1 Short to Ground
Dash Lamps MIL
accelerator pedal?
5

4. Measure the resistance between the Idle Validation Switch VCC1 connector (harness side) and ground. Is
4.a Yes; repair the short to ground between Idle Validation Switch VCC1 connector (harness side) and
ground.
4.b No; refer to OEM procedures to diagnose a short in the Idle Validation Switch.
6
465.4 SPN 524280/FMI 5 - GHG17

SPN 524280/FMI 5
Dash Lamps MIL
accelerator pedal?
7

ground.
8
465.5 SPN 524280/FMI 6 - GHG17

SPN 524280/FMI 6
Dash Lamps MIL
accelerator pedal?
9

10
SPN 524280 (CPC) (GHG17)
465.1 SPN 524280/FMI 2 - GHG17

SPN 524280/FMI 2
Description Idle Validation Switch Inputs Reversed
Monitored Parameter Idle Validation Switch Input
Dash Lamps MIL
accelerator pedal?
11
4. Disconnect the Idle Validation Switch. Go to step 5.
5. Is SPN 524280/FMI 2 still present?
5.b No; refer to OEM procedures to diagnose either a short in the Idle Validation Switch or incorrect wiring.
6. Reprogram the CPC. Is SPN 524280/FMI 2 still present?
12
465.2 SPN 524280/FMI 3 - GHG17

SPN 524280/FMI 3
Dash Lamps MIL
accelerator pedal?
13

14
465.3 SPN 524280/FMI 4 - GHG17

SPN 524280/FMI 4
Dash Lamps MIL
accelerator pedal?
15

ground.
16
465.4 SPN 524280/FMI 5 - GHG17

SPN 524280/FMI 5
Dash Lamps MIL
accelerator pedal?
17

ground.
18
465.5 SPN 524280/FMI 6 - GHG17

SPN 524280/FMI 6
Dash Lamps MIL
accelerator pedal?
19

20
466.1 SPN 524283/FMI 2 - GHG17

Check as follows:
parameter settings.
1
466.2 SPN 524283/FMI 14 - GHG17

Check as follows:
parameter settings.
configuration?
4.a Yes; replace the Common Powertrain Controller (CPC). Refer to Original Equipment Manufacturer
(OEM) literature.
2
SPN 524283 (CPC) (GHG17)
466.1 SPN 524283/FMI 2 - GHG17

Check as follows:
parameter settings.
3
466.2 SPN 524283/FMI 14 - GHG17

Check as follows:
parameter settings.
configuration?
4.a Yes; replace the Common Powertrain Controller (CPC). Refer to Original Equipment Manufacturer
(OEM) literature.
4
467.1 SPN 524284/FMI 14 - GHG17

SPN 524284/FMI 14
Description Powertrain Monitor Control (PMC) is a Safety Feature that
Protects the Truck. In this Case PMC Plausibility Calculation
Detected a Mismatch and PMC Has Turned Off
Monitored Parameter Powertrain Monitor Control
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
configuration?
1
467.2 SPN 524284/FMI 19 - GHG17

SPN 524284/FMI 19
Protects the Truck. In this Case an Implausible Signal was
Received Via PT-CAN From MCM2 or TCM
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
2
SPN 524284 (CPC) (GHG17)
467.1 SPN 524284/FMI 14 - GHG17

SPN 524284/FMI 14
Protects the Truck. In this Case PMC Plausibility Calculation
Detected a Mismatch and PMC Has Turned Off
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
configuration?
3
4
467.2 SPN 524284/FMI 19 - GHG17

SPN 524284/FMI 19
Protects the Truck. In this Case an Implausible Signal was
Received Via PT-CAN From MCM2 or TCM
Dash Lamps CEL
Verification Idle
WARNING
PERSONAL INJURY
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
5
468.1 SPN 524285/FMI 4 - GHG17

SPN 524285/FMI 4
Description J1939 DPF Regeneration Switch Failed Low
Monitored Parameter DPF Regeneration Switch
Dash Lamps CEL
code present?
configuration?
3.a Yes; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature. Go to step 4.
power down. Did the code return?
1
SPN 524285 (CPC) (GHG17)
468.1 SPN 524285/FMI 4 - GHG17

