International/Navistar N9, N10, N13 Diesel Engines Workshop Repair & Service Manual
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Model:
Complete digital workshop manual contains service, maintenance, and troubleshooting information for the International/Navistar N9, N10, N13 Diesel Engines. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for International/Navistar N9, N10, N13 Diesel Engines is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
FILILIST (540 MB PDF):
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0000002161 (07/2015) - N13 Engine with SCR Diagnostic Manual.pdf
0000002161 (10/2014) - N13 Engine with SCR Diagnostic Manual.pdf
0000002861 - 2013 HD-OBD Diagnostic Reference Manual.pdf
0000002861 - Service Manual 2013 HD-OBD Diagnostic Reference Manual.pdf
0000003481-R2 - N9 and N10 with SCR Engine Wiring Diagram.pdf
0000003721 (08/2015) - N9 and N10 Engine Diagnostic Manual.pdf
0000003721 (12/2014) - N9 and N10 Engine Diagnostic Manual.pdf
0000003823 (04/2014) - N13 Engine with SCR Engine Manual.pdf
0000003823 (06/2015) - N13 with SCR Engine Service Manual.pdf
0000004021 - N9 and N10 Engine Service Manual.pdf
0000004061 - Manuel de Reparation Moteurs Navistar N13 avec RCS.pdf
0000004062 - Manual de Servicio del Motor Navistar N13 con SCR.pdf
0000004081 - Manuel de Diagnostique Moteur N13 avec réduction catalytique sélective (SCR).pdf
0000004101 - Manual de Diagnóstico Motor N13 con SCR.pdf
0000004601 (06/2015) - 2015 N13 Engine Diagnostic Manual.pdf
0000004601 (10/2014) - 2015 N13 Engine Diagnostic Manual.pdf
0000004741 - 2015 N13 Engine Engine Service Manual.pdf
4328224R1 - N9 and N10 Engine Operation and Maintenance Manual.pdf
EXCERPT:
CRITICAL ENGINE CONTROLS
Engine Controls that are Critical for a Regen
The following controls do not prevent a Regen from occurring although they do need to function properly to ensure a successful Regen.
Exhaust Gas Recirculation (EGR) Valve
• The EGR system is used to reduce the amount of NOX created by the engine. The EGR valve re-circulates exhaust back into the intake stream. This cools the combustion process and reduces the formation of NOX.
Intake Throttle Valve (ITV)
• The ITV is used to control air/fuel mixture during a DPF Regen process. Even though a fault from this component does not inhibit a Regen, it does need to function properly to ensure a successful Regen.
Variable Geometry Turbocharger (VGT)
• The VGT is only used on the MaxxForce® 7, DT, 9, and 10 (medium duty) engines. The VGT is used to control air/fuel mixture during a DPF Regen process. Even though a fault from this component does not inhibit a Regen, it does need to function properly to ensure a successful Regen.
...
Table of Contents...3
Safety Terminology...7
Safety Instructions...7
Work Area...7
Safety Equipment...7
Protective Measures...7
Vehicle...7
Engine...8
Fire Prevention...8
Batteries...8
Compressed Air...8
Tools...8
Fluids Under Pressure...9
Fuel...9
Removal of Tools, Parts, and Equipment...9
Table of Contents...11
Diagnostic Trouble Code (DTCs) List...15
How To Use Symptom Based Diagnostics...28
Operational Checkout Procedures...29
1.0 - Preliminary Vehicle Operational Checkout Procedure...29
2.0 - Engine Does Not Start Operational Checkout Procedure...32
Overview...32
3.0 - Engine Hard to Start Operational Checkout Procedure...36
Overview...36
4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure...40
Overview...40
5.0 - Engine Running, Engine Under Load Operational Checkout Procedure...42
Overview...42
6.0 - Cooling System Operational Checkout Procedure...44
Overview...44
7.0 - Engine Oil System Operational Checkout Procedure...47
Overview...47
8.0 - Fuel System Operational Checkout Procedure...49
9.0 - Engine Compression Brake Operational Checkout Procedure...50
10.0 - SCR Aftertreatment Operational Checkout Procedure...51
Overview...51
Test Procedure...51
11.0 - ECM Loss of Communication...52
Overview...52
Possible Causes...52
Test Procedure...52
12.0 Soot Buildup at Exhaust Manifold / Gasket Out of Position...59
Overview...59
Possible Causes...59
Test Procedure...59
Engine Does Not Start Symptoms...63
2.1 - Engine Cranks Slow or Does Not Crank...63
Overview...63
Possible Causes...63
Test Procedure...63
2.2 - Engine No Start, Cold Ambient Temperature...66
Overview...66
Possible Causes...66
Test Procedure...66
2.3 - Engine at Operating Temperature, No Re-Start...68
Overview...68
Possible Causes...68
Test Procedure...68
2.4 - Engine Never Starts...70
Overview...70
Possible Causes...70
Test Procedure...70
Engine Hard to Start Symptoms...73
3.1 - Engine Hard to Start, Cold Ambient Temperature...73
Overview...73
Possible Causes...73
Test Procedure...73
3.2 - Engine at Operating Temperature, Hard to Re-Start...75
Overview...75
Possible Causes...75
Test Procedure...75
3.3 - Engine Starts, Then Stalls...77
Overview...77
Possible Causes...77
Test Procedure...77
Engine Running, Engine Not Under Load Symptoms...79
4.1 - Rough Idle...79
Overview...79
Possible Causes...79
Test Procedure...79
4.2 - Engine Unable To Reach Rated Speed (No Load)...83
Overview...83
Possible Causes...83
Test Procedure...83
4.3 - Popping Noise from Intake...86
Overview...86
Possible Causes...86
Test Procedure...86
Engine Running, Engine Under Load Symptoms...88
5.1 - Low Power (Slow Acceleration)...88
Overview...88
Possible Causes...88
Test Procedure...88
5.2 - Misfire (Stumble / Surge / Runs Rough)...94
Overview...94
Possible Causes...94
Test Procedure...94
5.3 - Engine Unable to Reach Desired Speed During PTO Operation...97
Overview...97
Possible Causes...97
Test Procedure...97
Engine Coolant Symptoms...100
6.1 - Coolant Overflow...100
Overview...100
Possible Causes...100
Test Procedure...100
6.2 - Coolant Over Temperature...103
Overview...103
Possible Causes...103
Test Procedure...103
6.3 - Engine Unable to Reach Operating Temperature...106
Overview...106
Possible Causes...106
Test Procedure...106
6.4 - Coolant Leak to Exhaust...108
Overview...108
Possible Causes...108
Test Procedure...108
6.5 - Coolant Leak to Intake...110
Overview...110
Possible Causes...110
Test Procedure...110
6.6 - Coolant Leak to Engine Oil ...111
Overview...111
Possible Causes...111
Test Procedure...111
Engine Lubrication Symptoms...112
7.1 - Engine Oil Contamination...112
Overview...112
Possible Causes...112
Test Procedure...112
7.2 - Engine Oil Leak to Intake...115
Overview...115
Possible Causes...115
Test Procedure...115
7.3 - Engine Oil Leak to Exhaust...117
Overview...117
Possible Causes...117
Test Procedure...117
7.4 - Low Engine Oil Pressure...118
Overview...118
Possible Causes...118
Test Procedure...118
7.5 - High Engine Oil Pressure...121
Overview...121
Possible Causes...121
Test Procedure...121
7.6 - Engine Oil Aeration...123
Overview...123
Possible Causes...123
Test Procedure...123
Fuel System Symptoms...125
8.1 - Fuel Delivery Pressure...125
Overview...125
Possible Causes...125
Test Procedure...125
8.2 - Fuel in Engine Oil...129
Overview...129
Possible Causes...129
Test Procedure...129
Engine Brake Symptoms...132
9.1 - Engine Compression Brake Inoperative...132
Overview...132
Possible Causes...132
Test Procedure...132
9.2 - Engine Compression Brake Engaged When Not Commanded ...135
Overview...135
Possible Causes...135
Test Procedure...135
Aftertreatment Symptoms...137
10.1 - Parked Regeneration Will Not Activate...137
Overview...137
Possible Causes...137
Test Procedure...137
10.2 - Black Smoke ...139
Overview...139
Possible Causes...139
Test Procedure...139
10.3 - White Smoke...144
Overview...144
Possible Causes...144
Test Procedure...144
Fault Code Diagnostics...149
Section Information...149
AAT Sensor (Ambient Air Temperature)...150
Overview of AAT Sensor...150
Overview ...150
SPN 171 FMI 2 - AAT Signal Erratic, Intermittent, or Incorrect...151
Fault Overview...151
Lamp Reaction...151
Associated Faults...151
Fault Facts...151
Drive Cycle to Determine Fault Status...151
Possible Causes...151
Pin-Point Test...155
Tools Required...155
SPN 171 FMI 3 - AAT Signal Out of Range HIGH...159
Fault Overview...159
Lamp Reaction...159
Associated Faults...159
Fault Facts...159
Drive Cycle...159
Possible Causes...159
Pin-Point Test...162
Tools Required...162
SPN 171 FMI 4 - AAT Signal Out of Range LOW...166
Fault Overview...166
Lamp Reaction...166
Associated Faults...166
Fault Facts...166
Drive Cycle to Determine Fault Status...166
Possible Causes...166
Pin-Point Tests (SPN 171 FMI 4)...168
Tools Required...168
ACM (Aftertreatment Control Module)...170
Overview of ACM Sensor...170
Overview ...170
SPN 168 FMI 15 - ACM Battery voltage too HIGH...171
Fault Overview...171
Lamp Reaction...171
Associated Faults...171
Fault Facts...171
Drive Cycle to Determine Fault Status...171
Possible Causes...171
SPN 168 FMI 17 - ACM Battery voltage too LOW...173
Fault Overview...173
Lamp Reaction...173
Associated Faults...173
Fault Facts...173
Drive Cycle to Determine Fault Status...173
Possible Causes...173
Pin-Point Tests (SPN 168 FMI 17)...175
Tools Required...175
AFT (Aftertreatment) System...177
Overview of AFT System Group...177
Overview...177
SPN 3251 FMI 0 - DPFDP excessively HIGH (Plugged filter)...179
Fault Overview...179
Lamp Reaction...179
Associated Faults...179
Fault Facts...179
Drive Cycle to Determine Fault Status...179
Possible Causes...179
Pin-Point Tests...183
Tools Required...183
SPN 3251 FMI 15 - DPF Soot Load - Least Severe Level...184
Fault Overview...184
Lamp Reaction...184
Associated Faults...184
Fault Facts...184
Drive Cycle to Determine Fault Status...184
Possible Causes...184
Pin-Point Tests...188
Tools Required...188
SPN 3251 FMI 16 - DPF Soot Load - Moderately Severe Level...189
Fault Overview...189
Lamp Reaction...189
Associated Faults...189
Fault Facts...189
Drive Cycle to Determine Fault Status...189
Possible Causes...189
Pin-Point Tests...193
Tools Required...193
SPN 3695 FMI 2- DPF Regen Inhibit Switch erratic, intermittent, or incorrect...194
Fault Overview...194
Lamp Reaction...194
Associated Faults...194
Fault Facts...194
Drive Cycle to Determine Fault Status...194
Possible Causes...194
SPN 3695 FMI 19 - DPF Regen Inhibit Switch status not detected on J1939 ...196
Fault Overview...196
Lamp Reaction...196
Associated Faults...196
Fault Facts...196
Drive Cycle to Determine Fault Status...196
Possible Causes...196
SPN 3703 FMI 31 - DPF Active Regeneration Inhibited Due to Inhibit Switch...198
Fault Overview...198
Lamp Reaction...198
Associated Faults...198
Fault Facts...198
Drive Cycle to Determine Fault Status...198
Possible Causes...198
SPN 3713 FMI 31 - DPF Active Regeneration Inhibited Due to System Timeout...200
Fault Overview...200
Lamp Reaction...200
Associated Faults...200
Drive Cycle to Determine Fault Status...200
Fault Fact...200
Possible Causes...200
SPN 3719 FMI 0: DPF Soot Load - Highest (level 3/3)...202
Fault Overview...202
Lamp Reaction...202
Associated Faults...202
Fault Facts...202
Drive Cycle to Determine Fault Status...202
Possible Causes...202
SPN 3719 FMI 15 DPF Soot Load - Lowest (level 1/3)...205
Fault Overview...205
Lamp Reaction...205
Associated Faults...205
Fault Facts...205
Drive Cycle to Determine Fault Status...205
Possible Causes...205
SPN 3719 FMI 16 - DPF Soot Load - Moderate (level 2/3)...208
Fault Overview...208
Lamp Reaction...208
Associated Faults...208
Fault Facts...208
Drive Cycle to Determine Fault Status...208
Possible Causes...208
SPN 3750 FMI 31 - DPF Regen inhibited due to low exhaust temperatures ...211
Fault Overview...211
Lamp Reaction...211
Associated Faults...211
Fault Facts...211
Drive Cycle to Determine Fault Status...211
Possible Causes...211
SPN 3936 FMI 14 - DOC / DPF Temperature module (Incorrect Part)...213
Fault Overview...213
Lamp Reaction...213
Associated Faults...213
Fault Facts...213
Drive Cycle to Determine Fault Status...213
Possible Causes...213
SPN 3936 FMI 15 - DPF System above Warning Pressure...215
Fault Overview...215
Lamp Reaction...215
Associated Faults...215
Fault Facts...215
Drive Cycle to Determine Fault Status...215
Possible Causes...215
SPN 3936 FMI 16 - DPF System above Maximum Pressure...219
Fault Overview...219
Lamp Reaction...219
Associated Faults...219
Fault Facts...219
Drive Cycle to Determine Fault Status...219
Possible Causes...219
SPN 4795 FMI 31 - DPFDP Excessively LOW (Sensor/Circuit Fault or Missing DPF)...223
Fault Overview...223
Lamp Reaction...223
Associated Faults...223
Fault Facts...223
Drive Cycle to Determine Fault Status...223
Possible Causes...223
SPN 4796 FMI 31 - Diesel Oxidation Catalyst Missing...225
Fault Overview...225
Lamp Reaction...225
Associated Faults...225
Fault Facts...225
Drive Cycle to Determine Fault Status...225
Possible Causes...225
SPN 5298 FMI 17 - DOC Efficiency fault, Temperature below minimum Regen Aborted...227
Fault Overview...227
Lamp Reaction...227
Associated Faults...227
Fault Facts...227
Drive Cycle to Determine Fault Status...227
Possible Causes...227
SPN 5298 FMI 18 - DOC Efficiency fault, Temperature below minimum...230
Fault Overview...230
Lamp Reaction...230
Associated Faults...230
Fault Facts...230
Drive Cycle to Determine Fault Status...230
Possible Causes...230
SPN 5319 FMI 31 - DPF incomplete Regeneration...232
Fault Overview...232
Lamp Reaction...232
Associated Faults...232
Fault Facts...232
Drive Cycle to Determine Fault Status...232
Possible Causes...232
AFTFSO (Aftertreatment Fuel Shutoff)...235
Overview of AFTFSO Sensor Group...235
Overview...235
SPN 3482 FMI 3 - AFT Fuel Enable Control Valve short to PWR...236
Fault Overview...236
Lamp Reaction...236
Associated Faults...236
Fault Facts...236
Drive Cycle to Determine Fault Status...236
Possible Causes...236
Pin-Point Tests...241
Tools Required...241
SPN 3482 FMI 4 - AFT Fuel Shutoff Valve open or short to GND...247
Fault Overview...247
Lamp Reaction...247
Associated Faults...247
Fault Facts...247
Drive Cycle to Determine Fault Status...247
Possible Causes...247
Pin-Point Tests...252
Tools Required...252
AFTFP1/AFTFT (Aftertreatment Fuel Pressure 1 / Aftertreatment Fuel Temperature) Sensor...258
Overview of AFTFP1/AFTFT Sensor Group...258
Overview...258
SPN 3480 FMI 3 - AFTFP1 signal Out of Range HIGH...260
Fault Overview...260
Lamp Reaction...260
Associated Faults...260
Fault Facts...260
Drive Cycle to Determine Fault Status...260
Possible Causes...260
Pin-Point Tests...263
Tools Required...263
SPN 3480 FMI 4 - AFTFP1 signal Out of Range LOW...267
Fault Overview...267
Lamp Reaction...267
Associated Faults...267
Fault Facts...267
Drive Cycle to Determine Fault Status...267
Possible Causes...267
Pin-Point Tests...270
Tools Required...270
SPN 5456 FMI 2 - AFTFT Signal Erratic, Intermittent, or Incorrect...274
Fault Overview...274
Lamp Reaction...274
Associated Faults...274
Fault Facts...274
Drive Cycle...274
Possible Causes...274
Pin - Point Tests...277
Tools Required...277
SPN 5456 FMI 3 - AFTFT Signal Out of Range - HIGH...279
Fault Overview...279
Lamp Reaction...279
Associated Faults...279
Fault Facts...279
Drive Cycle to Determine Fault Status...279
Possible Causes...279
Pin-Point Tests...282
Tools Required...282
SPN 5456 FMI 4 - AFTFT Signal Out of Range LOW...285
Fault Overview...285
Lamp Reaction...285
Associated Faults...285
Fault Facts...285
Drive Cycle to Determine Fault Status...285
Possible Causes...285
Pin-Point Tests...287
Tools Required...287
AFTFP2 (Aftertreatment Fuel Pressure 2) Sensor...288
Overview of AFTFP2 Sensor Group...288
Overview...288
SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high (Restricted injection)...289
Fault Overview...289
Lamp Reaction...289
Associated Faults...289
Fault Facts...289
Drive Cycle to Determine Fault Status...289
Possible Causes...289
SPN 3556 FMI 1 - AFT Fuel Pressure 2 below desired (Possible system leak)...291
Fault Overview...291
Lamp Reaction...291
Associated Faults...291
Fault Facts...291
Drive Cycle to Determine Fault Status...291
Possible Causes...291
Pin-Point Tests...294
Tools Required...294
SPN 3556 FMI 7 - AFT Fuel Injector not responding as expected...295
Fault Overview...295
Lamp Reaction...295
Associated Faults...295
Fault Facts...295
Drive Cycle to Determine Fault Status...295
Possible Causes...295
SPN 4077 FMI 3 - AFTFP2 Signal Out of Range HIGH...297
Fault Overview...297
Lamp Reaction...297
Associated Faults...297
Fault Facts...297
Drive Cycle to Determine Fault Status...297
Possible Causes...297
Pin-Point Tests...300
Tools Required...300
SPN 4077 FMI 4 - AFTFP2 Signal Out of Range LOW...303
Fault Overview...303
Lamp Reaction...303
Associated Faults...303
Fault Facts...303
Drive Cycle to Determine Fault Status...303
Possible Causes...303
Pin-Point Tests...305
Tools Required...305
AFTFPC (Aftertreatment Fuel Pressure Control) System...306
Overview of AFTFPC Sensor...306
Overview...306
SPN 3471 FMI 1 - AFT Fuel Pressure 1 below desired (Low system pressure)...307
Fault Overview...307
Lamp Reaction...307
Associated Faults...307
Fault Facts...307
Drive Cycle to Determine Fault Status...307
Possible Causes...307
Pin-Point Tests...310
Tools Required...310
SPN 3471 FMI 7 - AFT Fuel Doser Valve not responding as expected...313
Fault Overview...313
Lamp Reaction...313
Associated Faults...313
Fault Facts...313
Drive Cycle to Determine Fault Status...313
Possible Causes...313
Pin-Point Tests...316
Tools Required...316
SPN 3471 FMI 10 - AFT Fuel Pressure incorrect dosing pressure multiple events...319
Fault Overview...319
Lamp Reaction...319
Associated Faults...319
Fault Facts...319
Drive Cycle to Determine Fault Status...319
Possible Causes...319
Pin-Point Tests...322
Tools Required...322
SPN 3479 FMI 3 - AFT Fuel Doser Valve Short to PWR...325
Fault Overview...325
Lamp Reaction...325
Associated Faults...325
Fault Facts...325
Drive Cycle to Determine Fault Status...325
Possible Causes...325
Pin-Point Tests...330
Tools Required...330
SPN 3479 FMI 4 - AFT Fuel Doser Valve Short to GND...333
Fault Overview...333
Lamp Reaction...333
Associated Faults...333
Fault Facts...333
Drive Cycle to Determine Fault Status...333
Possible Causes...333
Pin-Point Tests...338
Tools Required...338
SPN 3479 FMI 5 - AFT Fuel Pressure Valve Open or Short to GND low side...341
Fault Overview...341
Lamp Reaction...341
Associated Faults...341
Fault Facts...341
Drive Cycle to Determine Fault Status...341
Possible Causes...341
Pin-Point Tests...346
Tools Required...346
SPN 3479 FMI 6 - AFT Fuel Doser Valve High Side Short circuit...349
Fault Overview...349
Lamp Reaction...349
Associated Faults...349
Fault Facts...349
Drive Cycle to Determine Fault Status...349
Possible Causes...349
Pin-Point Tests...354
Tools Required...354
NH3 (Aftertreatment Ammonia) Sensor and Sensor Module...357
Overview of NH3 Sensor Group...357
Overview...357
SPN 4377 FMI 2 - NH3 in range stuck fault...361
Fault Overview...361
Lamp Reaction...361
Associated Faults...361
Fault Facts...361
Drive Cycle to Determine Fault Status...361
Possible Causes...361
SPN 4377 FMI 3 - NH3 Sensor signal Out of Range HIGH...363
Fault Overview...363
Lamp Reaction...363
Associated Faults...363
Fault Facts...363
Drive Cycle to Determine Fault Status...363
Possible Causes...363
SPN 4377 FMI 4 - NH3 operation fault (circuit fault)...365
Fault Overview...365
Lamp Reaction...365
Associated Faults...365
Fault Facts...365
Drive Cycle to Determine Fault Status...365
Possible Causes...365
SPN 4377 FMI 10 - NH3 abnormal rate of change...367
Fault Overview...367
Lamp Reaction...367
Associated Faults...367
Fault Facts...367
Drive Cycle to Determine Fault Status...367
Possible Causes...367
SPN 4377 FMI 12 - NH3 internal chip error...368
Fault Overview...368
Lamp Reaction...368
Associated Faults...368
Fault Facts...368
Drive Cycle to Determine Fault Status...368
Possible Causes...368
SPN 4377 FMI 13 - NH3 operation fault (wrong sensor installed)...370
Fault Overview...370
Lamp Reaction...370
Associated Faults...370
Fault Facts...370
Drive Cycle to Determine Fault Status...370
Possible Causes...370
SPN 4377 FMI 19 - NH3 Sensor Module not detected on J1939...372
Fault Overview...372
Lamp Reaction...372
Associated Faults...372
Fault Facts...372
Drive Cycle to Determine Fault Status...372
Possible Causes...372
Pin-Point Tests (SPN 4377 FMI 19)...377
Tools Required...377
SPN 4380 FMI 2 - NH3 signal erratic, intermittent, or incorrect...382
Fault Overview...382
Lamp Reaction...382
Associated Faults...382
Fault Facts...382
Drive Cycle to Determine Fault Status...382
Possible Causes...382
Pin-Point Tests (SPN 4380 FMI 2)...385
Tools Required...385
SPN 4382 FMI 10 - NH3 sensor Heater abnormal rate of change...388
Fault Overview...388
Lamp Reaction...388
Associated Faults...388
Fault Facts...388
Drive Cycle to Determine Fault Status...388
Possible Causes...388
SPN 5302 FMI 18 - Post SCR NH3 Conversion Efficiency - Data Valid But Below Normal Operating Range - Moderately Severe Level...390
Fault Overview...390
Lamp Reaction...390
Associated Faults...390
Fault Facts...390
Drive Cycle to Determine Fault Status...390
Possible Causes...390
AMS (Air Management System)...393
Overview of AMS Sensor Group...393
Overview...393
SPN 1209 FMI 0 - EBP above desired level...394
Fault Overview...394
Lamp Reaction...394
Associated Faults...394
Fault Facts...394
Drive Cycle to Determine Fault Status...394
Possible Causes...394
SPN 1209 FMI 7 - EBP signal not responding as expected...397
Fault Overview...397
Lamp Reaction...397
Associated Faults...397
Fault Facts...397
Drive Cycle to Determine Fault Status...397
Possible Causes...397
SPN 2659 FMI 10 - EGR Slow Response Fault...399
Fault Overview...399
Lamp Reaction...399
Associated Faults...399
Fault Facts...399
Drive Cycle to Determine Fault Status...399
Possible Causes...399
SPN 2659 FMI 14 - EGR System Flow Rate Error During Air Management...403
Fault Overview...403
Lamp Reaction...403
Associated Faults...403
Fault Facts...403
Drive Cycle to Determine Fault Status...403
Possible Causes...403
SPN 2659 FMI 20 - EGR High Flow Rate detected...405
Fault Overview...405
Lamp Reaction...405
Associated Faults...405
Fault Facts...405
Drive Cycle to Determine Fault Status...405
Possible Causes...405
SPN 2659 FMI 21- EGR Low Flow Rate detected...408
Fault Overview...408
Lamp Reaction...408
Associated Faults...408
Fault Facts...408
Drive Cycle to Determine Fault Status...408
Possible Causes...408
APP Sensor (Accelerator Pedal Position)...411
Overview of APP Sensor Group...411
Overview...411
SPN 91 FMI 2 APP1 and APP2 signal conflict...412
Fault Overview...412
Lamp Reaction...412
Associated Faults...412
Fault Facts...412
Drive Cycle to Determine Fault Status...412
Possible Causes...412
Pin-Point Tests...415
Tools Required...415
SPN 91 FMI 3 - APP1 signal Out of Range HIGH...417
Fault Overview...417
Lamp Reaction...417
Associated Faults...417
Fault Facts...417
Drive Cycle to Determine Fault Status...417
Possible Causes...417
Pin-Point Tests (SPN 91 FMI 3)...420
Tools Required...420
SPN 91 FMI 4 - APP1 signal Out of Range LOW...422
Fault Overview...422
Lamp Reaction...422
Associated Faults...422
Fault Facts...422
Drive Cycle to Determine Fault Status...422
Possible Causes...422
Pin-Point Tests (SPN 91 FMI 4)...425
Tools Required...425
SPN 2623 FMI 3 - APP2 Signal Out of Range HIGH...429
Fault Overview...429
Lamp Reaction...429
Associated Faults...429
Fault Facts...429
Drive Cycle to Determine Fault Status...429
Possible Causes...429
Pin-Point Tests (SPN 2623 FMI 3)...432
Tools Required...432
SPN 2623 FMI 4 - APP2 Signal Out of Range LOW...434
Fault Overview...434
Lamp Reaction...434
Associated Faults...434
Fault Facts...434
Drive Cycle to Determine Fault Status...434
Possible Causes...434
Pin-Point Tests (SPN 2623 FMI 4)...437
Tools Required...437
Body...441
Overview of Body Sensor...441
Overview...441
SPN 521 FMI 2 - Brake applied while APP applied...442
Fault Overview...442
Lamp Reaction...442
Associated Faults...442
Fault Facts...442
Drive Cycle to Determine Fault Status...442
Possible Causes...442
SPN 596 FMI 19 Cruise Control Enable Switch not detected on J1939...445
Fault Overview...445
Lamp Reaction...445
Associated Faults...445
Fault Facts...445
Drive Cycle to Determine Fault Status...445
Possible Causes...445
SPN 597 FMI 2 - Missing J1939 Brake status signal request from Body module or Instrument Cluster...447
Fault Overview...447
Lamp Reaction...447
Associated Faults...447
Fault Facts...447
Drive Cycle to Determine Fault Status...447
Possible Causes...447
SPN 597 FMI 19 - Brake switch not detected on J1939...449
Fault Overview...449
Lamp Reaction...449
Associated Faults...449
Fault Facts...449
Drive Cycle to Determine Fault Status...449
Possible Causes...449
CACOT Sensor (Charge Air Cooler Outlet Temperature)...451
Overview of CACOT Sensor Group...451
Overview...451
SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect...452
Fault Overview...452
Lamp Reaction...452
Associated Faults...452
Fault Facts...452
Drive Cycle to Determine Fault Status...452
Possible Causes...452
Pin-Point Tests (SPN 2630 FMI 2)...455
Tools Required...455
SPN 2630 FMI 3 - CACOT Signal Out of Range HIGH...456
Fault Overview...456
Lamp Reaction...456
Associated Faults...456
Fault Facts...456
Drive Cycle to Determine Fault Status...456
Possible Causes...456
Pin-Point Tests (SPN 2630 FMI 3)...459
Tools Required...459
SPN 2630 FMI 4 - CACOT Signal Out of Range LOW...462
Fault Overview...462
Lamp Reaction...462
Associated Faults...462
Fault Facts...462
Drive Cycle to Determine Fault Status...462
Possible Causes...462
Pin-Point Tests (SPN 2630 FMI 4)...464
Tools Required...464
SPN 2630 FMI 16 - CACOT Undercooling...465
Fault Overview...465
Lamp Reaction...465
Associated Faults...465
Fault Facts...465
Drive Cycle to Determine Fault Status...465
Possible Causes...465
Pin-Point Tests (SPN 2630 FMI 2)...469
Tools Required...469
CCOSS Sensor (Crankcase Oil Separator Speed)...470
Overview of CCOSS Sensor Group...470
Overview...470
SPN 4227 FMI 7 - CC Oil Separator: Not spinning...471
Fault Overview...471
Lamp Reaction...471
Associated Faults...471
Fault Facts...471
Drive Cycle to Determine Fault Status...471
Possible Causes...471
Pin-Point Tests (SPN 4227 FMI 7)...474
Tools Required...474
CKP Sensor (Crankshaft Position)...476
Overview of CKP Sensor Group...476
Overview...476
SPN 637 FMI 8 - CKP signal noise...477
Fault Overview...477
Lamp Reaction...477
Associated Faults...477
Fault Facts...477
Drive Cycle to Determine Fault Status...477
Possible Causes...477
Pin-Point Tests...480
Tools Required...480
SPN 637 FMI 10 - CKP signal Inactive...484
Fault Overview...484
Lamp Reaction...484
Associated Faults...484
Fault Facts...484
Drive Cycle to Determine Fault Status...484
Possible Causes...484
Pin-Point Tests...488
Tools Required...488
CMP Sensor (Camshaft Position)...490
Overview of CMP Sensor Group...490
Overview...490
SPN 636 FMI 2 - CMP and CKP Synchronization Error...491
Fault Overview...491
Lamp Reaction...491
Associated Faults...491
Fault Facts...491
Drive Cycle to Determine Fault Status...491
Possible Causes...491
Pin-Point Tests...495
Tools Required...495
SPN 636 FMI 7 - CMP to CKP incorrect reference...500
Fault Overview...500
Lamp Reaction...500
Associated Faults...500
Fault Facts...500
Drive Cycle to Determine Fault Status...500
Possible Causes...500
DCU Power (Doser Control Unit)...502
Overview of DCU Power Sensor Group...502
Overview...502
SPN 609 FMI 19 - ACM not detected on J1939...503
Fault Overview...503
Lamp Reaction...503
Associated Faults...503
Fault Facts...503
Drive Cycle to Determine Fault Status...503
Possible Causes...503
Pin-Point Tests...508
Tools Required...508
SPN 5109 FMI 15 - DCU battery voltage too HIGH...519
Fault Overview...519
Lamp Reaction...519
Associated Faults...519
Fault Facts...519
Drive Cycle to Determine Fault Status...519
Possible Causes...519
SPN 5109 FMI 17 - DCU battery voltage too LOW...521
Fault Overview...521
Lamp Reaction...521
Associated Faults...521
Fault Facts...521
Drive Cycle to Determine Fault Status...521
Possible Causes...521
Pin-Point Tests (SPN 5109 FMI 17)...524
Tools Required...524
SPN 5109 FMI 19 - DCU not detected on J1939...525
Fault Overview...525
Lamp Reaction...525
Associated Faults...525
Fault Facts...525
Drive Cycle to Determine Fault Status...525
Possible Causes...525
Pin-Point Tests (SPN 5109 FMI 19)...530
Tools Required...530
DEF (Diesel Exhaust Fluid)...537
Overview of DEF Sensor Group...537
Overview...537
SPN 520668 FMI 31 - Controller Adaptation Outer Limits Reached (Low Reductant Delivery)...538
Fault Overview...538
Lamp Reaction...538
Associated Faults...538
Fault Facts...538
Drive Cycle to Determine Fault Status...538
Possible Causes...538
SPN 520669 FMI 31 - Controller Adaptation Inner Limits Reached (Low Reductant Delivery)...541
Fault Overview...541
Lamp Reaction...541
Associated Faults...541
Fault Facts...541
Drive Cycle to Determine Fault Status...541
Possible Causes...541
DEFSMH (Diesel Exhaust Fluid Supply Module Heater)...544
Overview of DEFSMH Sensor Group...544
Overview...544
SPN 5745 FMI 3 - DEF Dosing Unit Heater Out of Range HIGH...548
Fault Overview...548
Lamp Reaction...548
Associated Faults...548
Fault Facts...548
Drive Cycle to Determine Fault Status...548
Possible Causes...548
Pin-Point Tests (SPN 5745 FMI 3)...551
Tools Required...551
SPN 5745 FMI 4 - DEF Supply Module Heater Out of Range LOW...553
Fault Overview...553
Lamp Reaction...553
Associated Faults...553
Fault Facts...553
Drive Cycle to Determine Fault Status...553
Possible Causes...553
Pin-Point Tests (SPN 5745 FMI 4)...558
Tools Required...558
SPN 5745 FMI 18 - DEF Supply Module Heater below Warning Temperature ...565
Fault Overview...565
Lamp Reaction...565
Associated Faults...565
Fault Facts...565
Drive Cycle to Determine Fault Status...565
Possible Causes...565
Pin-Point Tests (SPN 5745 FMI 18)...569
Tools Required...569
SPN 5798 FMI 2 - DEF Supply Module Heater Temperature erratic, intermittent or incorrect...571
Fault Overview...571
Lamp Reaction...571
Associated Faults...571
Fault Facts...571
Drive Cycle to Determine Fault Status...571
Possible Causes...571
Pin-Point Tests (SPN 5798 FMI 2)...574
Tools Required...574
SPN 5798 FMI 10 - DEF Supply Module Heater Temperature abnormal rate of change...577
Fault Overview...577
Lamp Reaction...577
Associated Faults...577
Fault Facts...577
Drive Cycle to Determine Fault Status...577
Possible Causes...577
Pin-Point Tests (SPN 5798 FMI 10) ...580
Tools Required...580
DEFD (Diesel Exhaust Fluid Doser) Sensor...583
Overview of DEFD Sensor Group...583
Overview...583
SPN 5394 FMI 2 - DEF Dosing below desired (Low NOx conversion across SCR)...584
Fault Overview...584
Lamp Reaction...584
Associated Faults...584
Fault Facts...584
Drive Cycle to Determine Fault Status...584
Possible Causes...584
Pin-Point Tests (SPN 5394 FMI 2)...587
Tools Required...587
SPN 5394 FMI 5 - DEF Doser Valve open load/circuit...588
Fault Overview...588
Lamp Reaction...588
Associated Faults...588
Fault Facts...588
Drive Cycle to Determine Fault Status...588
Possible Causes...588
Pin-Point Tests (SPN 5394 FMI 5)...592
Tools Required...592
SPN 5394 FMI 7 - DEF Dosing Unit - Mechanical system not responding ...594
Fault Overview...594
Lamp Reaction...594
Associated Faults...594
Fault Facts...594
Drive Cycle to Determine Fault Status...594
Possible Causes...594
DEFLHR (Diesel Exhaust Fluid Line Heater Relay)...597
Overview of DEFLHR Sensor Group...597
Overview...597
SPN 5491 FMI 3 - DEF Line Heater Relay Open or short to PWR...599
Fault Overview...599
Lamp Reaction...599
Associated Faults...599
Fault Facts...599
Drive Cycle to Determine Fault Status...599
Possible Causes...599
Pin-Point Tests (SPN 5491 FMI 3)...602
Tools Required...602
SPN 5491 FMI 4 - DEF Line Heater Relay short to GND...606
Fault Overview...606
Lamp Reaction...606
Associated Faults...606
Fault Facts...606
Drive Cycle to Determine Fault Status...606
Possible Causes...606
Pin-Point Tests (SPN 5491 FMI 4)...608
Tools Required...608
DEFLP (Diesel Exhaust Fluid Line Pressure)...611
Overview of DEFLP Sensor Group...611
Overview...611
SPN 4334 FMI 2 - DEFLP signal erratic, intermittent or incorrect...614
Fault Overview...614
Lamp Reaction...614
Associated Faults...614
Fault Facts...614
Drive Cycle to Determine Fault Status...614
Possible Causes...614
SPN 4334 FMI 3 - DEFLP Signal Out of Range HIGH...618
Fault Overview...618
Lamp Reaction...618
Associated Faults...618
Fault Facts...618
Drive Cycle to Determine Fault Status...618
Possible Causes...618
Pin-Point Tests (SPN 4334 FMI 3)...621
Tools Required...621
SPN 4334 FMI 4 - DEFLP signal Out of Range LOW...623
Fault Overview...623
Lamp Reaction...623
Associated Faults...623
Fault Facts...623
Drive Cycle to Determine Fault Status...623
Possible Causes...623
Pin-Point Tests (SPN 4334 FMI 4)...626
Tools Required...626
SPN 4334 FMI 16 - DEF Absolute Pressure above maximum...629
Fault Overview...629
Lamp Reaction...629
Associated Faults...629
Fault Facts...629
Drive Cycle to Determine Fault Status...629
Possible Causes...629
SPN 4334 FMI 18 - DEF Absolute Pressure below normal...631
Fault Overview...631
Lamp Reaction...631
Associated Faults...631
Fault Facts...631
Drive Cycle to Determine Fault Status...631
Possible Causes...631
SPN 4337 FMI 2 - DEF Dosing Unit Temperature - Data Erratic, Intermittent, or Incorrect...634
Fault Overview...634
Lamp Reaction...634
Associated Faults...634
Fault Facts...634
Drive Cycle to Determine Fault Status...634
Possible Causes...634
Pin-Point Tests (SPN 4337 FMI 2)...637
Tools Required...637
SPN 4337 FMI 10 - DEF Dosing Unit Temperature abnormal rate of change...640
Fault Overview...640
Lamp Reaction...640
Associated Faults...640
Fault Facts...640
Drive Cycle to Determine Fault Status...640
Possible Causes...640
Pin-Point Tests (SPN 4337 FMI 10)...643
Tools Required...643
DEFSLH (Diesel Exhaust Fluid Supply Line Heater)...646
Overview of DEFSLH Sensor Group...646
Overview...646
SPN 4340 FMI 3 - DEF Supply Line Heater Short to PWR...648
Fault Overview...648
Lamp Reaction...648
Associated Faults...648
Fault Facts...648
Drive Cycle to Determine Fault Status...648
Possible Causes...648
Pin-Point Tests (SPN 4340 FMI 3)...651
Tools Required...651
SPN 4340 FMI 5 - DEF Supply Line Heater open load/circuit...654
Fault Overview...654
Lamp Reaction...654
Associated Faults...654
Fault Facts...654
Drive Cycle to Determine Fault Status...654
Possible Causes...654
Pin-Point Tests (SPN 4340 FMI 5)...658
Tools Required...658
DEFRLH (Diesel Exhaust Fluid Return Line Heater)...661
Overview of DEFRLH Sensor Group...661
Overview...661
SPN 4342 FMI 3 - DEF Return Line Heater Short to PWR...663
Fault Overview...663
Lamp Reaction...663
Associated Faults...663
Fault Facts...663
Drive Cycle to Determine Fault Status...663
Possible Causes...663
Pin-Point Tests (SPN 4342 FMI 3)...665
Tools Required...665
SPN 4342 FMI 5 - DEF Return Line Heater open load/circuit...668
Fault Overview...668
Lamp Reaction...668
Associated Faults...668
Fault Facts...668
Drive Cycle to Determine Fault Status...668
Possible Causes...668
Pin-Point Tests (SPN 4342 FMI 5)...672
Tools Required...672
DEFRV (Diesel Exhaust Fluid Reverting Valve)...675
Overview of DEFRV Sensor Group...675
Overview...675
SPN 4376 FMI 3 - DEF Reverting Control Valve short to PWR...676
Fault Overview...676
Lamp Reaction...676
Associated Faults...676
Fault Facts...676
Drive Cycle to Determine Fault Status...676
Possible Causes...676
Pin-Point Tests (SPN 4376 FMI 3)...679
Tools Required...679
SPN 4376 FMI 4 - DEF Reverting Control Valve short to GND...681
Fault Overview...681
Lamp Reaction...681
Associated Faults...681
Fault Facts...681
Drive Cycle to Determine Fault Status...681
Possible Causes...681
Pin-Point Tests (SPN 4376 FMI 4)...684
Tools Required...684
SPN 4376 FMI 7 - DEF Reverting Control Valve - Mechanical system not responding or out of adjustment...686
Fault Overview...686
Lamp Reaction...686
Associated Faults...686
Fault Fact...686
Drive Cycle to Determine Fault Status...686
Possible Causes...686
DEFPLH (Diesel Exhaust Fluid Pressure Line Heater)...688
Overview of DEFPLH Sensor Group...688
Overview...688
SPN 4344 FMI 3 - DEF Pressure Line Heater Short to PWR...691
Fault Overview...691
Lamp Reaction...691
Associated Faults...691
Fault Facts...691
Possible Causes...691
Pin-Point Tests (SPN 4344 FMI 3)...693
Tools Required...693
SPN 4344 FMI 5 - DEF Pressure Line Heater open load/circuit...696
Fault Overview...696
Lamp Reaction...696
Associated Faults...696
Fault Facts...696
Drive Cycle to Determine Fault Status...696
Possible Causes...696
Pin-Point Tests (SPN 4344 FMI 5)...700
Tools Required...700
DEFSP (Diesel Exhaust Fluid Supply Pump)...703
Overview of DEFSP Sensor Group...703
Overview...703
SPN 3361 FMI 2 - DEFSP Signal Erratic, Intermittent or Incorrect...707
Fault Overview...707
Lamp Reaction...707
Associated Faults...707
Fault Facts...707
Drive Cycle to Determine Fault Status...707
Possible Causes...707
Pin-Point Tests (SPN 3361 FMI 2)...710
Tools Required...710
SPN 3361 FMI 3 - DEFSP signal Out of Range HIGH...713
Fault Overview...713
Lamp Reaction...713
Associated Faults...713
Fault Facts...713
Drive Cycle to Determine Fault Status...713
Possible Causes...713
Pin-Point Tests (SPN 3361 FMI 3)...716
Tools Required...716
SPN 3361 FMI 4 - DEFSP Signal Out of Range LOW...718
Fault Overview...718
Lamp Reaction...718
Associated Faults...718
Fault Facts...718
Drive Cycle to Determine Fault Status...718
Possible Causes...718
Pin-Point Tests (SPN 3361 FMI 4)...721
Tools Required...721
SPN 3362 FMI 31 - DEF Dosing Unable to Prime...724
Fault Overview...724
Lamp Reaction...724
Associated Faults...724
Fault Facts...724
Drive Cycle to Determine Fault Status...724
Possible Causes...724
DEFTHV (Diesel Exhaust Fluid Tank Heater Valve)...729
Overview of DEFTHV...729
Overview...729
SPN 3363 FMI 3 - DEF Tank Heater Control Valve short to PWR...731
Fault Overview...731
Lamp Reaction...731
Associated Faults...731
Fault Facts...731
Drive Cycle to Determine Fault Status...731
Possible Causes...731
Pin-Point Tests (SPN 3363 FMI 3)...734
Tools Required...734
SPN 3363 FMI 4 - DEF Tank Heater Control Valve short to GND...737
Fault Overview...737
Lamp Reaction...737
Associated Faults...737
Fault Facts...737
Drive Cycle to Determine Fault Status...737
Possible Causes...737
Pin-Point Tests (SPN 3363 FMI 4)...740
Tools Required...740
SPN 3363 FMI 7 - DEF Tank Heater Control Valve Mechanical system not responding...742
Fault Overview...742
Lamp Reaction...742
Associated Faults...742
Drive Cycle to Determine Fault Status...742
Possible Causes...742
SPN 3363 FMI 16 - DEF Tank Heater Control Valve stuck open fault...745
Fault Overview...745
Lamp Reaction...745
Associated Faults...745
Fault Facts...745
Drive Cycle to Determine Fault Status...745
Possible Causes...745
SPN 3363 FMI 18 - DEF Tank Heater Control Valve unable to thaw frozen DEF...747
Fault Overview...747
Lamp Reaction...747
Associated Faults...747
Fault Facts...747
Drive Cycle to Determine Fault Status...747
Possible Causes...747
DEFTL & DEFTT (Diesel Exhaust Fluid Tank Level and Temperature) Sensor Module...750
Overview of DEFTL & DEFTT Sensor Group...750
Overview...750
SPN 1569 FMI 31 - SCR Tamperproof Warning & Protection System Inducement Severe...752
Fault Overview...752
Lamp Reaction...752
Associated Faults...752
Fault Facts...752
Drive Cycle to Determine Fault Status...752
Possible Causes...752
SPN 1761 FMI 1 - DEFTL Inducement (Level 3 - 4)...754
Fault Overview...754
Lamp Reaction...754
Associated Faults...754
Fault Facts...754
Drive Cycle to Determine Fault Status...754
Possible Causes...754
SPN 1761 FMI 3 - DEFTL signal Out of Range HIGH...756
Fault Overview...756
Lamp Reaction...756
Associated Faults...756
Fault Facts...756
Drive Cycle to Determine Fault Status...756
Possible Causes...756
SPN 1761 FMI 4 - DEFTL signal Out of Range LOW...758
Fault Overview...758
Lamp Reaction...758
Associated Faults...758
Fault Facts...758
Drive Cycle to Determine Fault Status...758