SPN 524285/FMI 4
Description J1939 DPF Regeneration Switch Failed Low
Monitored Parameter DPF Regeneration Switch
Dash Lamps CEL
code present?
configuration?
3.a Yes; replace the CPC. Refer to Original Equipment Manufacturer (OEM) literature. Go to step 4.
power down. Did the code return?
2
469.1 SPN 524286/FMI 1 - GHG17

Automatic Gear Selection - Automatic Mode Not Available
Check as follows:
3. Are there any other active transmission-related faults also present, other than SPN 524286/FMI 4 or SPN
524286/FMI 1?
5. Under instrumentation “transmission" tab, verify the clutch and transmission learned values display “learned
values available.”
5.a If learned values display “no learned values available” under the Actions dropdown menu
"Transmission Selection," perform the “Transmission Learn Procedure.”
5.b If learned values display correctly, Go to step 6.
6. In DiagnosticLink®, ensure auto-connect to J1708 and J1939 devices is enabled. Obtain a two-minute key
ON, engine OFF log file and contact the Detroit™ Customer Support Center at 855-253-0428 for further
transmission assistance.
1
469.2 SPN 524286/FMI 2

This fault indicates CPC4 has detected an incompatible or missing dataset.
1. Connect DiagnosticLink 8 8.05 SP2 or higher.
2. Turn ignition ON.
3. Under the "Identification" heading "Common" tab, verify a shift map part number is present in the CPC. Is a
shift map part number present?
3.b No; program CPC to latest server setting.
4. Under the "Identification" heading "Common" tab, verify the correct transmission type is set under the TCM
heading, based off of the metal identification plate on the lower left rear of the transmission. Is the
4.b No; under the "Actions" tab, "Transmission Heading," select "TCM replacement" and reset the
transmission type accordingly. After reset, perform a "Transmission/Clutch Relearn."
5. Reprogram the CPC/MCM/ACM/TCM to latest server configuration.
2
469.3 SPN 524286/FMI 4 - GHG17

Automatic Gear Selection: Gear Shift Not Plausible
Check as follows:
1. Has the vehicle’s Transmission Control Module (TCM), Aftertreatment Control Module (ACM), Motor
524286/FMI 1?
values available"?
Procedure."
9. In DiagnosticLink, ensure auto-connect to J1708 and J1939 devices is enabled. If the unit can be driven
obtain a driving log file, if the unit cannot be driven complete an engine idle Gear/Split/Range test going
through all gears, obtain DDEC Reports, and contact the Detroit™ Customer Support Center at 855-253-
0428 for further transmission assistance.
3
469.4 SPN 524286/FMI 6 - GHG17

Check as follows:
This fault indicates CPC is incorrectly parameterized. Reprogram the CPC with the latest server configuration.
4
469.5 SPN 524286/FMI 7 - GHG17

This fault indicates the Common Powertrain Controller (CPC) has detected inconsistent driveline speed inputs
based on current parameter setting. Usually, the tire size and/or axle ratio is incorrectly set.
1. Did fault occur after a recent CPC reprogramming?
1.a Yes; reset CPC to original configuration.
2. Did fault occur after ABS brake module replacement or update?
2.a Yes; refer to module manufacturer for programming set up.
3. Connect DiagnosticLink and extract CPC parameters in group PGR008 Vehicle Speed Sensor.
Verify/program axle ratio per component installed on truck. Verify or program tire revolution (revs) for front
and rear tires to components currently installed on vehicle. Tire revolutions per mile can be obtained from
tire manufacturers' website.
5
SPN 524286 (CPC) (GHG17)
469.1 SPN 524286/FMI 1 - GHG17

Automatic Gear Selection - Automatic Mode Not Available
Check as follows:
3. Are there any other active transmission-related faults also present, other than SPN 524286/FMI 4 or SPN
524286/FMI 1?
5. Under instrumentation “transmission" tab, verify the clutch and transmission learned values display “learned
values available.”
5.a If learned values display “no learned values available” under the Actions dropdown menu
"Transmission Selection," perform the “Transmission Learn Procedure.”
6. In DiagnosticLink®, ensure auto-connect to J1708 and J1939 devices is enabled. Obtain a two-minute key
ON, engine OFF log file and contact the Detroit™ Customer Support Center at 855-253-0428 for further
transmission assistance.
6
469.2 SPN 524286/FMI 2