Possible Causes...758
SPN 1761 FMI 10 - DEF Level abnormal rate of change...760
Fault Overview...760
Lamp Reaction...760
Associated Faults...760
Fault Facts...760
Drive Cycle to Determine Fault Status...760
Possible Causes...760
SPN 1761 FMI 11 - DEFTL signal erratic, intermittent, or incorrect ...762
Fault Overview...762
Lamp Reaction...762
Associated Faults...762
Fault Facts...762
Drive Cycle to Determine Fault Status...762
Possible Causes...762
SPN 1761 FMI 17 - DEFTL Inducement Level 1...764
Fault Overview...764
Lamp Reaction...764
Associated Faults...764
Fault Facts...764
Drive Cycle to Determine Fault Status...764
Possible Causes...764
SPN 1761 FMI 18 - DEFTL Inducement Level 2...766
Fault Overview...766
Lamp Reaction...766
Associated Faults...766
Fault Facts...766
Drive Cycle to Determine Fault Status...766
Possible Causes...766
SPN 1761 FMI 19 - DEFTL not detected on J1939...768
Fault Overview...768
Lamp Reaction...768
Associated Faults...768
Fault Facts...768
Drive Cycle...768
Possible Causes...768
Pin-Point Tests SPN 1761 FMI 19...772
Tools Required...772
SPN 3031 FMI 2 - DEFTT signal erratic, intermittent, or incorrect...780
Fault Overview...780
Lamp Reaction...780
Associated Faults...780
Fault Facts...780
Drive Cycle to Determine Fault Status...780
Possible Causes...780
Pin-Point Tests (SPN 3031 FMI 2)...783
Tools Required...783
SPN 3031 FMI 3 - DEFTT Signal Out of Range HIGH...785
Fault Overview...785
Lamp Reaction...785
Associated Faults...785
Fault Facts...785
Drive Cycle to Determine Fault Status...785
Possible Causes...785
SPN 3031 FMI 4 - DEFTT signal Out of Range LOW...787
Fault Overview...787
Lamp Reaction...787
Associated Faults...787
Fault Facts...787
Drive Cycle to Determine Fault Status...787
Possible Causes...787
SPN 3521 FMI 11 - Improper Reductant in DEF Tank...789
Fault Overview...789
Lamp Reaction...789
Associated Faults...789
Fault Facts...789
Drive Cycle to Determine Fault Status...789
Possible Causes...789
SPN 4094 FMI 31- DEF below acceptable quality...791
Fault Overview...791
Lamp Reaction...791
Associated Faults...791
Fault Facts...791
Drive Cycle to Determine Fault Status...791
Possible Causes...791
SPN 5246 FMI 15 - SCR Tamper Proof Inducement Level 1 status...794
Fault Overview...794
Lamp Reaction...794
Associated Faults...794
Fault Facts...794
Drive Cycle to Determine Fault Status...794
Possible Causes...794
DEFSMH Relay (Diesel Exhaust Fluid Supply Module Heater Relay) ...796
Overview of DEFSMH Relay Sensor Group...796
Overview...796
SPN 5746 FMI 3 - DEF Supply Module Heater Relay short to PWR...798
Fault Overview...798
Lamp Reaction...798
Associated Faults...798
Fault Facts...798
Drive Cycle to Determine Fault Status...798
Possible Causes...798
Pin-Point Tests (SPN 5746 FMI 3)...801
Tools Required...801
SPN 5746 FMI 4 - DEF Supply Module Heater Relay short to GND...804
Fault Overview...804
Lamp Reaction...804
Associated Faults...804
Fault Facts...804
Drive Cycle to Determine Fault Status...804
Possible Causes...804
Pin-Point Tests (SPN 5746 FMI 4)...806
Tools Required...806
DOC Temperature Sensor Module...808
Overview of DOC / DPF Temperature Sensor Group...808
Overview...808
SPN 5742 FMI 3 - DPF Thermocouple Controller Out of Range HIGH...809
Fault Overview...809
Lamp Reaction...809
Associated Faults...809
Fault Facts...809
Drive Cycle to Determine Fault Status...809
Possible Causes...809
Pin-Point Tests (SPN 5742 FMI 3)...811
Tools Required...811
SPN 5742 FMI 4 - DPF Thermocouple Controller Out of Range LOW...812
Fault Overview...812
Lamp Reaction...812
Associated Faults...812
Fault Facts...812
Drive Cycle to Determine Fault Status...812
Possible Causes...812
Pin-Point Tests (SPN 5742 FMI 4)...814
Tools Required...814
SPN 5742 FMI 11 - DPF Thermocouple Controller signal erratic, intermittent, or incorrect...816
Fault Overview...816
Lamp Reaction...816
Associated Faults...816
Fault Facts...816
Drive Cycle to Determine Fault Status...816
Possible Causes...816
Pin-Point Tests (SPN 5742 FMI 11)...819
Tools Required...819
SPN 5742 FMI 12 - DOC/DPF Temperature sensor module internal error...821
Fault Overview...821
Lamp Reaction...821
Associated Faults...821
Fault Facts...821
Drive Cycle to Determine Fault Status...821
Possible Causes...821
SPN 5742 FMI 16 – DPF Thermocouple Controller above Maximum Temperature...823
Fault Overview...823
Lamp Reaction...823
Associated Faults...823
Fault Facts...823
Drive Cycle to Determine Fault Status...823
Possible Causes...823
SPN 5742 FMI 19 - DOC/DPF Temperature module not detect J1939...825
Fault Overview...825
Lamp Reaction...825
Associated Faults...825
Fault Facts...825
Drive Cycle to Determine Fault Status...825
Possible Causes...825
Pin-Point Tests (SPN 5742 FMI 19)...829
Tools Required...829
DOCIT Sensor (Diesel Oxidation Catalyst Intake Temperature)...837
Overview of DOCIT Sensor Group...837
Overview...837
SPN 4765 FMI 0 - DOCIT above Critical Temperature...839
Fault Overview...839
Lamp Reaction...839
Associated Faults...839
Fault Facts...839
Drive Cycle to Determine Fault Status...839
Possible Causes...839
SPN 4765 FMI 2 - DOCIT Signal erratic, intermittent, or incorrect...842
Fault Overview...842
Lamp Reaction...842
Associated Faults...842
Fault Facts...842
Drive Cycle to Determine Fault Status...842
Possible Causes...842
SPN 4765 FMI 3 - DOCIT signal Out of Range HIGH...844
Fault Overview...844
Lamp Reaction...844
Associated Faults...844
Fault Facts...844
Drive Cycle to Determine Fault Status...844
Possible Causes...844
SPN 4765 FMI 4 - DOCIT Signal Out of Range LOW...846
Fault Overview...846
Lamp Reaction...846
Associated Faults...846
Fault Facts...846
Drive Cycle to Determine Fault Status...846
Possible Causes...846
SPN 4765 FMI 15 - DOCIT Above Warning Temperature...848
Fault Overview...848
Lamp Reaction...848
Associated Faults...848
Fault Facts...848
Drive Cycle to Determine Fault Status...848
Possible Causes...848
SPN 4765 FMI 16 - DOCIT Above Maximum Temperature...851
Fault Overview...851
Lamp Reaction...851
Associated Faults...851
Fault Facts...851
Drive Cycle to Determine Fault Status...851
Possible Causes...851
DPF (Diesel Particulate Filter) Sensor ...854
Overview of DPF Sensor...854
Overview...854
SPN 5397 FMI 31 - DPF regenerations are occurring too frequently...855
Fault Overview...855
Lamp Reaction...855
Associated Faults...855
Fault Facts...855
Drive Cycle to Determine Fault Status...855
Possible Causes...855
DPFDP / DPFOP (Diesel Particulate Filter Differential Pressure / Diesel Particulate Filter Outlet Pressure) Sensor...858
Overview of DPFDP / DPFOP Sensor...858
Overview...858
SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect...859
Fault Overview...859
Lamp Reaction...859
Associated Faults...859
Fault Facts...859
Drive Cycle to Determine Fault Status...859
Possible Causes...859
Pin-Point Tests (SPN 3251 FMI 2)...862
Tools Required...862
SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH...863
Fault Overview...863
Lamp Reaction...863
Associated Faults...863
Fault Facts...863
Drive Cycle to Determine Fault Status...863
Possible Causes...863
Pin-Point Tests (SPN 3251 FMI 3)...866
Tools Required...866
SPN 3251 FMI 4 - DPFDP signal Out of Range LOW...868
Fault Overview...868
Lamp Reaction...868
Associated Faults...868
Fault Facts...868
Drive Cycle to Determine Fault Status...868
Possible Causes...868
Pin-Point Tests (SPN 3251 FMI 4)...871
Tools Required...871
SPN 3610 FMI 2 - DPFOP Signal Erratic, Intermittent, or Incorrect...874
Fault Overview...874
Lamp Reaction...874
Associated Faults...874
Fault Facts...874
Drive Cycle to Determine Fault Status...874
Possible Causes...874
Pin-Point Tests (SPN 3610 FMI 2)...877
Tools Required...877
SPN 3610 FMI 3 - DPFOP signal Out of Range HIGH...879
Fault Overview...879
Lamp Reaction...879
Associated Faults...879
Fault Facts...879
Drive Cycle to Determine Fault Status...879
Possible Causes...879
Pin-Point Tests (SPN 3610 FMI 3)...882
Tools Required...882
SPN 3610 FMI 4 - DPFOP Signal Out of Range LOW...884
Fault Overview...884
Lamp Reaction...884
Associated Faults...884
Fault Facts...884
Drive Cycle to Determine Fault Status...884
Possible Causes...884
Pin-Point Tests (SPN 3610 FMI 4)...887
Tools Required...887
DPFIT Sensor (Diesel Particulate Filter Intake Temperature)...890
Overview of DPFIT Sensor Group...890
Overview...890
SPN 3242 FMI 0 - DPFIT above Critical Temperature...891
Fault Overview...891
Lamp Reaction...891
Associated Faults...891
Fault Facts...891
Drive Cycle to Determine Fault Status...891
Possible Causes...891
SPN 3242 FMI 2 - DPFIT signal erratic, intermittent, or incorrect...894
Fault Overview...894
Lamp Reaction...894
Associated Faults...894
Fault Facts...894
Drive Cycle to Determine Fault Status...894
Possible Causes...894
SPN 3242 FMI 3 - DPFIT signal Out of Range HIGH...896
Fault Overview...896
Lamp Reaction...896
Associated Faults...896
Fault Facts...896
Drive Cycle to Determine Fault Status...896
Possible Causes...896
SPN 3242 FMI 4 - DPFIT signal Out of Range LOW...898
Fault Overview...898
Lamp Reaction...898
Associated Faults...898
Fault Facts...898
Drive Cycle to Determine Fault Status...898
Possible Causes...898
SPN 3242 FMI 15 - DPFIT above Warning Temperature...900
Fault Overview...900
Lamp Reaction...900
Associated Faults...900
Fault Facts...900
Drive Cycle to Determine Fault Status...900
Possible Causes...900
SPN 3242 FMI 16 - DPFIT above Maximum Temperature...903
Fault Overview...903
Lamp Reaction...903
Associated Faults...903
Fault Facts...903
Drive Cycle to Determine Fault Status...903
Possible Causes...903
SPN 4766 FMI 15 - DPFIT Above Warning Temperature...906
Fault Overview...906
Lamp Reaction...906
Associated Faults...906
Fault Facts...906
Drive Cycle to Determine Fault Status...906
Possible Causes...906
SPN 4766 FMI 16 - DPFIT Above Maximum Temperature...909
Fault Overview...909
Lamp Reaction...909
Associated Faults...909
Fault Facts...909
Drive Cycle to Determine Fault Status...909
Possible Causes...909
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)...912
Overview of DPFOT Sensor Group...912
Overview...912
SPN 3246 FMI 0 - DPFOT above Critical Temperature...913
Fault Overview...913
Lamp Reaction...913
Associated Faults...913
Fault Facts...913
Drive Cycle to Determine Fault Status...913
Possible Causes...913
SPN 3246 FMI 2 - DPFOT Signal Erratic, Intermittent, or Incorrect...916
Fault Overview...916
Lamp Reaction...916
Associated Faults...916
Fault Facts...916
Drive Cycle to Determine Fault Status...916
Possible Causes...916
SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH...918
Fault Overview...918
Lamp Reaction...918
Associated Faults...918
Fault Facts...918
Drive Cycle to Determine Fault Status...918
Possible Causes...918
SPN 3246 FMI 4 - DPFOT Signal Out of Range LOW...920
Fault Overview...920
Lamp Reaction...920
Associated Faults...920
Fault Facts...920
Drive Cycle to Determine Fault Status...920
Possible Causes...920
SPN 3246 FMI 15 - DPFOT above Warning Temperature...922
Fault Overview...922
Lamp Reaction...922
Associated Faults...922
Fault Facts...922
Drive Cycle to Determine Fault Status...922
Possible Causes...922
SPN 3246 FMI 16 - DPFOT above Maximum Temperature...925
Fault Overview...925
Lamp Reaction...925
Associated Faults...925
Fault Facts...925
Drive Cycle to Determine Fault Status...925
Possible Causes...925
EBP Sensor (Exhaust Back Pressure)...928
Overview of EBP Sensor Group...928
Overview...928
SPN 1209 FMI 2 - EBP Signal erratic, intermittent, or incorrect...929
Fault Overview...929
Lamp Reaction...929
Associated Faults...929
Fault Facts...929
Drive Cycle to Determine Fault Status...929
Possible Causes...929
SPN 1209 FMI 3 - EBP Signal Out of Range HIGH...931
Fault Overview...931
Lamp Reaction...931
Associated Faults...931
Fault Facts...931
Drive Cycle to Determine Fault Status...931
Possible Causes...931
Pin-Point Tests (SPN 1209 FMI 3)...934
Tools Required...934
SPN 1209 FMI 4 - EBP Signal Out of Range LOW...936
Fault Overview...936
Lamp Reaction...936
Associated Faults...936
Fault Facts...936
Drive Cycle to Determine Fault Status...936
Possible Causes...936
Pin-Point Tests (SPN 1209 FMI 4)...939
Tools Required...939
EBPV (Exhaust Back Pressure Valve)...943
Overview of EBPV Sensor Group...943
Overview...943
SPN 5541 FMI 2 - TC1TOP signal erratic, intermittent, or incorrect ...944
Function...944
Lamp Reaction...944
Associated Faults...944
Fault Facts...944
Drive Cycle to Determine Fault Status...944
Possible Causes...944
SPN 5541 FMI 3 - TC1TOP signal Out of Range HIGH...946
Fault Overview...946
Lamp Reaction...946
Associated Faults...946
Fault Facts...946
Drive Cycle to Determine Fault Status...946
Possible Causes...946
Pin-Point Tests (SPN 5541 FMI 3)...948
Tools Required...948
SPN 5541 FMI 4 - TC1TOP signal Out of Range LOW...949
Fault Overview...949
Lamp Reaction...949
Associated Faults...949
Fault Facts...949
Drive Cycle to Determine Fault Status...949
Possible Causes...949
Pin-Point Tests (SPN 5541 FMI 4)...952
Tools Required...952
SPN 5542 FMI 15 - TC1TOP Above Desired...954
Fault Overview...954
Lamp Reaction...954
Associated Faults...954
Fault Facts...954
Drive Cycle to Determine Fault Status...954
Possible Causes...954
SPN 5543 FMI 3 - EBPC short to PWR...956
Fault Overview...956
Lamp Reaction...956
Associated Faults...956
Fault Facts...956
Drive Cycle to Determine Fault Status...956
Possible Causes...956
Pin-Point Tests (SPN 5543 FMI 3)...959
Tools Required...959
SPN 5543 FMI 4 - EBPC short to GND...962
Fault Overview...962
Lamp Reaction...962
Associated Faults...962
Fault Facts...962
Drive Cycle to Determine Fault Status...962
Possible Causes...962
Pin-Point Tests (SPN 5543 FMI 4)...964
Tools Required...964
SPN 5543 FMI 5 - EBPC open load/circuit...965
Fault Overview...965
Lamp Reaction...965
Associated Faults...965
Fault Facts...965
Drive Cycle to Determine Fault Status...965
Possible Causes...965
Pin-Point Tests (SPN 5543 FMI 5)...968
Tools Required...968
ECB1 (Engine Compression Brake Output 1)...970
Overview of ECB1 Sensor Group...970
Overview...970
SPN 4287 FMI 0 - ECBP above desired level...971
Fault Overview...971
Lamp Reaction...971
Associated Faults...971
Fault Facts...971
Drive Cycle to Determine Fault Status...971
Possible Causes...971
SPN 4287 FMI 1 - ECPB below desired level...974
Fault Overview...974
Lamp Reaction...974
Associated Faults...974
Fault Facts...974
Drive Cycle to Determine Fault Status...974
Possible Causes...974
SPN 4287 FMI 3 - ECBP signal Out of Range HIGH...976
Fault Overview...976
Lamp Reaction...976
Associated Faults...976
Fault Facts...976
Drive Cycle to Determine Fault Status...976
Possible Causes...976
Pin-Point Tests SPN 4287 FMI 3...980
Tools Required...980
SPN 4287 FMI 4 - ECBP signal Out of Range LOW...988
Fault Overview...988
Lamp Reaction...988
Associated Faults...988
Fault Facts...988
Drive Cycle to Determine Fault Status...988
Possible Causes...988
Pin-Point Tests (SPN 4287 FMI 4)...991
Tools Required...991
ECI Circuit (Engine Crank Inhibit)...992
Overview of ECI Circuit...992
Function...992
Location...992
Tools...992
ECI Circuit Diagnostics...994
ECI Circuit Operation...997
DDS Circuit...997
Ignition Switch...997
ECI Circuit...997
Engine Control Module (ECM)...997
Starter Relay...997
Clutch Switch...997
Neutral Switch...997
WTEC MD with Auto Neutral...997
Fault Detection / Management...998
ECM (Engine Control Module)...999
Overview of ECM Sensor ...999
Overview...999
SPN 108 FMI 2 - BARO Signal Erratic, Intermittent or Incorrect...1000
Fault Overview...1000
Lamp Reaction...1000
Associated Faults...1000
Fault Facts...1000
Drive Cycles...1000
Possible Cause...1000
SPN 108 FMI 3 - BARO signal Out of Range HIGH...1002
Fault Overview...1002
Lamp Reaction...1002
Associated Faults...1002
Fault Facts...1002
Drive Cycle to Determine Fault Status...1002
Possible Causes...1002
SPN 108 FMI 4 - BARO signal Out of Range LOW...1004
Fault Overview...1004
Lamp Reaction...1004
Associated Faults...1004
Fault Facts...1004
Drive Cycle to Determine Fault Status...1004
Possible Causes...1004
SPN 158 FMI 15 - ECM Switched voltage too HIGH...1006
Fault Overview...1006
Lamp Reaction...1006
Associated Faults...1006
Fault Facts...1006
Drive Cycle to Determine Fault Status...1006
Possible Causes...1006
SPN 158 FMI 17 - ECM Switched voltage too LOW...1008
Fault Overview...1008
Lamp Reaction...1008
Associated Faults...1008
Fault Facts...1008
Drive Cycle to Determine Fault Status...1008
Possible Causes...1008
Pin-Point Tests (SPN 158 FMI 17)...1012
Tools Required...1012
SPN 628 FMI 12 - ECM Memory Error...1017
Fault Overview...1017
Lamp Reaction...1017
Associated Faults...1017
Fault Facts...1017
Drive Cycle to Determine Fault Status...1017
Possible Causes...1017
SPN 629 FMI 0 - ECM Error - CPU Load Excessively HIGH...1019
Fault Overview...1019
Lamp Reaction...1019
Associated Faults...1019
Fault Facts...1019
Drive Cycle to Determine Fault Status...1019
Possible Causes...1019
SPN 629 FMI 8 - ECM Error - Engine Off Timer fault...1021
Fault Overview...1021
Lamp Reaction...1021
Associated Faults...1021
Fault Facts...1021
Drive Cycle to Determine Fault Status...1021
Possible Causes...1021
SPN 629 FMI 12 - ECM Internal chip Error...1024
Fault Overview...1024
Lamp Reaction...1024
Associated Faults...1024
Fault Facts...1024
Drive Cycle to Determine Fault Status...1024
Possible Causes...1024
SPN 1136 FMI 0 - ECM Error - over temperature...1026
Fault Overview...1026
Lamp Reaction...1026
Associated Faults...1026
Fault Facts...1026
Drive Cycle to Determine Fault Status...1026
Possible Causes...1026
SPN 1387 FMI 31 - Altitude Reference Adder Fault...1028
Fault Overview...1028
Lamp Reaction...1028
Associated Faults...1028
Fault Facts...1028
Drive Cycle to Determine Fault Status...1028
Possible Causes...1028
Pin-Point Tests...1033
Tools Required...1033
ECT1 Sensor (Engine Coolant Temperature 1)...1036
Overview of ECT1 Sensor Group...1036
Overview...1036
SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect...1038
Fault Overview...1038
Lamp Reaction...1038
Associated Faults...1038
Fault Facts...1038
Drive Cycle to Determine Fault Status...1038
Possible Causes...1038
Pin-Point Tests (SPN 110 FMI 2)...1041
Tools Required...1041
SPN 110 FMI 3 - ECT1 Signal Out of Range HIGH...1043
Fault Overview...1043
Lamp Reaction...1043
Associated Faults...1043
Fault Facts...1043
Drive Cycle to Determine Fault Status...1043
Possible Causes...1043
Pin-Point Tests (SPN 110 FMI 3)...1046
Tools Required...1046
SPN 110 FMI 4 - ECT1 signal Out of Range LOW...1049
Fault Overview...1049
Lamp Reaction...1049
Associated Faults...1049
Fault Facts...1049
Drive Cycle to Determine Fault Status...1049
Possible Causes...1049
Pin-Point Tests (SPN 110 FMI 4)...1051
Tools Required...1051
SPN 110 FMI 17 - ECT1 stuck in range Low...1052
Fault Overview...1052
Lamp Reaction...1052
Associated Faults...1052
Fault Facts...1052
Drive Cycle to Determine Fault Status...1052
Possible Causes...1052
SPN 110 FMI 18 - Engine Coolant System below closed loop minimum Temperature...1054
Fault Overview...1054
Lamp Reaction...1054
Associated Faults...1054
Fault Facts...1054
Drive Cycle to Determine Fault Status...1054
Possible Causes...1054
SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat...1056
Fault Overview...1056
Lamp Reaction...1056
Associated Faults...1056
Fault Facts...1056
Drive Cycle to Determine Fault Status...1056
Possible Causes...1056
Pin-Point Tests (SPN 1659 FMI 20)...1059
Tools Required...1059
EFP (Engine Fuel Pump)...1060
Overview of EFP Group...1060
Overview...1060
SPN 94 FMI 0 - Fuel Delivery Pressure above Critical...1061
Fault Overview...1061
Lamp Reaction...1061
Associated Faults...1061
Fault Facts...1061
Drive Cycle to Determine Fault Status...1061
Possible Causes...1061
SPN 94 FMI 1 - Fuel Delivery Pressure below Critical...1063
Fault Overview...1063
Lamp Reaction...1063
Associated Faults...1063
Fault Facts...1063
Drive Cycle to Determine Fault Status...1063
Possible Causes...1063