This fault indicates CPC4 has detected an incompatible or missing dataset.
1. Connect DiagnosticLink 8 8.05 SP2 or higher.
2. Turn ignition ON.
3. Under the "Identification" heading "Common" tab, verify a shift map part number is present in the CPC. Is a
shift map part number present?
3.b No; program CPC to latest server setting.
4. Under the "Identification" heading "Common" tab, verify the correct transmission type is set under the TCM
heading, based off of the metal identification plate on the lower left rear of the transmission. Is the
4.b No; under the "Actions" tab, "Transmission Heading," select "TCM replacement" and reset the
transmission type accordingly. After reset, perform a "Transmission/Clutch Relearn."
5. Reprogram the CPC/MCM/ACM/TCM to latest server configuration.
7
469.3 SPN 524286/FMI 4 - GHG17

Automatic Gear Selection: Gear Shift Not Plausible
Check as follows:
1. Has the vehicle’s Transmission Control Module (TCM), Aftertreatment Control Module (ACM), Motor
524286/FMI 1?
values available"?
Proc

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Detroit Diesel

GHG17 Heavy Duty Troubleshooting Manual

California Proposition 65 Warning and Engine Idle Notice

Troubleshooting Manual Introduction

Scope and Use of This Troubleshooting Manual

3.1 Mechanical Troubleshooting

3.2 Electronic Troubleshooting

4.1 Exhaust (Start/Run Engine)

4.5 Work Place

4.7 Power Tools

4.9 Fluids and Pressure

The following cautions should be followed when filling a fuel tank:

Fire Extinguisher Work Environment

4.13 Cleaning Agent

4.14 Working on a Running Engine

4.15 Turbocharger Compressor Inlet Shield

4.16 Fluoroelastomer (VITON®) Caution

5.1 Detroit Diesel Electronic Control System

5.2 Motor Control Module

1. 21–pin Connector (OEM Responsibility)

Fig 5.1, Motor Control Module

The following is a summary of the tasks the MCM monitors:

5.2.1 MCM 21–pin Connector

MCM 21–pin Connector

5.2.2 DD13 120-Pin Connector Pin-Out

MCM Connector – DD13 (1 of 2)

MCM Connector – DD13 (2 of 2)

5.2.3 DD15 120-Pin Connector Pin-Out

MCM Connector – DD15 (1 of 2)

Needle control Electrostatic Oil

MCM Connector – DD15 (2 of 2)

88 SGND Not Used 118 A07_S Not Used

5.2.4 DD16 120-Pin Connector Pin-Out

MCM Connector – DD16 (1 of 2)

Needle control Electrostatic Oil

MCM Connector – DD16 (2 of 2)

88 SGND Not Used 118 A07_S Not Used

5.2.1 Removal of the Motor Control Module

5.2.2 Inspection of the Motor Control Module

5.2.3 Installation of the Motor Control Module

8. Start the engine.

5.3 Common Powertrain Controller

Fig 5.2, Common Powertrain Controller

Fig 5.3, Common Powertrain Controller Dimensions

Fig 5.4, NAFTA Architecture On-highway

Connector #1 Pin Assignments

Connector #2 Pin Assignments

Connector #3 Pin Assignments

Connector #4 Pin Assignments

5.4 Description and Operation of the 1-BOX™

Fig 5.5, Aftertreatment Control Module (ACM) Components

5.4.1 Removal of the 1-BOX™ Aftertreatment Control Module

5.4.2 Installation of the 1-BOX™ Aftertreatment Control Module

5.5 Description and Operation of the Two-BOX (2V2)

Fig 5.6, Aftertreatment Control Module

5.5.1 Removal of the Two-BOX (2V2) Aftertreatment Control Module

5.5.2 Installation of the Two-BOX (2V2) Aftertreatment Control Module

5.6 Instrument Panel Lamps

5.6.2 Amber Warning Lamp

Lamp Lamp Name Description Result

Lamp Solid Lamp Flashing

5.6.3 Red Stop Lamp

Lamp Lamp Name Description Result