SPN 931 FMI 3 - EFP short to PWR...1065
Fault Overview...1065
Lamp Reaction...1065
Associated Faults...1065
Fault Facts...1065
Drive Cycle to Determine Fault Status...1065
Possible Causes...1065
Pin-Point Test SPN 931 FMI 3...1068
Tools Required...1068
SPN 931 FMI 4 - EFP open load / circuit or short to GND...1071
Fault Overview...1071
Lamp Reaction...1071
Associated Faults...1071
Fault Facts...1071
Drive Cycle to Determine Fault Status...1071
Possible Causes...1071
Pin-Point Test SPN 931 FMI 4...1074
Tools Required...1074
EGR Actuator (Exhaust Gas Recirculation)...1080
Overview of EGR Actuator Sensor Group...1080
Overview...1080
SPN 27 FMI 0 - EGRP fault: over temperature...1082
Fault Overview...1082
Lamp Reaction...1082
Associated Faults...1082
Fault Facts...1082
Drive Cycle to Determine Fault Status...1082
Possible Causes...1082
SPN 27 FMI 14 - EGR internal circuit failure...1084
Fault Overview...1084
Lamp Reaction...1084
Associated Faults...1084
Fault Facts...1084
Drive Cycle to Determine Fault Status...1084
Possible Causes...1084
SPN 2791 FMI 2 - EGR feedback communication fault...1086
Fault Overview...1086
Lamp Reaction...1086
Associated Faults...1086
Fault Facts...1086
Drive Cycle to Determine Fault Status...1086
Possible Causes...1086
Pin-Point Tests (SPN 2791 FMI 2)...1090
Tools Required...1090
SPN 2791 FMI 3 - EGRV supply voltage is too HIGH...1092
Fault Overview...1092
Lamp Reaction...1092
Associated Faults...1092
Fault Facts...1092
Drive Cycle to Determine Fault Status...1092
Possible Causes...1092
SPN 2791 FMI 4 - EGRV supply voltage is too LOW...1094
Fault Overview...1094
Lamp Reaction...1094
Associated Faults...1094
Fault Facts...1094
Drive Cycle to Determine Fault Status...1094
Possible Causes...1094
Pin-Point Tests (SPN 2791 FMI 4)...1096
Tools Required...1096
SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position...1098
Fault Overview...1098
Lamp Reaction...1098
Associated Faults...1098
Fault Facts...1098
Drive Cycle to Determine Fault Status...1098
Possible Causes...1098
SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal...1100
Fault Overview...1100
Lamp Reaction...1100
Associated Faults...1100
Fault Facts...1100
Drive Cycle to Determine Fault Status...1100
Possible Causes...1100
Pin-Point Tests (SPN 2791 FMI 8)...1104
Tools Required...1104
SPN 2791 FMI 12 - EGR Valve Internal self test fault...1109
Fault Overview...1109
Lamp Reaction...1109
Associated Fault...1109
Fault Facts...1109
Drive Cycle to Determine Fault Status...1109
Possible Causes...1109
SPN 2791 FMI 14 - EGR Valve did not seat...1111
Fault Overview...1111
Lamp Reaction...1111
Associated Fault...1111
Fault Facts...1111
Drive Cycle to Determine Fault Status...1111
Possible Causes...1111
SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temp above expected...1113
Fault Overview...1113
Lamp Reaction...1113
Associated Faults...1113
Fault Facts...1113
Drive Cycle to Determine Fault Status...1113
Possible Causes...1113
EGT Sensor (Exhaust Gas Temperature)...1116
Overview of EGT Sensor Group...1116
Overview...1116
SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect...1118
Fault Overview...1118
Lamp Reaction...1118
Associated Faults...1118
Fault Facts...1118
Drive Cycle to Determine Fault Status...1118
Possible Causes...1118
Pin-Point Tests (SPN 173 FMI 2)...1121
Tools Required...1121
SPN 173 FMI 3 - EGT Signal Out of Range HIGH...1123
Fault Overview...1123
Lamp Reaction...1123
Associated Faults...1123
Fault Facts...1123
Drive Cycle to Determine Fault Status...1123
Possible Causes...1123
Pin-Point Tests (SPN 173 FMI 3)...1126
Tools Required...1126
SPN 173 FMI 4 - EGT Signal Out of Range LOW...1129
Fault Overview...1129
Lamp Reaction...1129
Associated Faults...1129
Fault Facts...1129
Drive Cycle to Determine Fault Status...1129
Possible Causes...1129
Pin-Point Tests (SPN 173 FMI 4)...1131
Tools Required...1131
Engine...1132
Overview of Engine Sensor ...1132
SPN 188 FMI 0 - Engine Low Idle RPM above normal...1133
Fault Overview...1133
Lamp Reaction...1133
Associated Faults...1133
Fault Facts...1133
Drive Cycle to Determine Fault Status...1133
Possible Causes...1133
SPN 188 FMI 1 - Engine Low Idle RPM below normal...1135
Fault Overview...1135
Lamp Reaction...1135
Associated Faults...1135
Fault Facts...1135
Drive Cycle to Determine Fault Status...1135
Possible Causes...1135
SPN 1322 FMI 31 Misfire - Multiple Cylinders...1138
Fault Overview...1138
Lamp Reaction...1138
Associated Faults...1138
Fault Facts...1138
Drive Cycle to Determine Fault Status...1138
Possible Causes...1138
SPN 1323 FMI 31 - Misfire - Cylinder 1...1142
Fault Overview...1142
Lamp Reaction...1142
Associated Faults...1142
Fault Facts...1142
Drive Cycle to Determine Fault Status...1142
Possible Causes...1142
Pin-Point Tests...1146
Tools Required...1146
SPN 1324 FMI 31 - Misfire - Cylinder 2...1147
Fault Overview...1147
Lamp Reaction...1147
Associated Faults...1147
Fault Facts...1147
Drive Cycle to Determine Fault Status...1147
Possible Causes...1147
Pin-Point Tests...1151
Tools Required...1151
SPN 1325 FMI 31 - Misfire - Cylinder 3...1152
Fault Overview...1152
Lamp Reaction...1152
Associated Faults...1152
Fault Facts...1152
Drive Cycle to Determine Fault Status...1152
Possible Causes...1152
Pin-Point Tests...1156
Tools Required...1156
SPN 1326 FMI 31 - Misfire - Cylinder 4...1157
Fault Overview...1157
Lamp Reaction...1157
Associated Faults...1157
Fault Facts...1157
Drive Cycle to Determine Fault Status...1157
Possible Causes...1157
Pin-Point Tests...1161
Tools Required...1161
SPN 1327 FMI 31 - Misfire - Cylinder 5...1162
Fault Overview...1162
Lamp Reaction...1162
Associated Faults...1162
Fault Facts...1162
Drive Cycle to Determine Fault Status...1162
Possible Causes...1162
Pin-Point Tests...1166
Tools Required...1166
SPN 1328 FMI 31 - Misfire - Cylinder 6...1167
Fault Overview...1167
Lamp Reaction...1167
Associated Faults...1167
Fault Facts...1167
Drive Cycle to Determine Fault Status...1167
Possible Causes...1167
Pin-Point Tests...1171
Tools Required...1171
SPN 5395 FMI 0 Engine unable to achieve desired idle torque (too high)...1172
Fault Overview...1172
Lamp Reaction...1172
Associated Faults...1172
Fault Facts...1172
Drive Cycle to Determine Fault Status...1172
Possible Causes...1172
SPN 5395 FMI 1 Engine unable to achieve desired idle torque (too low)...1175
Fault Overview...1175
Lamp Reaction...1175
Associated Faults...1175
Fault Facts...1175
Drive Cycle to Determine Fault Status...1175
Possible Causes...1175
EOP Sensor (Engine Oil Pressure)...1178
Overview of EOP Sensor Group...1178
Overview...1178
SPN 100 FMI 3 - EOP signal Out of Range HIGH...1179
Fault Overview...1179
Lamp Reaction...1179
Associated Faults...1179
Fault Facts...1179
Drive Cycle to Determine Fault Status...1179
Possible Causes...1179
Pin-Point Tests (SPN 100 FMI 3)...1182
Tools Required...1182
SPN 100 FMI 4 - EOP Signal Out of Range LOW...1184
Fault Overview...1184
Lamp Reaction...1184
Associated Faults...1184
Fault Facts...1184
Drive Cycle to Determine Fault Status...1184
Possible Causes...1184
Pin-Point Tests (SPN 100 FMI 4)...1187
Tools Required...1187
EOT Sensor (Engine Oil Temperature)...1190
Overview of EOT Sensor Group...1190
Overview...1190
SPN 175 FMI 2 - EOT signal erratic, intermittent, or incorrect...1192
Fault Overview...1192
Lamp Reaction...1192
Associated Faults...1192
Fault Facts...1192
Drive Cycle to Determine Fault Status...1192
Possible Causes...1192
Pin-Point Tests (SPN 175 FMI 2)...1195
Tools Required...1195
SPN 175 FMI 3 - EOT signal Out of Range HIGH...1197
Fault Overview...1197
Lamp Reaction...1197
Associated Faults...1197
Fault Facts...1197
Drive Cycle to Determine Fault Status...1197
Possible Causes...1197
Pin-Point Tests (SPN 175 FMI 3)...1200
Tools Required...1200
SPN 175 FMI 4 - EOT signal Out of Range LOW...1203
Fault Overview...1203
Lamp Reaction...1203
Associated Faults...1203
Fault Facts...1203
Drive Cycle to Determine Fault Status...1203
Possible Causes...1203
Pin-Point Tests (SPN 175 FMI 4)...1205
Tools Required...1205
SPN 175 FMI 7 - EOT not warming along with engine...1206
Fault Overview...1206
Lamp Reaction...1206
Associated Faults...1206
Fault Facts...1206
Drive Cycle to Determine Fault Status...1206
Possible Causes...1206
Pin-Point Tests (SPN 175 FMI 7)...1209
Tools Required...1209
ETP (Engine Throttle Valve Position)...1212
Overview of ETP Sensor Group...1212
Overview...1212
SPN 51 FMI 3 - ETP signal Out of Range HIGH...1214
Fault Overview...1214
Lamp Reaction...1214
Associated Faults...1214
Drive Cycle to Determine Fault Status...1214
Possible Causes...1214
SPN 51 FMI 4 - ETP signal Out of Range LOW...1216
Fault Overview...1216
Lamp Reaction...1216
Associated Faults...1216
Fault Facts...1216
Drive Cycle to Determine Fault Status...1216
Possible Causes...1216
Pin-Point Tests (SPN 51 FMI 4)...1219
Tools Required...1219
SPN 51 FMI 7 - ETP does not agree with commanded position...1223
Fault Overview...1223
Lamp Reaction...1223
Associated Faults...1223
Fault Facts...1223
Drive Cycle to Determine Fault Status...1223
Possible Causes...1223
SPN 3464 FMI 31 - Intake Throttle Valve short circuit fault...1225
Fault Overview...1225
Lamp Reaction...1225
Associated Faults...1225
Fault Facts...1225
Drive Cycle to Determine Fault Status...1225
Possible Causes...1225
Pin-Point Tests (SPN 3464 FMI 31)...1228
Tools Required...1228
EWPS (Engine Warning Protection System)...1230
Overview of EWPS Sensor Group...1230
Overview...1230
Standard Warning...1230
3-way Warning...1230
3-way Protection...1230
Warning (Amber Triangle Light):...1231
Critical (Exclamation Mark Stop Lamp):...1231
Event log (if equipped):...1231
EWPS Programmable Parameters...1231
ECT Warning Temperature:...1231
ECT Critical Temperature:...1231
EOP Engine Speed Region Boundary 1 (600 RPM):...1231
EOP Engine Speed Region Boundary 2 (800 RPM):...1231
EOP Engine Speed Region Boundary 3 (1000 RPM):...1231
EOP Warning Pressure for Region 1 (10 psi / 69 kPa):...1231
EOP Warning pressure for Region 2 (16 psi / 110 kPa):...1231
EOP Warning Pressure for Region 3 (20 psi / 138 kPa):...1232
EOP Critical Pressure for Region 1 (7.5 psi / 52 kPa):...1232
EOP Critical Pressure for Region 2 (12 psi / 83 kPa):...1232
EOP Critical Pressure for Region 3. (15 psi / 103 kPa):...1232
SPN 100 FMI 1 - Engine Oil System below Critical Pressure...1233
Fault Overview...1233
Associated Faults...1233
Fault Facts...1233
Drive Cycle to Determine Fault Status...1233
Possible Causes...1233
SPN 100 FMI 18 - Engine Oil System below Warning Pressure...1235
Fault Overview...1235
Associated Faults...1235
Fault Facts...1235
Drive Cycle to Determine Fault Status...1235
Possible Causes...1235
SPN 110 FMI 0 - Engine Cooling System above Critical Temperature...1237
Fault Overview...1237
Lamp Reaction...1237
Associated Faults...1237
Fault Facts...1237
Drive Cycle to Determine Fault Status...1237
Possible Causes...1237
SPN 110 FMI 15 - Engine Cooling System above Warning Temperature...1239
Fault Overview...1239
Lamp Reaction...1239
Associated Faults...1239
Fault Facts...1239
Drive Cycle to Determine Fault Status...1239
Possible Causes...1239
SPN 110 FMI 16 - ECT1 stuck in range High...1241
Fault Overview...1241
Lamp Reaction...1241
Associated Faults...1241
Fault Facts...1241
Drive Cycle to Determine Fault Status...1241
Possible Causes...1241
SPN 111 FMI 1 - ECL Below Warning / Critical Level...1243
Fault Overview...1243
Lamp Reaction...1243
Associated Faults...1243
Fault Facts...1243
Drive Cycle to Determine Fault Status...1243
Possible Causes...1243
Pin-Point Tests (SPN 111 FMI 31)...1245
SPN 111 FMI 2 - ECL signal erratic, intermittent, or incorrect...1246
Fault Overview...1246
Lamp Reaction...1246
Associated Faults...1246
Fault Facts...1246
Drive Cycle to Determine Fault Status...1246
Possible Causes...1246
Pin-Point Tests...1248
Tools Required...1248
SPN 175 FMI 15 - Engine Oil System above Warning Temperature...1249
Fault Overview...1249
Lamp Reaction...1249
Associated Faults...1249
Fault Facts...1249
Drive Cycle to Determine Fault Status...1249
Possible Causes...1249
Pin-Point Tests (SPN 175 FMI 15)...1252
Tools Required...1252
SPN 190 FMI 0 - Engine overspeed - Most Severe Level...1255
Fault Overview...1255
Lamp Reaction...1255
Associated Faults...1255
Fault Facts...1255
Drive Cycle to Determine Fault Status...1255
Possible Causes...1255
SPN 593 FMI 31 - Engine Stopped by IST...1257
Function...1257
Tools...1257
Idle Shutdown Warning...1257
Engine Idle Shutdown Timer (IST) for California ESS Compliant Engines...1257
CARB Idle Shutdown Timer (IST) Conditions...1258
Idle Shutdown Timer (IST) (Federal – Optional)...1258
Federal IST Conditions...1258
Common Enable Conditions for All Federal IST Options...1258
Federal IST Mode 1: PTO Operation Option Enable Conditions...1259
Federal IST Mode 2: No Load/Light Load Limit Option Enable Conditions...1259
Federal IST Mode 3: Tamper Proof Option Enable Conditions...1259
Fault Detection / Management...1259
SPN 1378 FMI 31 - Change Engine Oil Service Interval...1260
Fault Overview...1260
Lamp Reaction...1260
Associated Faults...1260
Fault Facts...1260
Drive Cycle to Determine Fault Status...1260
Possible Causes...1260
SPN 3936 FMI 0 - DPF Soot Load – Severe De-Rate...1262
Fault Overview...1262
Lamp Reaction...1262
Associated Faults...1262
Fault Facts...1262
Drive Cycle to Determine Fault Status...1262
Possible Causes...1262
FDP (Fuel Delivery Pressure) Sensor...1266
Overview of FDP Sensor Group...1266
Overview...1266
SPN 94 FMI 3 - FDP signal Out of Range HIGH...1268
Fault Overview...1268
Lamp Reaction...1268
Associated Faults...1268
Fault Facts...1268
Drive Cycle to Determine Fault Status...1268
Possible Causes...1268
Pin-Point Tests (SPN 94 FMI 3)...1271
Tools Required...1271
SPN 94 FMI 4 - FDP signal Out of Range LOW...1273
Fault Overview...1273
Lamp Reaction...1273
Associated Faults...1273
Fault Facts...1273
Drive Cycle to Determine Fault Status...1273
Possible Causes...1273
Pin-Point Tests (SPN 94 FMI 4)...1276
Tools Required...1276
SPN 94 FMI 17 - Fuel Delivery Pressure below minimum...1279
Fault Overview...1279
Lamp Reaction...1279
Associated Faults...1279
Fault Facts...1279
Drive Cycle to Determine Fault Status...1279
Possible Causes...1279
SPN 94 FMI 18 - Fuel Delivery Pressure below min during cranking...1281
Fault Overview...1281
Lamp Reaction...1281
Associated Faults...1281
Fault Facts...1281
Drive Cycles...1281
Possible Causes...1281
FLI (Fuel Level Signal)...1283
Overview of FLI Sensor Group...1283
Overview...1283
SPN 96 FMI 3 - Fuel Level signal Out of Range HIGH...1284
Fault Overview...1284
Lamp Reaction...1284
Associated Faults...1284
Fault Facts...1284
Drive Cycle to Determine Fault Status...1284
Possible Causes...1284
SPN 96 FMI 4 - Fuel Level signal Out of Range LOW...1286
Fault Overview...1286
Lamp Reaction...1286
Associated Faults...1286
Fault Facts...1286
Drive Cycle to Determine Fault Status...1286
Possible Causes...1286
SPN 96 FMI 19 - Fuel Level not detected on J1939...1288
Fault Overview...1288
Lamp Reaction...1288
Associated Faults...1288
Fault Facts...1288
Drive Cycle to Determine Fault Status...1288
Possible Causes...1288
IAHC (Intake Air Heater Control)...1290
Overview of IAHC Group...1290
Overview...1290
SPN 729 FMI 3 - IAHC short to PWR...1291
Fault Overview...1291
Lamp Reaction...1291
Associated Faults...1291
Fault Facts...1291
Drive Cycle to Determine Fault Status...1291
Possible Causes...1291
Pin-Point Tests (SPN 729 FMI 3)...1293
Tools Required...1293
SPN 729 FMI 4 - IAHC short to GND...1294
Fault Overview...1294
Lamp Reaction...1294
Associated Faults...1294
Fault Facts...1294
Drive Cycle to Determine Fault Status...1294
Possible Causes...1294
Pin-Point Tests...1296
Tools Required...1296
SPN 729 FMI 5 - IAHC open load / circuit...1297
Fault Overview...1297
Lamp Reaction...1297
Associated Faults...1297
Fault Facts...1297
Drive Cycle to Determine Fault Status...1297
Possible Causes...1297
Pin-Point Tests (SPN 729 FMI 5)...1299
Tools Required...1299
SPN 729 FMI 18 - IAH Monitor fault: Lack of Heat in the Intake Manifold...1302
Fault Overview...1302
Lamp Reaction...1302
Associated Faults...1302
Fault Facts...1302
Drive Cycle to Determine Fault Status...1302
Possible Causes...1302
Pin-Point Tests...1305
Tools Required...1305
ICP Sensor (Injection Control Pressure)...1306
Overview of ICP Sensor Group...1306
Overview...1306
SPN 164 FMI 0 - ICP above KOEO Specification...1307
Fault Overview...1307
Lamp Reaction...1307
Associated Faults...1307
Fault Facts...1307
Drive Cycle to Determine Fault Status...1307
Possible Causes...1307
SPN 164 FMI 1 - ICP Unable to Build During Engine Cranking...1309
Fault Overview...1309
Lamp Reaction...1309
Associated Faults...1309
Fault Facts...1309
Drive Cycle to Determine Fault Status...1309
Possible Causes...1309
SPN 164 FMI 3 - ICP signal Out of Range HIGH...1312
Fault Overview...1312
Lamp Reaction...1312
Associated Faults...1312
Fault Facts...1312
Drive Cycle to Determine Fault Status...1312
Possible Causes...1312
Pin-Point Tests (SPN 164 FMI 3)...1316
Tools Required...1316
SPN 164 FMI 4 - ICP signal Out of Range LOW...1323
Fault Overview...1323
Lamp Reaction...1323
Associated Faults...1323
Fault Facts...1323
Drive Cycle to Determine Fault Status...1323
Possible Causes...1323
Pin-Point Tests (SPN 164 FMI 4)...1326
Tools Required...1326
SPN 164 FMI 15 - ICP too high during test...1328
Fault Overview...1328
Lamp Reaction...1328
Associated Faults...1328
Fault Facts...1328
Drive Cycle to Determine Fault Status...1328
Possible Causes...1328
SPN 164 FMI 16 - ICP above desired level...1331
Fault Overview...1331
Lamp Reaction...1331
Associated Faults...1331
Fault Facts...1331
Drive Cycle to Determine Fault Status...1331
Possible Causes...1331
SPN 164 FMI 17 - ICP unable to build during test...1334
Fault Overview...1334
Lamp Reaction...1334
Associated Faults...1334
Fault Facts...1334
Drive Cycle to Determine Fault Status...1334
Possible Causes...1334
SPN 164 FMI 18 - ICP below desired level...1338
Fault Overview...1338
Lamp Reaction...1338
Associated Faults...1338
Fault Facts...1338
Drive Cycle to Determine Fault Status...1338
Possible Causes...1338
IMP (Intake Manifold Pressure)...1342
Overview of IMP Sensor Group...1342
Overview...1342
SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect...1343
Fault Overview...1343
Lamp Reaction...1343
Associated Faults...1343
Fault Facts...1343
Drive Cycle to Determine Fault Status...1343
Possible Causes...1343
SPN 102 FMI 3 - IMP signal Out of Range HIGH...1345
Fault Overview...1345
Lamp Reaction...1345
Associated Faults...1345
Fault Facts...1345
Drive Cycle to Determine Fault Status...1345
Possible Causes...1345
Pin-Point Tests (SPN 102 FMI 3)...1348
Tools Required...1348
SPN 102 FMI 4 - IMP signal Out of Range LOW...1349
Fault Overview...1349
Lamp Reaction...1349
Associated Faults...1349
Fault Facts...1349
Drive Cycle to Determine Fault Status...1349
Possible Causes...1349
Pin-Point Tests (SPN 102 FMI 4)...1352
Tools Required...1352
SPN 102 FMI 7 - IMP signal not responding as expected...1355
Fault Overview...1355
Lamp Reaction...1355
Associated Faults...1355
Fault Facts...1355
Drive Cycle to Determine Fault Status...1355
Possible Causes...1355
SPN 102 FMI 10 - Boost slow response fault...1357
Fault Overview...1357
Lamp Reaction...1357
Associated Faults...1357
Fault Facts...1357
Drive Cycle to Determine Fault Status...1357
Possible Causes...1357
SPN 102 FMI 16 - Overboost...1362
Fault Overview...1362
Lamp Reaction...1362
Associated Faults...1362
Fault Facts...1362
Drive Cycle to Determine Fault Status...1362
Possible Causes...1362
SPN 102 FMI 18 - Underboost...1365
Fault Overview...1365
Lamp Reaction...1365
Associated Faults...1365
Fault Facts...1365
Drive Cycle to Determine Fault Status...1365
Possible Causes...1365
IMT Sensor (Intake Manifold Temperature)...1370
Overview of IMT Sensor Group...1370
Overview...1370
SPN 105 FMI 2 - IMT signal Erratic, Intermittent, or Incorrect...1371
Fault Overview...1371
Lamp Reaction...1371
Associated Faults...1371
Fault Facts...1371
Drive Cycle to Determine Fault Status...1371
Possible Causes...1371
Pin-Point Tests (SPN 105 FMI 2)...1374
Tools Required...1374
SPN 105 FMI 3 - IMT signal Out of Range HIGH...1376
Fault Overview...1376
Lamp Reaction...1376
Associated Faults...1376
Fault Facts...1376
Drive Cycle to Determine Fault Status...1376
Possible Causes...1376
Pin-Point Tests (SPN 105 FMI 3)...1379
Tools Required...1379
SPN 105 FMI 4 - IMT signal Out of Range LOW...1382
Fault Overview...1382
Lamp Reaction...1382
Associated Faults...1382
Fault Facts...1382
Drive Cycle to Determine Fault Status...1382
Possible Causes...1382
Pin-Point Tests (SPN 105 FMI 4)...1384
Tools Required...1384
INJ (Injector) Circuits...1385
Overview of INJ Sensor Group...1385
Overview...1386
SPN 651 FMI 4 - Injector 1 open coil - short circuit...1388
Fault Overview...1388
Lamp Reaction...1388
Associated Faults...1388
Fault Facts...1388
Drive Cycle to Determine Fault Status...1388
Possible Causes...1388
Pin-Point Tests (SPN 651 FMI 4)...1391
Tools Required...1391
SPN 652 FMI 4 - Injector 2 open coil - short circuit...1392
Fault Overview...1392
Lamp Reaction...1392
Associated Faults...1392
Fault Facts...1392
Drive Cycle to Determine Fault Status...1392
Possible Causes...1392
Pin-Point Tests (SPN 652 FMI 4)...1395
Tools Required...1395
SPN 653 FMI 4 - Injector 3 open coil - short circuit...1396
Fault Overview...1396
Lamp Reaction...1396
Associated Faults...1396
Fault Facts...1396
Drive Cycle to Determine Fault Status...1396
Possible Causes...1396
Pin-Point Tests (SPN 653 FMI 4)...1399
Tools Required...1399
SPN 654 FMI 4 - Injector 4 open coil - short circuit...1400
Fault Overview...1400
Lamp Reaction...1400
Associated Faults...1400
Fault Facts...1400
Drive Cycle to Determine Fault Status...1400
Possible Causes...1400
Pin-Point Tests (SPN 654 FMI 4)...1403
Tools Required...1403
SPN 655 FMI 4 - Injector 5 open coil - short circuit...1404
Fault Overview...1404
Lamp Reaction...1404
Associated Faults...1404
Fault Facts...1404
Drive Cycle to Determine Fault Status...1404
Possible Causes...1404
Pin-Point Tests (SPN 655 FMI 4)...1407
Tools Required...1407
SPN 656 FMI 4 - Injector 6 open coil - short circuit...1408
Fault Overview...1408
Lamp Reaction...1408
Associated Faults...1408
Fault Facts...1408
Drive Cycle to Determine Fault Status...1408
Possible Causes...1408
Pin-Point Tests (SPN 656 FMI 4)...1411
Tools Required...1411
SPN 651 FMI 5 - Injector 1 open coil - open circuit...1412
Fault Overview...1412
Lamp Reaction...1412
Associated Faults...1412
Fault Facts...1412
Drive Cycle to Determine Fault Status...1412
Possible Causes...1412
Pin-Point Tests (SPN 651 FMI 5)...1415
Tools Required...1415
SPN 652 FMI 5 - Injector 2 open coil - open circuit...1419
Fault Overview...1419
Lamp Reaction...1419
Associated Faults...1419
Fault Facts...1419
Drive Cycle to Determine Fault Status...1419
Possible Causes...1419
Pin-Point Tests (SPN 652 FMI 5)...1422
Tools Required...1422
SPN 653 FMI 5 - Injector 3 open coil - open circuit...1426
Fault Overview...1426
Lamp Reaction...1426
Associated Faults...1426
Fault Facts...1426
Drive Cycle to Determine Fault Status...1426
Possible Causes...1426
Pin-Point Tests (SPN 653 FMI 5)...1429
Tools Required...1429
SPN 654 FMI 5 - Injector 4 open coil - open circuit...1433
Fault Overview...1433
Lamp Reaction...1433
Associated Faults...1433
Fault Facts...1433
Drive Cycle to Determine Fault Status...1433
Possible Causes...1433
Pin-Point Tests (SPN 654 FMI 5)...1436
Tools Required...1436
SPN 655 FMI 5 - Injector 5 open coil - open circuit...1440
Fault Overview...1440
Lamp Reaction...1440
Associated Faults...1440
Fault Facts...1440
Drive Cycle to Determine Fault Status...1440
Possible Causes...1440
Pin-Point Tests (SPN 655 FMI 5)...1443
Tools Required...1443
SPN 656 FMI 5 - Injector 6 open coil - open circuit...1447
Fault Overview...1447
Lamp Reaction...1447
Associated Faults...1447
Fault Facts...1447
Drive Cycle to Determine Fault Status...1447
Possible Causes...1447
Pin-Point Tests (SPN 656 FMI 5)...1450
Tools Required...1450
SPN 651 - 656 FMI 7 - Injector 1 (through 6) Spool Motion Compensation Max Authority Reached...1454
Fault Overview...1454
Lamp Reaction...1454
Associated Faults...1454
Fault Facts...1454
Drive Cycle to Determine Fault Status...1454
Possible Causes...1454
SPN 651 FMI 14 - Injector 1 Fuel quantity/timing error...1456
Fault Overview...1456
Lamp Reaction...1456
Associated Faults...1456
Fault Facts...1456
Drive Cycle to Determine Fault Status...1456
Possible Causes...1456
SPN 652 FMI 14 - Injector 2 Fuel quantity/timing error...1461
Fault Overview...1461
Lamp Reaction...1461
Associated Faults...1461
Fault Facts...1461
Drive Cycle to Determine Fault Status...1461
Possible Causes...1461
SPN 653 FMI 14 - Injector 3 Fuel quantity/timing error...1466
Fault Overview...1466
Lamp Reaction...1466
Associated Faults...1466
Fault Facts...1466
Drive Cycle to Determine Fault Status...1466
Possible Causes...1466
SPN 654 FMI 14 - Injector 4 Fuel quantity/timing error...1471
Fault Overview...1471
Lamp Reaction...1471
Associated Faults...1471
Fault Facts...1471
Drive Cycle to Determine Fault Status...1471
Possible Causes...1471
SPN 655 FMI 14 - Injector 5 Fuel quantity/timing error...1476
Fault Overview...1476
Lamp Reaction...1476
Associated Faults...1476
Fault Facts...1476
Drive Cycle to Determine Fault Status...1476
Possible Causes...1476
SPN 656 FMI 14 - Injector 6 Fuel quantity/timing error...1481
Fault Overview...1481
Lamp Reaction...1481
Associated Faults...1481
Fault Facts...1481
Drive Cycle to Determine Fault Status...1481
Possible Causes...1481
SPN 2797 FMI 6 - Injector Control Group 1 - short circuit (INJ 1, 2, 3)...1486
Fault Overview...1486
Lamp Reaction...1486
Associated Faults...1486
Fault Facts...1486
Drive Cycle to Determine Fault Status...1486
Possible Causes...1486
Pin-Point Tests (SPN 2797 FMI 6)...1495
Tools Required...1495
SPN 2798 FMI 6 - Injector Control Group 2 - short circuit (INJ 4, 5, 6)...1510
Fault Overview...1510
Lamp Reaction...1510
Associated Faults...1510
Fault Facts...1510
Drive Cycle to Determine Fault Status...1510
Possible Causes...1510
Pin-Point Tests (SPN 2798 FMI 6)...1519
Tools Required...1519
SPN 3055 FMI 2 - IPR Adaptation In-Range Fault...1534
Fault Overview...1534
Lamp Reaction...1534
Associated Faults...1534
Fault Facts...1534
Drive Cycle to Determine Fault Status...1534
Possible Causes...1534
SPN 3659 FMI 4 - Injector 1 close coil – short circuit...1537
Fault Overview...1537
Lamp Reaction...1537
Associated Faults...1537
Fault Facts...1537
Drive Cycle to Determine Fault Status...1537
Possible Causes...1537
Pin-Point Tests (SPN 3659 FMI 4)...1540
Tools Required...1540
SPN 3660 FMI 4 - Injector 2 close coil – short circuit...1541
Fault Overview...1541
Lamp Reaction...1541
Associated Faults...1541
Fault Facts...1541
Drive Cycle to Determine Fault Status...1541
Possible Causes...1541
Pin-Point Tests (SPN 3660 FMI 4)...1544
Tools Required...1544
SPN 3661 FMI 4 - Injector 3 close coil – short circuit...1545
Fault Overview...1545
Lamp Reaction...1545
Associated Faults...1545
Fault Facts...1545
Drive Cycle to Determine Fault Status...1545
Possible Causes...1545
Pin-Point Tests (SPN 3661 FMI 4)...1548
Tools Required...1548
SPN 3662 FMI 4 - Injector 4 close coil – short circuit...1549
Fault Overview...1549
Lamp Reaction...1549
Associated Faults...1549
Fault Facts...1549
Drive Cycle to Determine Fault Status...1549
Possible Causes...1549
Pin-Point Tests (SPN 3662 FMI 4)...1552
Tools Required...1552
SPN 3663 FMI 4 - Injector 5 close coil – short circuit...1553
Fault Overview...1553
Lamp Reaction...1553
Associated Faults...1553
Fault Facts...1553
Drive Cycle to Determine Fault Status...1553
Possible Causes...1553
Pin-Point Tests (SPN 3663 FMI 4)...1556
Tools Required...1556
SPN 3664 FMI 4 - Injector 6 close coil – short circuit...1557
Fault Overview...1557
Lamp Reaction...1557
Associated Faults...1557
Fault Facts...1557
Drive Cycle to Determine Fault Status...1557
Possible Causes...1557
Pin-Point Tests (SPN 3664 FMI 4)...1560
Tools Required...1560
SPN 3659 FMI 5 - Injector 1 close coil – open circuit...1561
Fault Overview...1561
Lamp Reaction...1561
Associated Faults...1561
Fault Facts...1561
Drive Cycle to Determine Fault Status...1561
Possible Causes...1561
Pin-Point Tests (SPN 3659 FMI 5)...1564
Tools Required...1564
SPN 3660 FMI 5 - Injector 2 close coil – open circuit...1568
Fault Overview...1568
Lamp Reaction...1568
Associated Faults...1568
Fault Facts...1568
Drive Cycle to Determine Fault Status...1568
Possible Causes...1568
Pin-Point Tests (SPN 3660 FMI 5)...1571
Tools Required...1571
SPN 3661 FMI 5 - Injector 3 close coil – open circuit...1575
Fault Overview...1575
Lamp Reaction...1575
Associated Faults...1575
Fault Facts...1575
Drive Cycle to Determine Fault Status...1575
Possible Causes...1575
Pin-Point Tests (SPN 3661 FMI 5)...1578
Tools Required...1578
SPN 3662 FMI 5 - Injector 4 close coil – open circuit...1582
Fault Overview...1582
Lamp Reaction...1582
Associated Faults...1582
Fault Facts...1582
Drive Cycle to Determine Fault Status...1582
Possible Causes...1582
Pin-Point Tests (SPN 3662 FMI 5)...1585
Tools Required...1585
SPN 3663 FMI 5 - Injector 5 close coil – open circuit...1589
Fault Overview...1589
Lamp Reaction...1589
Associated Faults...1589
Fault Facts...1589
Drive Cycle to Determine Fault Status...1589
Possible Causes...1589
Pin-Point Tests (SPN 3663 FMI 5)...1592
Tools Required...1592
SPN 3664 FMI 5 - Injector 6 close coil – open circuit...1596
Fault Overview...1596
Lamp Reaction...1596
Associated Faults...1596
Fault Facts...1596
Drive Cycle to Determine Fault Status...1596
Possible Causes...1596
Pin-Point Tests (SPN 3664 FMI 5)...1599
Tools Required...1599
SPN 4257 FMI 7 - Injector Coking Compensation Factor Reached Maximum Authority...1603
Fault Overview...1603
Lamp Reaction...1603
Associated Faults...1603
Fault Facts...1603
Drive Cycle to Determine Fault Status...1603
Possible Causes...1603
SPN 4257 FMI 16 - Multiple Injector High Flow fault...1605
Fault Overview...1605
Lamp Reaction...1605
Associated Faults...1605
Fault Facts...1605
Drive Cycle to Determine Fault Status...1605
Possible Causes...1605
SPN 4257 FMI 18 - Multiple Injector Low Flow fault...1608
Fault Overview...1608
Lamp Reaction...1608
Associated Faults...1608
Fault Facts...1608
Drive Cycle to Determine Fault Status...1608
Possible Causes...1608
IPR (Injection Pressure Regulator)...1611
Overview of IPR Sensor Group...1611
Overview...1611
SPN 679 FMI 3 - IPR Short to PWR...1612
Fault Overview...1612
Lamp Reaction...1612
Associated Faults...1612
Fault Facts...1612
Drive Cycle to Determine Fault Status...1612
Possible Causes...1612
Pin-Point Tests (SPN 679 FMI 3)...1614
Tools Required...1614
SPN 679 FMI 4 - IPR Open or short to GND...1616
Fault Overview...1616
Lamp Reaction...1616
Associated Faults...1616
Fault Facts...1616
Drive Cycle to Determine Fault Status...1616
Possible Causes...1616
Pin-Point Tests (SPN 679 FMI 4)...1619
Tools Required...1619
J1939 Data Link Communications...1623
Overview of J1939 Sensor Group...1623
Overview...1623
SPN 639 FMI 14 - J1939 Data Link Error (ECM unable to transmit)...1624
Fault Overview...1624
Lamp Reaction...1624
Associated Faults...1624
Fault Facts...1624
Drive Cycle to Determine Fault Status...1624
Possible Causes...1624
Pin-Point Tests...1627
Tools Required...1627
MAF Sensor (Mass Air Flow)...1629
Overview of MAF Sensor Group...1629
Overview...1629
SPN 132 FMI 0 - Engine Intake Air Mass Flow Rate High...1630
Fault Overview...1630
Lamp Reaction...1630
Associated Faults...1630
Fault Facts...1630
Drive Cycle to Determine Fault Status...1630
Possible Causes...1630
SPN 132 FMI 1 - Engine Intake Air Mass Flow Rate Low...1632
Fault Overview...1632
Lamp Reaction...1632
Associated Faults...1632
Fault Facts...1632
Drive Cycle to Determine Fault Status...1632
Possible Causes...1632
SPN 132 FMI 4 - MAF Frequency out of range...1634
Fault Overview...1634
Lamp Reaction...1634
Associated Faults...1634
Fault Facts...1634
Drive Cycle to Determine Fault Status...1634
Possible Causes...1634
Pin-Point Tests (SPN 132 FMI 4)...1636
Tools Required...1636
SPN 132 FMI 11 - MAF Sensor Calibration – Insufficient number of data points...1638
Fault Overview...1638
Lamp Reaction...1638
Associated Faults...1638
Fault Facts...1638
Drive Cycle to Determine Fault Status...1638
Possible Causes...1638
SPN 132 FMI 13 - MAF Sensor Calibration Needed...1640
Fault Overview...1640
Lamp Reaction...1640
Associated Faults...1640
Fault Facts...1640
Drive Cycle to Determine Fault Status...1640
Possible Causes...1640
SPN 132 FMI 14 - MAF Sensor Calibration Failed...1642
Fault Overview...1642
Lamp Reaction...1642
Associated Faults...1642
Fault Facts...1642
Drive Cycle to Determine Fault Status...1642
Possible Causes...1642
SPN 132 FMI 31 - MAF Frequency Not Detected...1644
Fault Overview...1644
Lamp Reaction...1644
Associated Faults...1644
Fault Facts...1644
Drive Cycle to Determine Fault Status...1644
Possible Causes...1644
Pin-Point Tests (SPN 132 FMI 31)...1649
Tools Required...1649
SPN 172 FMI 2 - IAT Signal Erratic, Intermittent, or Incorrect...1657
Fault Overview...1657
Lamp Reaction...1657
Associated Faults...1657
Fault Facts...1657
Drive Cycle to Determine Fault Status...1657
Possible Causes...1657
Pin-Point Tests (SPN 172 FMI 2)...1660
Tools Required...1660
SPN 172 FMI 3 - IAT Signal Out of Range HIGH...1663
Fault Overview...1663
Lamp Reaction...1663
Associated Faults...1663
Fault Facts...1663
Drive Cycle to Determine Fault Status...1663
Possible Causes...1663
Pin-Point Tests (SPN 172 FMI 3)...1666
Tools Required...1666
SPN 172 FMI 4 - IAT Signal Out of Range LOW...1670
Fault Overview...1670
Lamp Reaction...1670
Associated Faults...1670
Fault Facts...1670
Drive Cycle to Determine Fault Status...1670
Possible Causes...1670
Pin-Point Tests (SPN 172 FMI 4)...1672
Tools Required...1672
NOx (Nitrogen Oxides) Sensor Module...1673
Overview of NOx Sensor Group...1673
Overview...1673
SPN 3216 FMI 4 - NOxIN signal Out of Range LOW...1677
Fault Overview...1677
Lamp Reaction...1677
Associated Faults...1677
Fault Facts...1677
Drive Cycle to Determine Fault Status...1677
Possible Causes...1677
SPN 3216 FMI 10 - NOxIN signal abnormal rate of change...1679
Fault Overview...1679
Lamp Reaction...1679
Associated Faults...1679
Fault Facts...1679
Drive Cycle to Determine Fault Status...1679
Possible Causes...1679
SPN 3216 FMI 13 - NOx IN Out of Calibration...1681
Fault Overview...1681
Lamp Reaction...1681
Associated Faults...1681
Fault Facts...1681
Drive Cycle...1681
Possible Causes...1681
SPN 3216 FMI 19 - NOx IN not detected on J1939...1683
Fault Overview...1683
Lamp Reaction...1683
Associated Faults...1683
Fault Facts...1683
Drive Cycle to Determine Fault Status...1683
Possible Causes...1683
Pin-Point Tests (SPN 3216 FMI 19)...1688
Tools Required...1688
SPN 3216 FMI 20 - NOxIN signal drifted HIGH...1696
Fault Overview...1696
Lamp Reaction...1696
Associated Faults...1696
Drive Cycle to Determine Fault Status...1696
Possible Causes...1696
SPN 3216 FMI 21 - NOxIN signal drifted LOW...1698
Fault Overview...1698
Lamp Reaction...1698
Associated Faults...1698
Fault Facts...1698
Drive Cycle to Determine Fault Status...1698
Possible Causes...1698
SPN 3218 FMI 2 - NOxIN power supply signal erratic, intermittent or incorrect...1700
Fault Overview...1700
Lamp Reaction...1700
Associated Faults...1700
Drive Cycle to Determine Fault Status...1700
Pin-Point Tests (SPN 3218 FMI 2)...1703
Tools Required...1703
SPN 3226 FMI 2 - NOx OUT Signal Erratic, Intermittent, or Incorrect ...1706
Fault Overview...1706
Lamp Reaction...1706
Associated Faults...1706
Fault Facts...1706
Drive Cycle to Determine Fault Status...1706
Possible Causes...1706
Pin-Point Tests SPN 3226 FMI 2...1709
Tools Required...1709
SPN 3226 FMI 4 - NOxOUT signal Out of Range LOW...1712
Fault Overview...1712
Lamp Reaction...1712
Associated Faults...1712
Fault Facts...1712
Drive Cycle to Determine Fault Status...1712
Possible Causes...1712
SPN 3226 FMI 10 - NOx OUT Signal Abnormal Rate of Change...1714
Fault Overview...1714
Lamp Reaction...1714
Associated Faults...1714
Fault Facts...1714
Drive Cycle to Determine Fault Status...1714
Possible Causes...1714
SPN 3226 FMI 13 - NOxOUT Out of Calibration...1716
Fault Overview...1716
Lamp Reaction...1716
Associated Faults...1716
Fault Facts...1716
Drive Cycle to Determine Fault Status...1716
Possible Causes...1716
SPN 3226 FMI 19 - NOxOUT not detected on J1939...1718
Fault Overview...1718
Lamp Reaction...1718
Associated Faults...1718
Fault Facts...1718
Drive Cycle to Determine Fault Status...1718
Possible Causes...1718
Pin-Point Tests (SPN 3226 FMI 19)...1722
Tools Required...1722
SPN 3226 FMI 20 - NOxOUT signal drifted HIGH...1729
Fault Overview...1729
Lamp Reaction...1729
Associated Faults...1729
Fault Facts...1729
Drive Cycle to Determine Fault Status...1729
Possible Causes...1729
SPN 3226 FMI 21 - NOxOUT signal drifted LOW...1731
Fault Overview...1731
Lamp Reaction...1731
Associated Faults...1731
Fault Facts...1731
Drive Cycle to Determine Fault Status...1731
Possible Causes...1731
SPN 3228 FMI 2 - NOxOUT power supply signal erratic, intermittent or incorrect...1733
Fault Overview...1733
Lamp Reaction...1733
Associated Faults...1733
Fault Facts...1733
Drive Cycle to Determine Fault Status...1733
Possible Causes...1733
Pin-Point Tests (SPN 3228 FMI 2)...1736
Tools Required...1736
SPN 5024 FMI 10 - NOxIN Sensor Heater abnormal rate of change...1739
Fault Overview...1739
Lamp Reaction...1739
Associated Faults...1739
Fault Facts...1739
Drive Cycle to Determine Fault Status...1739
Possible Causes...1739
Pin-Point Tests (SPN 5024 FMI 10)...1742
Tools Required...1742
SPN 5031 FMI 10 - NOxOUT Sensor Heater not reading correctly...1745
Fault Overview...1745
Lamp Reaction...1745
Associated Faults...1745
Fault Facts...1745
Drive Cycle to Determine Fault Status...1745
Possible Causes...1745
Pin-Point Tests (SPN 5031 FMI 10)...1748
Tools Required...1748
RAPP (Remote APP) Sensor...1751
Overview of RAPP Sensor Group...1751
Overview...1751
SPN 974 FMI 3 - Remote APP signal Out of Range HIGH...1752
Fault Overview...1752
Lamp Reaction...1752
Associated Faults...1752
Fault Facts...1752
Drive Cycle to Determine Fault Status...1752
Possible Causes...1752
Pin-Point Tests...1754
Tools Required...1754
SCR (Temperature Sensor Module)...1756
Overview of SCR Sensor Group...1756
Overview...1756
SPN 3061 FMI 31 - CSER Exhaust warm up time fault...1759
Fault Overview...1759
Lamp Reaction...1759
Associated Faults...1759
Fault Facts...1759
Drive Cycle to Determine Fault Status...1759
Possible Causes...1759
SPN 4364 FMI 18- Low NOx Conversion Detected...1762
Fault Overview...1762
Lamp Reaction...1762
Associated Faults...1762
Fault Facts...1762
Drive Cycle to Determine Fault Status...1762
Possible Causes...1762
SPN 4792 FMI 7 - SCR Catalyst System - Mechanical system not responding or out of adjustment...1765
Fault Overview...1765
Lamp Reaction...1765
Associated Faults...1765
Fault Facts...1765
Drive Cycle to Determine Fault Status...1765
Possible Causes...1765
SPN 4792 FMI 14 - SCR Temperature Module (Incorrect Part)...1767
Fault Overview...1767
Lamp Reaction...1767
Associated Faults...1767
Fault Facts...1767
Drive Cycle to Determine Fault Status...1767
Possible Causes...1767
SPN 4794 FMI 31 - SCR Catalyst System Missing...1769
Fault Overview...1769
Lamp Reaction...1769
Associated Faults...1769
Fault Facts...1769
Drive Cycle to Determine Fault Status...1769
Possible Causes...1769
SPN 5743 FMI 3 - SCR Thermocouple Controller Out of Range HIGH...1771
Fault Overview...1771
Lamp Reaction...1771
Associated Faults...1771
Fault Facts...1771
Drive Cycle to Determine Fault Status...1771
Possible Causes...1771
Pin-Point Tests (SPN 5743 FMI 3)...1773
Tools Required...1773
SPN 5743 FMI 4 - SCR Thermocouple Controller Out of Range LOW...1775
Fault Overview...1775
Lamp Reaction...1775
Associated Faults...1775
Fault Facts...1775
Drive Cycle to Determine Fault Status...1775
Possible Causes...1775
Pin-Point Tests (SPN 5743 FMI 4)...1778
Tools Required...1778
SPN 5743 FMI 11 - SCR Thermocouple Controller signal erratic, intermittent, or incorrect...1781
Fault Overview...1781
Lamp Reaction...1781
Associated Faults...1781
Fault Facts...1781
Drive Cycle to Determine Fault Status...1781
Possible Causes...1781
Pin-Point Tests (SPN 5743 FMI 11)...1784
Tools Required...1784
SPN 5743 FMI 12 - SCR Temperature sensor module internal error...1787
Fault Overview...1787
Lamp Reaction...1787
Associated Faults...1787
Fault Facts...1787
Drive Cycle to Determine Fault Status...1787
Possible Causes...1787
SPN 5743 FMI 16 - SCR Thermocouple Controller above Maximum Temperature...1789
Fault Overview...1789
Lamp Reaction...1789
Associated Faults...1789
Fault Facts...1789
Drive Cycle to Determine Fault Status...1789
Possible Causes...1789
SPN 5743 FMI 19 - SCR Temperature module not detect J1939...1791
Fault Overview...1791
Lamp Reaction...1791
Associated Faults...1791
Fault Facts...1791
Drive Cycle to Determine Fault Status...1791
Possible Causes...1791
Pin-Point Tests (SPN 5743 FMI 19)...1796
Tools Required...1796
SCRIT (Selective Catalyst Reduction Intake Temperature) Sensor...1804
Overview of SCRIT Sensor Group...1804
Overview...1804
SPN 4360 FMI 0 - SCRIT above Critical Temperature...1805
Fault Overview...1805
Lamp Reaction...1805
Associated Faults...1805
Fault Facts...1805
Drive Cycle to Determine Fault Status...1805
Possible Causes...1805
SPN 4360 FMI 2- SCRIT signal erratic, intermittent or incorrect...1808
Fault Overview...1808
Lamp Reaction...1808
Associated Faults...1808
Fault Facts...1808
Drive Cycle to Determine Fault Status...1808
Possible Causes...1808
SPN 4360 FMI 3 - SCRIT Signal Out of Range HIGH...1810
Fault Overview...1810
Lamp Reaction...1810
Associated Faults...1810
Fault Facts...1810
Drive Cycle to Determine Fault Status...1810
Possible Causes...1810
SPN 4360 FMI 4 - SCRIT Signal Out of Range LOW...1812
Fault Overview...1812
Lamp Reaction...1812
Associated Faults...1812
Fault Facts...1812
Drive Cycle to Determine Fault Status...1812
Possible Causes...1812
SPN 4360 FMI 15 - SCRIT above Warning Temperature...1814
Fault Overview...1814
Lamp Reaction...1814
Associated Faults...1814
Fault Facts...1814
Drive Cycle to Determine Fault Status...1814
Possible Causes...1814
SPN 4360 FMI 16 - SCRIT above Maximum Temperature...1817
Fault Overview...1817
Lamp Reaction...1817
Associated Faults...1817
Fault Fact...1817
Drive Cycle to Determine Fault Status...1817
Possible Causes...1817
SCROT (Selective Catalyst Reduction Outlet Temperature) Sensor...1820
Overview of SCROT Sensor Group...1820
Overview...1820
SPN 4363 FMI 0 - SCROT above Critical Temperature...1821
Fault Overview...1821
Lamp Reaction...1821
Associated Faults...1821
Fault Facts...1821
Drive Cycle to Determine Fault Status...1821
Possible Causes...1821
SPN 4363 FMI 2 - SCROT signal erratic, intermittent or incorrect...1824
Fault Overview...1824
Lamp Reaction...1824
Associated Faults...1824
Fault Facts...1824
Drive Cycle to Determine Fault Status...1824
Possible Causes...1824
SPN 4363 FMI 3 - SCROT signal Out of Range HIGH...1826
Fault Overview...1826
Lamp Reaction...1826
Associated Faults...1826
Fault Facts...1826
Drive Cycle to Determine Fault Status...1826
Possible Causes...1826
SPN 4363 FMI 4 - SCROT signal Out of Range LOW...1828
Fault Overview...1828
Lamp Reaction...1828
Associated Faults...1828
Fault Facts...1828
Drive Cycle to Determine Fault Status...1828
Possible Causes...1828
SPN 4363 FMI 15 - SCROT above Warning Temperature...1830
Fault Overview...1830
Lamp Reaction...1830
Associated Faults...1830
Fault Facts...1830
Drive Cycle to Determine Fault Status...1830
Possible Causes...1830
SPN 4363 FMI 16 - SCROT above Maximum Temperature...1833
Fault Overview...1833
Lamp Reaction...1833
Associated Faults...1833
Fault Facts...1833
Drive Cycle to Determine Fault Status...1833
Possible Causes...1833
TC2CIT (Turbocharger 2 Compressor Intake Temperature)...1836
Overview of TC2CIT Sensor Group...1836
Overview...1836
SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect ...1837
Fault Overview...1837
Lamp Reaction...1837
Associated Faults...1837
Fault Facts...1837
Drive Cycle to Determine Fault Status...1837
Possible Causes...1837
Pin-Point Tests (SPN 1173 FMI 2)...1840
Tools Required...1840
SPN 1173 FMI 3 - TC2CIT Signal Out of Range HIGH...1842
Fault Overview...1842
Lamp Reaction...1842
Associated Faults...1842
Fault Facts...1842
Drive Cycle to Determine Fault Status...1842
Possible Causes...1842
Pin-Point Tests (SPN 1173 FMI 3)...1845
Tools Required...1845
SPN 1173 FMI 4 - TC2CIT Signal Out of Range LOW...1848
Fault Overview...1848
Lamp Reaction...1848
Associated Faults...1848
Fault Facts...1848
Drive Cycle to Determine Fault Status...1848
Possible Causes...1848
Pin-Point Tests (SPN 1173 FMI 4)...1850
Tools Required...1850
SPN 1173 FMI 16 - TC2CIT signal above desired (Low Pressure CAC Interstage under cooling)...1851
Fault Overview...1851
Lamp Reaction...1851
Associated Faults...1851
Fault Facts...1851
Drive Cycle to Determine Fault Status...1851
Possible Causes...1851
TC2WG (Turbocharger 2 Wastegate Position)...1854
Overview of TC2WG Group...1854
Overview...1854
SPN 1189 FMI 3 - TC2WC short to PWR...1855
Fault Overview...1855
Lamp Reaction...1855
Associated Faults...1855
Fault Facts...1855
Drive Cycle to Determine Fault Status...1855
Possible Causes...1855
Pin-Point Tests SPN 1189 FMI 3...1857
Tools Required...1857
SPN 1189 FMI 4 - TC2WC Open or short to GND...1859
Fault Overview...1859
Lamp Reaction...1859
Associated Faults...1859
Fault Facts...1859
Drive Cycle to Determine Fault Status...1859
Possible Causes...1859
Pin-Point Tests (SPN 1189 FMI 4)...1862
Tools Required...1862
TOSS (Transmission Output Shaft Speed) Sensor...1866
Overview of TOSS Sensor Group...1866
Overview...1866
SPN 191 FMI 3 - TOSS/VSS signal out of range HIGH...1868
Fault Overview...1868
Lamp Reaction...1868
Associated Faults...1868
Fault Facts...1868
Drive Cycle to Determine Fault Status...1868
Possible Causes...1868
Pin-Point Tests (SPN 191 FMI 3)...1870
Tools Required...1870
SPN 191 FMI 4 - TOSS/VSS signal out of range LOW...1871
Fault Overview...1871
Lamp Reaction...1871
Associated Faults...1871
Fault Facts...1871
Drive Cycle to Determine Fault Status...1871
Possible Causes...1871
Pin-Point Tests (SPN 191 FMI 4)...1873
Tools Required...1873
SPN 191 FMI 5 - TOSS/VSS Open Circuit fault...1874
Fault Overview...1874
Lamp Reaction...1874
Associated Faults...1874
Fault Facts...1874
Drive Cycle to Determine Fault Status...1874
Possible Causes...1874
Pin-Point Tests (SPN 191 FMI 5)...1877
Tools Required...1877
SPN 191 FMI 14 - TOSS/VSS Error invalid signal...1878
Fault Overview...1878
Lamp Reaction...1878
Associated Faults...1878
Fault Facts...1878
Drive Cycle to Determine Fault Status...1878
Possible Causes...1878
VREF (Voltage Reference)...1880
Overview of VREF Sensor Group...1880
Overview...1880
SPN 3509 FMI 3 - VREF 1 voltage above maximum...1881
Fault Overview...1881
Lamp Reaction...1881
Associated Faults...1881
Fault Facts...1881
Drive Cycle to Determine Fault Status...1881
Possible Causes...1881
Pin-Point Tests (SPN 3509 FMI 3)...1884
Tools Required...1884
SPN 3509 FMI 4 - VREF 1 voltage below minimum...1890
Fault Overview...1890
Lamp Reaction...1890
Associated Faults...1890
Fault Facts...1890
Drive Cycle to Determine Fault Status...1890
Possible Causes...1890
Pin-Point Tests (SPN 3509 FMI 4)...1894
Tools Required...1894
SPN 3510 FMI 3 - VREF 2 voltage above maximum...1906
Fault Overview...1906
Lamp Reaction...1906
Associated Faults...1906
Fault Facts...1906
Drive Cycle to Determine Fault Status...1906
Possible Causes...1906
SPN 3510 FMI 4 - VREF 2 voltage below minimum...1908
Fault Overview...1908
Lamp Reaction...1908
Associated Faults...1908
Fault Facts...1908
Drive Cycle to Determine Fault Status...1908
Possible Causes...1908
Pin-Point Tests (SPN 3510 FMI 4)...1910
Tools Required...1910
SPN 3511 FMI 3 - VREF 3 voltage above maximum...1913
Fault Overview...1913
Lamp Reaction...1913
Associated Faults...1913
Fault Facts...1913
Drive Cycle to Determine Fault Status...1913
Possible Causes...1913
Pin-Point Tests (SPN 3511 FMI 3)...1915
Tools Required...1915
SPN 3511 FMI 4 - VREF 3 voltage below minimum...1917
Fault Overview...1917
Lamp Reaction...1917
Associated Faults...1917
Fault Facts...1917
Drive Cycle to Determine Fault Status...1917
Possible Causes...1917
Pin-Point Tests (SPN 3511 FMI 4)...1920
Tools Required...1920
SPN 5125 FMI 14 - VREF 7 voltage above or below normal...1925
Fault Overview...1925
Lamp Reaction...1925
Associated Faults...1925
Fault Facts...1925
Drive Cycle to Determine Fault Status...1925
Possible Causes...1925
SPN 5126 FMI 14 - VREF 8 voltage above or below normal...1927
Fault Overview...1927
Lamp Reaction...1927
Associated Faults...1927
Fault Facts...1927
Drive Cycle to Determine Fault Status...1927
Possible Causes...1927
Pin-Point Tests (SPN 5126 FMI 14)...1929
Tools Required...1929
SPN 5127 FMI 14 - VREF 9 voltage above or below normal...1930
Fault Overview...1930
Lamp Reaction...1930
Associated Faults...1930
Fault Facts...1930
Drive Cycle to Determine Fault Status...1930
Possible Causes...1930
Pin-Point Tests (SPN 5126 FMI 14)...1933
Tools Required...1933
WIF Sensor (Water In Fuel)...1935
Overview of WIF Sensor Group...1935
Overview...1935
SPN 4192 FMI 3 - WIF signal Out of Range HIGH...1936
Fault Overview...1936
Lamp Reaction...1936
Associated Faults...1936
Fault Facts...1936
Drive Cycle to Determine Fault Status...1936
Possible Causes...1936
Pin-Point Tests SPN 4192 FMI 3...1938
Tools Required...1938
SPN 4192 FMI 4 - WIF signal Out of Range LOW...1940
Fault Overview...1940
Lamp Reaction...1940
Associated Faults...1940
Fault Facts...1940
Drive Cycle to Determine Fault Status...1940
Possible Causes...1940
Pin-Point Tests SPN 4192 FMI 4...1942
Tools Required...1942
SPN 4192 FMI 5 - WIF signal Open or Short to PWR...1943
Fault Overview...1943
Lamp Reaction...1943
Associated Faults...1943
Fault Facts...1943
Drive Cycle to Determine Fault Status...1943
Possible Causes...1943
Pin-Point Tests SPN 4192 FMI 5...1946
Tools Required...1946
SPN 4192 FMI 31 - Water in Fuel Detected...1949
Fault Overview...1949
Lamp Reaction...1949
Associated Faults...1949
Fault Facts...1949
Drive Cycle to Determine Fault Status...1949
Possible Causes...1949
Table of Contents...1951
ServiceMaxx™ Software Procedures...1955
ServiceMaxx™ Connection and Data Recording...1955
Overview...1955
Engine Auto-Detection...1955
Connection (Sniffer)...1955
Tools Required...1955
Equipment Condition...1955
Test Setup...1956
Test Procedure...1957
Snapshot Recording Procedure:...1957
Snapshot Playback Procedure...1958
Diagnostic Trouble Code Overview...1960
DTC Type:...1960
Pending DTC...1960
Active DTC...1960
Healing DTC...1960
Previously Active DTC...1960
DTC Count...1960
Freeze Frame...1960
Check for DTCs...1961
Procedure:...1961
Session Files...1962
Overview...1962
Hot Run Sensor Comparison Test...1964
Purpose...1964
Tools Required...1964
Obtain Vehicle Health Report...1966
Overview...1966
Tools Required...1966
Equipment Condition...1966
Test Setup...1966
Test Procedure...1966
Expected Outcome...1966
Follow-On Procedure...1966
Programmable Features...1967
Overview...1967
Tool Required...1967
Equipment Condition...1967
Test Setup...1968
Test Procedure...1969
Expected Outcome...1971
Follow-On Procedure...1971
Record Snapshot of KOEO Data...1972
Overview...1972
Tools Required...1972
Equipment Condition...1972
Test Setup...1972
Test Procedure...1972
Expected Outcome...1972
Follow-On Procedure...1972
Injector Coil End of Motion (CEOM) Reset Procedure...1973
Overview...1973
Tools Required...1973
Equipment Condition...1973
Test Setup...1974
Test Procedure...1975
Fuel Pressure Adaptation Reset...1976
Overview...1976
Tools Required...1976
Equipment Condition...1976
Test Setup...1977
Test Procedure...1977
Follow-On Procedure...1978
KOEO DOC / DPF Replacement / Reset Procedure...1979
Overview...1979
Tools Required...1979
Equipment Condition...1980
Test Setup...1980
Test Procedure...1980
Intermittent or Inactive Fault Diagnostic Procedure...1982
Overview...1982
Tools Required...1982
Equipment Condition...1982
Test Setup...1982
Test Procedure...1982
Expected Outcome...1982
Follow-On Procedure...1982
Connecting EST with ServiceMaxx™ Software to Engine...1983
Interface Device Selection...1983
Connecting ServiceMaxx™ Software...1986
Pinpoint Diagnostic Graphic Legend...1987
Service Bay Tests...1995
Engine Off Tests...1995
KOEO Standard Test...1995
Overview...1995
Tools Required...1995
Equipment Condition...1995
Test Setup...1996
Test Procedure...1997
Expected Outcome...1998
Follow-On Procedure...1998
KOEO Low to High Idle Test...1999
Overview...1999
Tools Required...1999
Equipment Condition...1999
Test Setup...1999
Test Procedure...2000
Expected Outcome...2002
Follow-On Procedure...2002
KOEO Output State High or Low...2003
Overview...2003
Actuators that cycle during this test:...2003
Tools Required...2003
Equipment Condition...2003
Test Setup...2003
Test Procedure...2003
Expected Outcome...2004
Follow-On Procedure...2004
Continuous Monitor...2005
Overview...2005
Position Sensor Voltages are Monitored:...2006
Pressure Sensor Voltages are Monitored:...2006
Temperature Sensor Voltages are Monitored:...2006
Other Voltage Signals Monitored:...2006
Tools Required...2006
Equipment Condition...2006
Test Setup...2007
Test Procedure...2007
Follow-on Procedure...2008
KOEO DEF Tank Heater Test...2009
Overview...2009
Tools Required...2009
Equipment Conditions...2009
Test Setup...2010
Test Procedure...2011
Expected Outcome...2011
Follow-On Procedure...2011
KOEO Injector Test...2012
Overview...2012
Tools Required...2012
Equipment Condition...2012
Test Setup...2012
Test Procedure...2012
Expected Outcome...2014
Follow-on Procedure...2014
KOEO DCU Actuator Test – Actuator Output High and Low Diagnostics...2015
Overview...2015
Tools Required...2015
Test Setup...2016
Test Procedure...2016
Expected Outcome...2017
Follow-On Procedure...2017
KOEO DEF System Leak Test...2018
Overview...2018
Tools Required...2018
Equipment Condition...2018
Test Setup...2018
Test Procedure...2018
Expected Outcome...2019
Follow-On Procedure...2019
KOEO DEF Line Heater Test...2020
Overview...2020
Tools Required...2020
Equipment Condition...2020
Test Setup...2020
Test Procedure...2020
Expected Outcome...2021
Follow-On Procedure...2021
KOEO DEF Reverting Control Valve Test...2022
Overview...2022
Tools Required...2022
Test Setup...2022
Test Procedure...2023
Expected Outcome...2023
Follow-On Procedure...2023
KOEO DEF Supply Pump Override Test...2024
Overview...2024
Tools Required...2024
Equipment Conditions...2024
Test Setup...2024
Test Procedure...2024
Expected Outcome...2025
Follow-On Procedure...2025
Relative Compression Test...2026
Overview...2026
Tools Required...2026
Test Setup...2026
Test Procedure...2027
Expected Outcome...2028
Follow-On Procedure...2028
SCR Faults Reset Request Procedure...2029
Overview...2029
Tools Required...2029
Equipment Condition...2029
Test Setup...2029
Test Procedure...2029
Expected Outcome...2030
Follow-On Procedure...2030
Engine Cranking Test...2031
Overview...2031
Tools Required...2031
Equipment Condition...2031
Test Setup...2031
Procedure...2032
Expected Outcome...2033
Follow-on Procedure...2033
Engine Running Tests...2034
Air Management Test...2034
Overview...2034
Tools Required...2034
Equipment Conditions...2034
Test Setup...2035
Test Procedure...2035
Expected Outcome...2035
Follow-On Procedure...2035
Air Management System Graph (GOOD)...2036
Overview...2036
Tools Required...2036
Equipment Condition...2036
Test Setup...2036
Test Procedure...2037
Expected Outcome...2037
Follow-On Procedure...2037
Air Management System Graph (BAD) ...2038
Overview...2038
Tools Required...2038
Equipment Condition...2038
Test Setup...2038
Test Procedure...2039
Expected Outcome...2039
Follow-On Procedure...2039
KOER Standard Test...2040
Overview...2040
Tools Required...2040
Equipment Conditions...2040
Test Setup...2041
Test Procedure...2042
Expected Outcome...2042
Follow-On Procedure...2042
KOER Cylinder Cutout Test...2043
Overview...2043
Tools Required...2043
Equipment Condition...2043
Test Setup...2043
Test Procedure...2044
Expected Outcome...2045
Follow-on Procedure...2045
KOER DSI System Test...2046
Overview...2046
Tools Required...2046
Equipment Conditions...2047
Test Setup...2047
Test Procedure...2047
Expected Outcome...2048
Follow-On Procedure...2048
KOER DSI Deaeration Procedure...2049
Overview...2049
Tools Required...2049
Equipment Condition...2049
Test Setup...2050
Test Procedure...2051
Expected Outcome...2051
Follow-On Procedure...2051
DPF Regeneration Procedure...2052
Overview...2052
Tools Required...2052
Equipment Condition...2052
Test Setup...2053
Test Procedure...2054
Expected Outcome...2055
Follow-On Procedure...2055
Connect Cylinder Performance Analyzer (CPA) Tool...2056
Overview...2056
Tools Required...2056
Equipment Condition...2056
Test Setup...2057
Test Procedure...2058
Expected Outcome...2059
Follow-on Procedure...2059
CPA Cold Idle Test...2060
Overview...2060
Tools Required...2060
Equipment Condition...2060
Test Setup...2060
Test Procedure...2063
Expected Outcome...2064
Follow-on Procedure...2064
CPA Signal Check...2065
Overview...2065
Tools Required...2065
Equipment Condition...2065
Test Setup...2065
Test Procedure...2067
Expected Outcome...2070
Follow-On Procedure...2070
CPA Hot Idle Test...2071
Overview...2071
Tools Required...2071
Equipment Condition...2071
Test Setup...2071
Test Procedure...2074
Expected Outcome...2075
Follow-On Procedure...2075
CPA Road Test...2076
Overview...2076
Tools Required...2076
Equipment Condition...2076
Test Setup...2076
Test Procedure...2079
Expected Outcome...2080
Follow-On Procedure...2080
CPA Advanced Testing...2081
Overview...2081
Tools Required...2081
Equipment Condition...2081
Test Setup...2081
Test Procedure...2083
Expected Outcome...2085
Follow-on Procedure...2085
CPA High-Pressure Oil Pump (HPOP) Test...2086
Overview...2086
Tools Required...2086
Equipment Condition...2086
Test Setup...2086
Test Procedure...2088
Expected Outcome...2090
Follow-on Procedure...2090
Record Snapshot of Engine Running Data...2091
Overview...2091
Tools Required...2091
Equipment Condition...2091
Test Setup...2091
Test Procedure...2092
Expected Outcome...2094
Follow-On Procedure...2094
Road Test...2095
0 to 60 MPH Test...2095
Overview...2095
Tools Required...2095
Equipment Condition...2095
Test Setup...2095
Test Procedure...2095
Expected Outcome...2098
Follow-on Procedure...2098
0 to 60 MPH ICP and ICPD Graph ...2099
Overview...2099
Tools Required...2099
Equipment Condition...2099
Test Setup...2099
Test Procedure...2100
Expected Outcome...2100
Follow-On Procedure...2100
0 to 60 MPH, RPM, Load, IMP, EBP, and APP1 Graph...2101
Overview...2101
Tools Required...2101
Equipment Condition...2101
Test Setup...2101
Test Procedure...2102
Expected Outcome...2102
Follow-On Procedure...2103
Normal Exhaust Gas Temperature Graph...2104
Overview...2104
Tools Required...2104
Equipment Condition...2104
Test Setup...2104
Test Procedure...2105
Expected Outcome...2105
Follow-On Procedure...2106
Erratic Exhaust Gas Temperatures Graph...2107
Overview...2107
Tools Required...2107
Equipment Condition...2107
Test Setup...2107
Test Procedure...2108
Expected Outcome ...2108
Follow-On Procedure...2109
Low Exhaust Gas Temperatures Graph...2110
Overview...2110
Tools Required...2110
Equipment Condition...2110
Test Setup...2110
Test Procedure...2111
Expected Outcome...2111
Follow-On Procedure...2112
Air Control Valve (ACV) Test...2113
Exhaust Back Pressure Valve (EBPV) Test...2113
Overview...2113
Tools Required...2113
Equipment Condition...2113
Test Setup...2113
Test Procedure...2113
Expected Outcome...2114
Follow-on Procedure...2114
Boost Control System Test...2115
Overview...2115
Tools Required...2115
Equipment Condition...2115
Test Setup...2115
Test Procedure...2116
Expected Outcome...2117
Follow-On Procedure...2117
Turbocharger 2 Wastegate Position (TC2WG) Operational Test...2118
Overview...2118
Tools Required...2118
Equipment Condition...2118
Test Setup...2118
Test Procedure...2120
Expected Outcome...2120
Follow-On Procedure...2121
Turbocharger 2 Wastegate Position (TC2WG) Solenoid Test...2122
Overview...2122
Tools Required...2122
Equipment Condition...2122
Test Setup...2122
Test Procedure...2122
Expected Outcome...2122
Follow-On Procedure...2122
Turbocharger 2 Wastegate Position (TC2WG) Isolated Actuator Test...2123
Overview...2123
Tools Required...2123
Equipment Condition...2123
Test Setup...2124
Test Procedure...2125
Expected Outcome...2126
Follow-On Procedure...2126
KOER MAF Sensor Calibrations...2127
Overview...2127
Tools Required...2127
Equipment Condition...2127
MAF Calibration Pre-Checks...2127
Test Setup...2128
Test Procedure...2129
Expected Outcome...2129
Follow-On Procedure...2129
Exhaust Gas Recirculation Valve (EGRV) Operational Test...2130
Overview...2130
Tool Required...2130
Equipment Condition...2130
Test Setup...2130
Test Procedure...2130
Expected Outcome...2131
Follow-On Maintenance...2131
Low-Pressure Fuel System Tests...2132
Fuel Delivery Pressure (FDP) Test...2132
Overview...2132
Tools Required...2132
Equipment Condition...2132
Test Setup...2133
Test Procedure...2134
Expected Outcome...2134
Follow-On Procedure...2134
Fuel Pump Voltage Test...2135
Overview...2135
Tools Required...2135
Equipment Condition...2135
Test Setup...2135
Test Procedure...2136
Expected Outcome...2137
Follow-On Procedure...2137
Clean Fuel Source Test...2138
Overview...2138
Tools Required...2138
Equipment Condition...2138
Test Setup...2138
Test Procedure...2140
Expected Outcome...2140
Follow-on Procedure...2141
Intake Air Heater (IAH) Tests...2142
Intake Air Heater System Test...2142
Overview...2142
Tools Required...2142
Equipment Condition...2142
Test Setup...2142
Test Procedure...2143
Expected Outcome...2143
Follow-on Procedure...2143
Intake Air Heater (IAH) Current Draw Test...2144
Overview...2144
Tools Required...2144
Equipment Condition...2144
Test Setup...2144
Test Procedure...2145
Expected Outcome...2146
Intake Air Heater (IAH) Relay Test...2147
Overview...2147
Tools Required...2147
Equipment Condition...2147
Test Setup...2147
Test Procedure...2148
Expected Outcome...2149
Follow-On Procedure...2149
High-Pressure Charge Air Cooler (HPCAC) Pressure Test...2150
Overview...2150
Tools Required...2150
Equipment Condition...2150
Test Setup...2151
Test Procedure...2152
Expected Outcome...2156
Follow-On Procedure...2156
Interstage Cooler (ISC) Pressure Test...2157
Overview...2157
Tools Required...2157
Equipment Condition...2157
Test Setup...2158
Test Procedure...2158
Expected Outcome...2159
Follow-On Procedure...2159
Crankcase Pressure Test...2160
Overview...2160
Tools Required...2160
Equipment Condition...2160
Test Setup...2160
Test Procedure...2163
Expected Outcome...2164
Follow-on Procedure...2164
General Test Procedures...2165
Coolant Heater Assembly Test...2165
Overview...2165
Tools Required...2165
Equipment Condition...2165
Test Setup...2165
Test Procedure...2165
Expected Outcome...2166
Follow-On Procedure...2166
Oil Pan Heater Test...2167
Overview...2167
Tools Required...2167
Equipment Condition...2167
Test Setup...2167
Test Procedure...2167
Expected Outcome...2168
Follow-On Procedure...2168
Relay Diagnostics...2169
Overview...2169
Relay Diagnostics Applicability Table...2169
Relay Test 1 - Switched-86 GND...2170
Overview...2170
Tools Required...2170
Equipment Conditions...2170
Test Setup...2170
Test Procedure...2170
Expected Outcome...2171
Follow-on Procedure...2171
Relay Test 2 – Switched-86 PWR...2172
Overview...2172
Tools Required...2172
Equipment Conditions...2172
Test Setup...2172
Test Procedure...2172
Expected Outcome...2173
Follow-on Procedure...2173
Relay Test 3 – Switched-85 GND...2174
Overview...2174
Tools Required...2174
Equipment Conditions...2174
Test setup...2174
Test Procedure...2174
Expected Outcome...2176
Follow-on Procedure...2176
Relay Test 4 – Switched-85 Shared 30...2177
Overview...2177
Tools Required...2177
Equipment Conditions...2177
Test setup...2177
Test Procedure...2177
Expected Outcome...2179
Follow-on Procedure...2179
Relay Test 5 – Switched-85 GND, FMI 4...2180
Overview...2180
Tools Required...2180
Equipment Conditions...2180
Test setup...2180
Test Procedure...2180
Expected Outcome...2181
Follow-on Procedure...2181
Relay Test 6 – Switched-86 PWR, No Code...2182
Overview...2182
Tools Required...2182
Equipment Conditions...2182
Test setup...2182
Test Procedure...2182
Expected Outcome...2183
Follow-on Procedure...2183
Relay Test 7 – Switched-85 GND, No Code...2184
Overview...2184
Tools Required...2184
Equipment Conditions...2184
Test setup...2184
Test Procedure...2184
Expected Outcome...2185
Follow-on Procedure...2185
Coolant Test Procedures...2186
Deaeration Tank Cap Test...2186
Overview...2186
Tools Required...2186
Equipment Condition...2187
Test Setup...2188
Test Procedure...2188
Expected Outcome...2188
Follow-on Procedure...2188
Cooling System Pressure Test...2189
Overview...2189
Tools Required...2189
Equipment Condition...2189
Test Setup...2190
Test Procedure...2191
Expected Outcome...2191
Follow-on Procedure...2192
Coolant Over-Flow / Over-Temperature Test...2193
Overview...2193
Tools Required...2193
Equipment Condition...2193
Test Setup...2193
Test Procedure...2193
Expected Outcome...2193
Follow-On Procedure...2193
Thermostat Operational Test...2194
Overview...2194
Tools Required...2194
Equipment Condition...2194
Test Setup...2194
Test Procedure...2194
Expected Outcome...2194
Follow-On Procedure...2194
Engine Cooling Fan Test...2195
Overview...2195
Tools Required...2195
Equipment Condition...2195
Test Setup...2195
Test Procedure...2195
Expected outcome...2196
Air Compressor Coolant Leak Test...2197
Overview...2197
Tools Required...2197
Equipment Condition...2197
Test Setup...2197
Test Procedure...2198
Expected Outcome...2198
Follow-on Procedure...2198
Air Compressor Overflow Test...2199
Overview...2199
Tools Required...2199
Equipment Condition...2199
Test Setup...2199
Test Procedure...2199
Expected Outcome...2199
Follow-on Procedure...2199
Combustion in Cooling System Test...2200
Overview...2200
Tools Required...2200
Equipment Condition...2200
Test set-up...2200
Test Procedure...2201
Expected Outcome...2201
Follow-On Procedure...2201
On-Engine EGR Cooler Leak Test...2202
Overview...2202
Tools Required...2202
Equipment Condition...2202
Test Setup...2202
Test Procedure...2204
Expected Outcome...2204
Follow-On Procedure...2204
Instrument Cluster Temperature Gauge Validation Test...2205
Overview...2205
Tools Required...2205
Equipment Condition...2205
Test Setup...2205
Test Procedure...2205
Expected Outcome...2206
Follow-On Procedure...2206
Engine Oil Tests...2207
Oil Cooler Pressure Test...2207
Overview...2207
Tools Required...2207
Equipment Condition...2207
Test Setup...2207
Test Procedure...2208
Expected Outcome...2209
Follow-on Procedure...2209
Oil Pressure Verification Test...2210
Overview...2210
Tools Required...2210
Equipment Condition...2210
Test Setup...2210
Test Procedure...2211
Expected Outcome...2211
Follow-on Procedure...2212
Instrument Cluster Engine Oil Pressure Gauge Validation Test...2213
Overview...2213
Tools Required...2213
Equipment Condition...2213
Test Setup...2214
Test Procedure...2214
Expected Outcome...2215
Follow-On Procedure...2215
Oil Breather Separator Test...2216
Overview...2216
Tools Required...2216
Equipment Condition...2216
Test Setup...2216
Test Procedure...2217
Expected Outcome...2217
Follow-on Procedure...2217
Engine System Inspections...2218
Fuel System Inspection...2218
Overview...2218
Tools Required...2218
Equipment Condition...2218
Inspection Procedure...2218
Expected Outcome...2218
Fuel Quality Inspection...2219
Overview...2219
Tools Required...2219
Inspection Procedure...2220
Expected Outcome...2220
Fuel Level Inspection...2221
Overview...2221
Tools Required...2221
Equipment Condition...2221
Inspection Procedure...2221
Expected Outcome...2221
Engine Oil Level and Quality Check...2222
Overview...2222
Tools Required...2222
Equipment Condition...2222
Inspection Procedure...2222
Expected Outcome...2223
Coolant Level Inspection...2224
Overview...2224
Tools Required...2224
Equipment Condition...2224
Inspection Procedure...2224
Expected Outcome...2224
Coolant Quality Inspection...2225
Overview...2225
Tools Required...2225
Equipment Condition...2225
Inspection Procedure...2225
Expected Outcome...2225
Coolant in Exhaust Inspection...2226
Overview...2226
Tools Required...2226
Inspection Procedure...2226
Expected Outcome...2226
Interstage Cooler (ISC) Inspection...2227
Overview...2227
Tools Required...2227
Equipment Condition...2227
Inspection Procedure...2228
Expected Outcome...2228
Coolant Leak Visual Inspection ...2229
Overview...2229
Tools Required...2229
Equipment Condition...2229
Inspection Procedure...2229
Expected Outcome...2229
Coolant To Intake Inspection...2230
Overview...2230
Tools Required...2230
Equipment Condition...2230
Inspection Procedure...2231
Expected Outcome...2231
Charge Air Cooler Inspection...2232
Overview...2232
Tools Required...2232
Equipment Condition...2232
Inspection Procedure...2232
Expected Outcome...2233
Intake Air Inspection...2234
Overview...2234
Tools Required...2234
Equipment Condition...2234
Inspection Procedure...2234
Expected Outcome...2234
Front Gear Train Coolant Leak Inspection...2235
Overview...2235
Tools Required...2235
Equipment Condition...2235
Inspection Procedure...2235
Expected Outcome...2236
Exhaust and Aftertreatment System Inspection...2237
Overview...2237
Tools Required...2237
Equipment Condition...2237
Inspection Procedure...2237
Expected Outcome...2238
Diesel Particulate Filter (DPF) Inspection...2239
Overview...2239
Tools Required...2239
Equipment Condition...2239
Inspection Procedure...2240
Expected Outcome...2241
Diesel Oxidation Catalyst (DOC) Inspection...2242
Overview...2242
Tools Required...2242
Equipment Condition...2242
Inspection Procedure...2243
Expected Outcome...2243
Selective Catalyst Reduction (SCR) Inspection...2244
Overview...2244
Tools Required...2244
Equipment Condition...2244
Inspection Procedure...2244
Expected Outcome...2245
Follow-On Procedure...2245
Diesel Exhaust Fluid Dosing Unit (DEFD) Inspection...2246
Overview...2246
Tools Required...2246
Equipment Condition...2246
Inspection Procedure...2247
Expected Outcome...2248
Decomposition Reactor Tube Inspection...2249
Overview...2249
Tools Required...2249
Equipment Condition...2249
Inspection Procedure...2249
Expected Outcome...2250
Diesel Exhaust Fluid (DEF) Quality Inspection...2251
Overview...2251
Tools Required...2251
Equipment Condition...2251
Inspection Procedure...2251
Expected Outcome...2251
Diesel Exhaust Fluid (DEF) Level & Gauge Inspection...2252
Overview...2252
Tools Required...2252
Equipment Condition...2252
Inspection Procedure...2252
Expected Outcome...2253
Coolant to Engine Oil Inspection ...2254
Overview...2254
Tools Required...2254
Inspection Procedure...2254
Expected Outcome...2254
Oil Pressure Regulator Inspection...2255
Overview...2255
Tools Required...2255
Equipment Condition...2255
Inspection Procedure...2256
Expected Outcome...2256
Cylinder Sleeve Cavitation and Crack Inspection...2257
Overview...2257
Tools Required...2257
Equipment Condition...2257
Inspection Procedure...2257
Expected Outcome...2257
Oil and Crankcase Inspection...2258
Overview...2258
Tools Required...2258
Equipment Condition...2258
Inspection Procedure...2258
Expected Outcome...2260
High-Pressure (HP) Turbocharger Radial Play Inspection...2261
Overview...2261
Tools Required...2261
Equipment Condition...2261
Inspection Procedure...2261
Expected Outcome...2261
Batteries and Electrical System Inspection...2262
Overview...2262
Tools Required...2262
Equipment Condition...2262
Inspection Procedure...2262
Expected Outcome...2262
Aftertreatment...2263
Snap Acceleration Test...2263
Overview...2263
Tools Required...2263
Equipment Condition...2263
Test Setup...2263
Test Procedure...2263
Expected Outcome...2263
Follow-On Procedure...2263
Downstream Injection System Operation Test...2264
Overview...2264
Tools Required...2264
Equipment Condition...2264
Test Setup...2264
Test Procedure...2265
Expected Outcome...2266
Follow-on Procedure...2266
Table of Contents...2267
All Ratings...2269
Engine Specifications...2269
Key-On Engine-Off...2270
Position Sensors...2270
Engine Cranking Specs...2271
Low Idle, No Load, Stabilized Engine Operating Temperature Specs...2272
High Idle, No Load, Stabilized Engine Operating Temperature Specs...2273
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature Specs...2274
Engine Coolant Temperatures ECT1, ECT2, Engine Oil Temp, Intake Manifold Temp (IMAT) Specs...2275
Intake Air Temp (IAT) Specs...2276
Diesel Oxidation Catalyst Intake Temp (DOCIT), Diesel Particulate Filter Intake Temp (DPFIT), Diesel Particulate Outlet Temp (DPFOT) Specs...2277
Soot Load Level versus Exhaust Gas Target Temperature Chart...2278
Overview...2278
Soot Load Level versus Exhaust Gas Target Temperature Chart...2278
Other Components Specs...2279
Navistar® 9 (9.3L)...2280
300 hp @ 2000 rpm (12NWC)...2280
315 hp @ 2000 rpm (12NWD)...2281
330 hp @ 2000 rpm (12NWE)...2282
Navistar® 10 (9.3L)...2283
310 hp @ 2000 rpm (12NWG)...2283
330 hp @ 2000 rpm (12NWH)...2284
350 hp @ 2000 rpm (12NWJ)...2285
Fluids...2286
Fluid Specifications and Info...2286
Fuel...2286
Ultra Low Sulfur Diesel (ULSD)...2286
Acceptable Fuel Blends...2286
Use of Higher Biodiesel Fuel Blends (B6 to B20)...2286
Engine Lubrication Oil...2286
SAE Oil Viscosity Grades and Temperature Ranges...2287
Coolant...2288
Cooling System Capacity...2288
Coolant Mixtures...2288
Table of Contents...2289
Electrical Tools...2291
180-Pin Breakout Box...2291
Breakout Harness 18-050-01 (20-way DEF Harness Interconnect)...2292
Breakout Harness 18-650-01 (Ammonia (NH3) Sensor)...2292
Breakout Harness 18-801-01 (Ammonia (NH3) Sensor Module)...2293
Breakout Harness 18-909-01 (DEF Supply Module)...2293
Breakout Harness 18-047-01 DEF Line 3 Heater (Pressure)...2294
Breakout Harness 18-046-01 DEF Line 2 Heater (Return)...2294
Breakout Harness 18-045-01 DEF Line 1 Heater (Supply)...2295
Breakout Harness 18-124-01 (DEF Tank Level and Temperature Sensor)...2295
Breakout Harness 18-649-01 (NOx Out and DOC / DPF Temperature Sensor Module)...2296
Breakout Harness 12-575-01 (DPF Differential Pressure / Outlet Pressure Sensor)...2296
Breakout Harness 18-648-01 (NOx In Sensor Module and SCR Temperature Sensor Module)...2297
Breakout Harness 12-574-01 (8-way DPF Jumper Harness)...2297
Breakout Harness 18-250-01 (12-way SCR Jumper Harness)...2298
Breakout Harness 18-500-01 (12-way AFT Interconnect)...2298
Digital Multimeter (DMM) ZTSE4357...2299
Breakout Harness ZTSE6023 (EFP)...2299
International® Electronic Engine Terminal Test Kit ZTSE4435C...2300
Breakout Harness ZTSE4485A (APP)...2301
Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT)...2301
Breakout Harness ZTSE4735A (ETV)...2302
Amp Clamp ZTSE4575...2302
3-Banana Plug Harness ZTSE4498...2303
500-Ohm Resistor Harness ZTSE4497...2303
Breakout Harness ZTSE4484 (IPR)...2304
Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV)...2304
Breakout Harness ZTSE4674 (ECM and ACT PWR Relays)...2305
Breakout Harness ZTSE4830 (AFTFIS)...2305
Breakout Harness ZTSE4831 (TC2WG)...2306
Breakout Harness ZTSE4834 (EBPV)...2306
Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP)...2307
Breakout Harness ZTSE4908 (EFAN)...2307
Breakout Harness ZTSE4946 (EGT)...2308
Breakout Harness ZTSE4948 (EGR)...2308
Breakout Harness ZTSE4950 (CKP)...2309
Breakout Harness ZTSE4951 (CMP)...2309
Breakout Harness ZTSE4952 (ICP, ECB, and ECBP)...2310
Breakout Harness ZTSE4993 (IMT)...2310
Breakout Harness ZTSE6002 (WIF)...2311
Breakout Harness ZTSE6020 (24-pin)...2311
Breakout Harness ZTSE6021 (AFTFD)...2311
Breakout Harness ZTSE6025 (IAH)...2312
Breakout Harness ZTSE6027 (AFTFP)...2312
Under Valve Cover (UVC) ZTSE4793...2312
DEF Tank Heat Coolant Flow Valve ZTSE4827...2313
Diesel Exhaust Fluid Dosing Unit (DEFDU) ZTSE4828...2313
Mass Air Flow (MAF) Sensor ZTSE4960...2314
Noid Lamp 15-909-01...2314
Mechanical Tools...2315
Radiator Pressure Test Kit ZTSE2384...2315
Pressure Test Kit ZTSE4409...2315
Interstage Cooler Test Kit ZTSE4937...2316
Oil Cooler Test Plate ZTSE4939...2317
Cylinder Head Pressure Test Adapter ZTSE4289A...2318
Thermostat Opening Pressure Test Adapter ZTSE4647...2318
Water Supply Press Test Adapter ZTSE4648...2319
ICP Adapter Pressure Test Fitting ZTSE4927...2319
High Pressure Test Gauge ZTSE4954...2320
Pressure Gauge Adapter 18-538-01...2321
IPR Plug Tester ZTSE4816...2321
Crankcase Pressure Test Tool ZTSE4039...2322
Slack Tube® Manometer ZTSE2217A...2323
Fuel Pressure Gauge ZTSE4681...2324
Fuel Pressure Test Kit ZTSE4657...2325
Charge Air Cooler Test Kit ZTSE4341...2325
EGR Mixing Bowl Guide Pins ZTSE4945...2326
EGR Valve Puller ZTSE4941...2326
Fuel Intake Restriction and Aeration Tool ZTSE6009...2327
Fuel/Oil Pressure Test Coupler ZTSE4526...2327
Fuel Test Fitting ZTSE4692...2328
ICP Test Kit ZTSE4655...2328
Turbo Lifting Bracket ZTSE4942...2329
UV Leak Detection Kit ZTSE4618...2329
Clean Fuel Source Tool 15-637-01...2330
Table of Contents...2331
Engine Component Locator...2333
Aftertreatment Component Locator...2341
Table of Contents...2343
Engine Identification...2347
Engine Serial Number...2347
Engine Serial Number Examples:...2347
Engine Serial Number Codes:...2347
Engine Emission Label...2348
Engine Accessory Labels...2348
Air Management System...2350
Air Flow-Pre Combustion...2351
Air Flow-Post Combustion...2351
Air Management Components...2351
Turbochargers...2351
Interstage Cooler (ISC)...2352
Exhaust Gas Recirculation (EGR) System...2353
The EGR system includes the following: ...2353
Exhaust Gas Recirculation (EGR) Valve...2354
Exhaust Gas Recirculation (EGR) Closed Loop System...2354
Crankcase Ventilation System...2355
Aftertreatment System...2357
Aftertreatment (AFT) System...2357
AFT Control System...2357
DPF...2358
DOC...2358
Selective Catalyst Reduction (SCR) Catalyst ...2358
Decomposition reactor tube ...2358
Sensors...2358
Exhaust Back Pressure Valve (EBPV)...2358
AFT Conditions and Responses ...2358
Diesel Exhaust Fluid (DEF) Injection ...2359
Downstream Injection System ...2360
Fuel Management System...2361
Fuel Management System...2361
Injection Control Pressure (ICP) System...2362
High-Pressure Oil System...2363
Injection Control Pressure (ICP) Closed Loop System ...2363
ICP Control System ...2364
Fuel Injector...2365
Intensifier Piston and Plunger...2366
Plunger and Barrel...2366
Injector Needle...2366
Fuel Injector Operation...2366
Fill Stage ...2367
Injection...2367
End of Injection ...2368
Fuel Supply System...2369
Fuel Supply System Flow ...2370
Intake Air Heater System...2374
Intake Air Heater System...2374
Intake Air Heater (IAH)...2374
Engine Lubrication System...2375
Engine Cooling System...2377
Cooling System Description...2377
Cooling System Components...2378
Coolant Heater (optional)...2378
Thermostat Operation...2378
Electronic Control System ...2381
Electronic Control System Components ...2381
Operation and Function...2381
Doser Control Unit (DCU)...2381
Reference Voltage (VREF)...2381
Microprocessor...2381
Diagnostic Trouble Codes...2381
Microprocessor Memory...2381
Read Only Memory (ROM)...2382
Random Access Memory (RAM)...2382
Actuator Control...2382
ECM Actuators and Sensors...2383
Exhaust Gas Recirculation Valve (EGRV)...2384
Intake Air Heater (IAH) System...2384
Electric Fuel Pump (EFP)...2384
Engine Throttle Valve (ETV) and Engine Throttle Valve Position (ETP) Sensor...2384
Turbocharger 2 Wastegate (TC2WG) position valve...2384
Exhaust Back Pressure Control (EBPC)...2385
Engine Compression Brake Output 1 (ECB1) valve...2385
Injectors...2385
Injection Pressure Regulator (IPR) valve...2385
ACM Actuators...2386
AFT Fuel Shutoff (AFTFSO)...2387
Aftertreatment Fuel Pressure Control (AFTFPC)...2387
Diesel Exhaust Fluid Dosing Unit (DEFD)...2387
Diesel Exhaust Fluid Unit Heater Relay (DEFSMH Relay)...2387
Diesel Exhaust Fluid Line Heater Relay (DEFLHR)...2387
EF Supply Line Heater (DEFSLH)...2387
DEF Return Line Heater (DEFRLH)...2387
DEF Pressure Line Heater (DEFPLH)...2388
DEF Tank Heater Valve (DEFTHV)...2388
Diesel Exhaust Fluid Supply Module Heater (DEFSMH)...2388
Diesel Exhaust Fluid Supply Pump (DEFSP) and DEF Tank Temperature (DEFTT) Sensors...2388
Diesel Exhaust Fluid Reverting Control Valve (DEFRCV)...2388
Engine and Vehicle Sensors...2388
Engine Temperature Sensors...2388
Engine Coolant Temperature 1 (ECT1) Sensor...2389
Engine Oil Temperature (EOT) Sensor...2389
Turbocharger 2 Compressor Intake Temperature (TC2CIT) Sensor...2389
Exhaust Gas Temperature (EGT) Sensor...2389
Charge Air Cooler Outlet Temperature (CACOT) Sensor...2390
Intake Air Heater (IAT) Sensor...2390
Intake Manifold Temperature (IMT) Sensor...2390
Ambient Air Temperature (AAT) Sensor...2390
Aftertreatment Temperature Sensors...2390
Diesel Exhaust Fluid Tank Level and Temperature (DEFTLT) Sensor Module...2391
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensor Module...2391
Diesel Oxidation Catalyst Intake Temperature (DOCIT) Sensor...2391
Diesel Particulate Filter Intake Temperature (DPFIT) Sensor...2391
Diesel Particulate Filter Outlet Temperature (DPFOT) Sensor...2391
Selective Catalyst Reduction (SCR) Temperature Sensor Module...2391
Variable Capacitance Sensors...2392
Fuel Delivery Pressure (FDP) sensor...2392
Engine Oil Pressure (EOP) Sensor...2393
Exhaust Back Pressure (EBP) Sensor...2393
Mass Air Flow (MAF) Sensor...2393
Intake Manifold Pressure (IMP) Sensor...2393
Aftertreatment Fuel Pressure 1 (AFTFP1) sensor...2393
Aftertreatment Fuel Temperature (AFTFT) sensor...2393
Aftertreatment Fuel Pressure 2 (AFTFP2) sensor...2393
DEF Line Pressure (DEFLP) sensor...2394
Diesel Particulate Filter Differential Pressure (DPFDP) / DPF Outlet Pressure (DPFOP) sensor...2394
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)...2394
High-pressure Sensors...2394
Brake Control Pressure (BCP) Sensor...2394
Injection Control Pressure (ICP) Sensor...2395
Magnetic Pickup Sensors...2395
Crankshaft Position (CKP) Sensor...2395
Camshaft Position (CMP) Sensor...2395
Vehicle Speed Sensor (VSS)...2396
Crankcase Oil Separator Speed (CCOSS) Sensor...2396
Switches...2396
Driveline Disengagement Switch (DDS)...2396
Engine Coolant Level (ECL) Sensor...2396
Water In Fuel (WIF)...2397
Potentiometer Sensors...2397
Accelerator Pedal Position (APP)...2397
Engine Throttle Valve Control System...2398
Exhaust and Engine Brake System...2399
Exhaust Brake...2399
Engine Brake...2400
Exhaust Back Pressure Control (ECBC)...2400
Engine Compression Brake Output 1 (ECB1)...2401
Brake Pressure Relief Valve...2401
Exhaust Back Pressure (EBP) Sensor...2401
High-pressure Oil Manifold...2401
Operation...2401
Operation Modes...2403
Coast Mode...2403
Latched Mode...2403
Cruise Mode...2403
Chassis Mounted Features...2403
Charge Air Cooler (CAC)...2403
Additional Sensors...2403
Ammonia (NH3) Sensor Module...2403
Nitrogen Oxides (NOx) IN Sensor Module...2404
Nitrogen Oxides (NOx) OUT Sensor Module...2404
Oxygen Sensor (O2S)...2404
Humidity Sensor (HS)...2405
Relays...2406
ECM Power Relay...2407
Actuator Power Relay...2408
Engine Fan Relay...2409
Fuel Pump Relay...2409
Fuel Heater Relay...2410
Starter Relay...2411
Heavy Duty On Board Diagnostics (HD-OBD) Description...2412
Overview...2412
Table of Contents...2413
Standard Electronic Control Features...2415
Aftertreatment (AFT) System...2415
Intake Air Heater...2415
Coolant Temperature Compensation (CTC)...2415
Electronic Speedometer and Tachometer...2415
Engine Crank Inhibit (ECI)...2415
Electronic Governor Control...2415
Event Logging System...2415
Fast Idle Advance...2416
J1939 Datalink...2416
Service Diagnostics...2416
Optional Electronic Control Features...2417
Cruise Control...2417
Engine Brake...2417
Engine Warning Protection System (EWPS)...2417
Idle Shutdown Timer (IST)...2417
IST for California ESS Compliant Engines...2417
Engine Idle Shutdown Timer (IST for Federal – Optional) ...2418
Automatic Engine Speed Control (AESC)...2418
Service Interval...2418
Traction Control...2418
Road Speed Limiter...2418
Table of Contents...2421
Abbreviations and Acronyms...2423
Abbreviations and Acronyms...2423
Table of Contents...2433
Terminology...2435
Terms...2435
tables...5
Technical Service Literature...5
SPN...750
FMI...750
Description...750
Voltage Check at Relay...995
Voltage Check at ECM...995
Harness Resistance Check – ECM to Relay...996
Operational Voltage Check...996
Harness Resistance Check – Relay to Battery...996
SPN...1836
FMI...1836
Description...1836
SPN...1854
FMI...1854
Description...1854
Air Management Test Setup...2036
Navistar® 9, and 10 Diesel Engines...2269
Key-On Engine-Off...2270
Key-On Engine-Off...2270
Engine Cranking...2271
Low Idle, no load, stabilized engine operating temperature...2272
Low Idle, no load, stabilized engine operating temperature...2272
High Idle, Parasitic load, at stabilized operating temperature...2273
Crankcase Pressure...2273
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature...2274
Engine Component Locations...2338
Component...2338
Location...2338
SCR Switchback Assembly Component Locator Table...2342
Component...2342
Location...2342
Table of Contents...3
Safety Terminology...7
Safety Instructions...7
Work Area...7
Safety Equipment...7
Protective Measures...7
Vehicle...7
Engine...7
Fire Prevention...7
Batteries...7
Compressed Air...8
Tools...8
Fluids Under Pressure...8
Fuel...8
Removal of Tools, Parts, and Equipment...8
Table of Contents...9
Engine Identification...11
Engine Serial Number...11
Engine Serial Number Examples...11
Engine Serial Number Codes...11
Engine Emission Label...11
Engine Accessory Labels...11
Engine Description...12
Standard Features...13
Optional Features...14
Optional Cold Climate Features...14
Chassis Mounted Features...14
Engine Component Locator...15
Table of Contents...23
Engine Preparation...25
Clean Engine ...25
Drain Coolant ...25
Drain Oil ...25
Removing Engine from Vehicle...25
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve ...25
Turbo Air Inlet Duct Assembly...25
NOxIN Concentration Sensor and Module assembly...25
Hydrocarbon Injector Assembly...25
Throttle Coupling Assembly...25
Exhaust Brake Valve Assembly...26
ISC Inlet Duct Assembly...26
ISC Cooler Assembly...26
Turbo Oil Supply Assembly...26
Turbo Wastegate Assembly...26
Dual Stage Turbo Assembly...26
Drain High Fin Density EGR Cooler...26
High Fin Density EGR Cooler Assembly...26
Oil Filter Removal ...26
Oil Cooler Removal Assembly...26
Mounting Engine Stand Bracket and Engine...26
Mounting Engine Stand Bracket...26
Table of Contents...29
Illustrations...31
Electronic Components – Top...31
Electronic Components – Front...32
Electronic Components – Exhaust Side...33
Electronic Components – Intake Side...34
Electronic Components – Rear...35
Removal...36
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve...36
Crankshaft Position (CKP) Sensor...37
Camshaft Position (CMP) Sensor...37
Exhaust Back Pressure (EBP) Sensor...38
Engine Control Module (ECM) and Mounting Bracket...38
Engine Coolant Temperature 1 (ECT1) Sensor...39
CCOS Sensor...39
NOxIN Concentration Sensor and Module...40
Electric Fuel Pump Connector...40
Fuel Delivery Pressure (FDP) Sensor...40
Exhaust Gas Recirculation (EGR) Valve Connector...41
Exhaust Gas Temperature (EGT) Sensor...41
Engine Oil Pressure (EOP) Sensor...41
Engine Oil Temperature (EOT) Sensor...41
Fuel Heater (250 watt)...42
Intake Air Heater (IAH) Relay Assembly...42
Injection Control Pressure (ICP) Sensor...43
Engine Throttle Valve (ETV) Assembly Connector...43
Injection Pressure Regulator (IPR) Valve Connector...43
Intake Manifold Pressure (IMP) Sensor...44
Intake Manifold Temperature (IMT) Sensor...44
Downstream Injection (DSI) Assembly Connectors...45
Water In Fuel (WIF) Sensor...45
Engine Harness Assembly...46
Valve Cover Gasket Assembly...48
Inspect...49
Inspect Wiring Harness, Connectors, and Electrical Components...49
Installation...50
Engine Harness Assembly and Camshaft Position (CMP) Sensor...50
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve...53
Crankshaft Position (CKP) Sensor...53
Exhaust Back Pressure (EBP) Sensor...53
Electronic Control Module (ECM) and Mounting Bracket...54
Engine Coolant Temperature 1 (ECT1) Sensor...54
CCOS Sensor...55
NOxIN Concentration Sensor and Module ...55
Fuel Delivery Pressure (FDP) Sensor...55
Exhaust Gas Recirculation (EGR) Control Valve Connector...55
Electric Fuel Pump Connector...56
Exhaust Gas Temperature (EGT) Sensor...56
Engine Oil Pressure (EOP) Sensor...57
Engine Oil Temperature (EOT) Sensor...57
Fuel Heater (250 watt) Connector...57
Intake Air Heater (IAH) Relay Assembly...58
Injector Control Pressure (ICP) Sensor...58
Engine Throttle Valve (ETV) Assembly Connector...59
Injection Pressure Regulator (IPR) Valve Connector...59
Intake Manifold Temperature (IMT) Sensor...59
Intake Manifold Pressure (IMP) Sensor...60
Downstream Injection (DSI) Assembly Connectors...60
Water In Fuel (WIF) Sensor...60
Valve Cover Gasket Assembly...61
Table of Contents...63
Exploded Views...65
Down Stream Injection (DSI) Assembly...65
Hydrocarbon Injector Assembly...66
Removal...67
Down Stream Injection (DSI) Assembly...67
Injection Unit Inlet Tube Assembly...68
Hydrocarbon Injector Assembly...69
Cleaning and Inspection...71
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning...71
Exhaust Back Pressure Valve Housing Cleaning...71
Installation...72
Hydrocarbon Injector Assembly...72
Injection Unit Inlet Tube Assembly...73
Down Stream Injection (DSI) Assembly...74
Table of Contents...77
Exploded View...79
Removal...84
Interstage Inlet Duct Assembly...85
Interstage Cooler (ISC)...88
Throttle Coupling...90
Turbocharger Oil Supply Tube Assembly...90
Exhaust Brake Valve and Turbocharger Outlet Elbow...91
Turbocharger Air Inlet Duct...93
Turbocharger Wastegate Actuator Assembly...94
Dual Stage Turbocharger Assembly...94
High-Pressure Turbocharger Center Section...95
Cleaning, Inspection, and Testing...101
Inspect and Clean Dual Stage Turbocharger Assembly and Related Parts...101
Dual Turbocharger Compressor Cleaning and Inspection...101
Inspection...101
Removal of Turbocharger Compressor Covers...101
Assembly...103
Inspect Turbine and Compressor...103
Inspect High-Pressure Turbine Housing...104
Crossover Tube Seal...104
Installation...105
High Pressure Turbocharger Center Section Assembly...105
Dual Stage Turbocharger Assembly...111
Turbocharger Wastegate Actuator Assembly (without precise regulated shop air pressure)...112
Turbocharger Wastegate Actuator Assembly (with precise regulated shop air pressure)...113
Turbocharger Air Inlet Duct...114
Exhaust Brake Valve and Turbocharger Outlet Elbow...114
Turbocharger Oil Supply Tube Assembly...116
Throttle Coupling...117
Interstage Cooler (ISC)...118
Interstage Inlet Duct Assembly...121
Table of Contents...125
Exploded View...127
Removal...130
Draining High Fin Density EGR Cooler...130
High Fin Density EGR Cooler and Components...131
EGR Valve Assembly...134
Engine Throttle Valve (ETV) Assembly...134
Air and EGR Mixer Duct Assembly...134
Cleaning, Inspecting, and Testing...136
Cleaning and Inspecting EGR System Components...136
Air and EGR Mixer Duct Assembly...136
EGR Valve Assembly...136
Engine Throttle Valve Assembly...136
High Fin Density EGR Cooler...136
Pressure Testing High Fin Density EGR Cooler...136
EGR Cooler Vent Tool...137
EGR Cooler Coolant Port Tool...137
EGR Cooler Exhaust Inlet Tool...137
EGR Cooler Exhaust Outlet Tool...137
SAE J512 Plugs...138
EGR Cooler Leak Test...138
Installation...139
Air and EGR Mixer Duct Assembly...139
Engine Throttle Valve (ETV) Assembly...140
EGR Valve Assembly...140
High Fin Density EGR Cooler and Components...141
Table of Contents...145
Exploded View...147
Removal...149
Exhaust Manifold...150
Intake Manifold, Fuel Valve, and Fuel Rail Plugs...151
Cleaning, Inspection, and Measurements...154
Exhaust Manifold...154
Exhaust Back Pressure (EBP) Sensor Tube Assembly...154
Intake Manifold...154
Installation...155
Exhaust Manifold...155
Intake Manifold, Fuel Valve, and Fuel Rail Plugs...157
Table of Contents...161
Exploded Views...163
Periodic Service...167
Fuel Strainer...167
Fuel Filter...168
Draining Water From Fuel Filter Assembly...168
Removal...169
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater...169
Water Drain Valve Assembly...169
Brushless Electric Fuel Pump Assembly...170
Fuel Pressure Regulator Valve Assembly...170
Fuel Filter Assembly...172
High-pressure Oil Hose and Elbows...173
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly...174
High-pressure Oil Manifold...176
Injector Oil Inlet Adapter (Puck) Assembly...177
Fuel Injector Assemblies...178
Cleaning and Inspection...179
Fuel Filter Assembly Service Recommendations...179
High-pressure Oil System Components...179
Installation...181
Fuel Injector Assemblies...181
Injector Oil Inlet Adapter (Puck) Assembly...182
High-pressure Oil Manifold...182
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly...184
High-pressure Oil Hose and Elbows...186
Fuel Filter Assembly...188
Water Drain Valve Assembly...189
Brushless Electric Fuel Pump Assembly and Fuel Strainer...189
Fuel Pressure Regulator Valve Assembly...190
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater...190
Table of Contents...193
Exploded View and Description...195
High-pressure Oil Manifold (Brake)...195
Periodic Service...196
Engine Brake Lash Adjustment...196
Removal...199
Engine Compression Brake (ECB) Valve...199
Engine Compression Brake Pressure (ECBP) Sensor...199
Valve Cover Gasket (Harness) Assembly (Brake)...200
High-pressure Oil Manifold (Brake)...201
Oil Pressure Relief Valve...202
Brake Actuator Piston Assembly...202
Cleaning and Inspection...204
Installation...205
Brake Actuator Piston Assembly...205
Oil Pressure Relief Valve...205
High-pressure Oil Manifold (Brake)...206
Valve Cover Gasket (Harness) Assembly (Brake)...208
Engine Compression Brake Pressure (ECBP) Sensor...208
Engine Compression Brake (ECB) valve assembly...209
Table of Contents...211
Illustrations...213
Air Compressor...213
Power Steering Pump...214
Description...215
Air Compressor...215
Power Steering Pump...215
Removal...215
Power Steering Pump...216
Air Compressor...217
Cleaning and Inspection...218
Installation...219
Air Compressor...219
Power Steering Pump Without Air Compressor...220
Power Steering Pump With Air Compressor...220
Table of Contents...221
Exploded View and Description...223
Removal...224
Drain Coolant...224
Oil Cooler Module...226
Disassemble...227
Pressure Regulator Valve (Oil)...227
Thermal Valve (Oil)...227
Oil Cooler...228
Cleaning, Inspection, and Testing...229
Clean Oil Cooler Housing...229
Oil Cooler Pressure Test...231
Assemble...232
Oil Cooler...232
Thermal Valve (Oil)...233
Regulator Valve (Oil)...234
Installation...234
Oil Cooler Module...234
Oil Filter...236
Prime Lubrication System...236
Priming System...236
Cranking Method (Alternate)...237
Table of Contents...239
Exploded Views...241
Front Sump...241
Rear Sump...242
Removal...243
Drain Engine Oil...243
Oil Pan and Gasket...243
Suction Tube Assembly...244
Cleaning and Inspecting...245
Oil Pan and Suction Tube...245
Installation...246
Suction Tube Assembly...246
Oil Pan and Gasket...247
Fill Engine with Oil...248
Table of Contents...251
Exploded View...253
Removal...255
Dual Drive Belt...255
Single Drive Belt...256
Dual Idler Pulleys...257
Alternator Support...258
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate...259
Coolant Supply Housing (Refrigerant Compressor Mount)...260
Water Outlet Tube and Thermostat...260
Water Pump Assembly...261
Water Inlet Elbow...261
Fan Drive...262
Spin-on Fan Drive...262
Horton DriveMaster® Fan Drive...263
Vibration Damper, Hub, and Wear Sleeve...264
Vibration Damper—Single Drive Belt Engines...264
Vibration Damper—Dual Drive Belt Engines...264
Damper Hub...265
Oil Pump Assembly...266
Front Engine Mount...267
Front Cover (Front Half)...268
Idler Gears...269
Front Cover (Rear Half)...271
Cleaning, Inspection, and Measurement...272
Cleaning and Inspection...272
Measuring Gear Backlash...272
Lower Idler Gear Backlash...272
Upper Idler Gear Backlash...273
Camshaft Gear Backlash...273
Measuring Oil Pump Side Clearance...274
Measuring Oil Pump End Clearance...274
Installation...275
Front Cover (Rear Half)...275
Idler Gears...277
Front Cover (Front Half)...279
Front Engine Mount...281
Oil Pump Assembly...281
Vibration Damper, Hub, and Wear Sleeve...284
Damper Hub...284
Vibration Damper—Dual Drive Belt Engines...286
Vibration Damper—Single Drive Belt Engines...287
Fan Drive...287
Spin-on Fan Drive...287
Horton DriveMaster® Fan Drive...289
Water Outlet Tube and Thermostat...290
Water Pump Assembly...290
Water Inlet Elbow...291
Coolant Housing (Refrigerant Compressor Mount)...291
Alternator Support...293
Dual Idler Pulleys...294
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate...295
Single Drive Belt...297
Dual Drive Belt...298
Table of Contents...301
Illustrations and Description...303
Exploded View of Cylinder Head and Valve Train Components...303
Description...304
Periodic Service...305
Valve Lash Adjustment...305
Removal...309
Valve Cover...309
Rocker Arm Assembly...311
Rocker Arms...312
Cylinder Head...312
Roller Tappets and Guides...313
Cleaning, Inspection, Measurement, and Testing...314
Measuring Camshaft Lobe Lift...314
Cylinder Head Cleaning...314
Cleaning and Inspection of Roller Tappets and Guides...315
Cleaning and Inspection of Push Rods...315
Measuring Rocker Shaft...315
Inspection and Measurement of Rocker Arms...316
Measuring Cylinder Head Warpage...317
Measuring Cylinder Head Thickness...318
Measuring Valve Seat Leakage...318
Inspecting Cylinder Head for Cracks...318
Cylinder Head Pressure Test...319
Reconditioning...321
Removal of Valves from Cylinder Head...321
Inspection and Measurement of Valve Guides...321
Replacing Valve Guides...323
Inspecting and Measurement of Valve...324
Refacing Valves...325
Valve Face...325
Refacing Valve Stem Tip...326
Valve Face-to-Seat Contact Inspection...326
Resurfacing Valve Seats...327
Replacing Valve Seats...328
Removal...328
Installation...330
Valve Spring Inspection...331
Inspecting Valve Rotators and Retainers...333
Inspecting Valve Spring Retainer Keys...333
Replacing Fuel Injector Sleeves...334
Removal...334
Tool Removal...336
Cleaning...336
Installation...336
Installing Valves...338
Cleaning...338
Assembly...338
Installation...339
Roller Tappets and Guides...339
Cylinder Head...339
Torque Procedure for Torque-to-yield Head Bolts...341
Rocker Arms...343
Rocker Arm Assembly...344
Valve Cover...346
Table of Contents...351
Exploded View and Description...353
Flywheel housing SAE 1...354
Flywheel housing SAE 1A...354
Flywheel housing SAE 2...354
Flywheel housing (Bus) SAE 2...354
Flywheel and Flexplate Applications...354
Manual Transmissions...354
Automatic Transmissions...356
Removal...358
Flywheel Assembly...358
Flexplate (Automatic Transmissions)...359
Allison 2000 Series Transmissions...360
MD-3000 Series Transmissions...360
Crankshaft Timing Disk...361
Rear Oil Seal Assembly...362
Flywheel Housing...363
Cleaning, Inspection, and Measurement...365
Clean and Inspect...365
Measurement of Flywheel Housing Face Runout...365
Measurement of Flywheel Housing Bore Concentricity...366
Measurement of Crankshaft Pilot Concentricity...366
Measurement of Flywheel Surface Runout...367
Recondition...368
Resurface Flywheel...368
Replacement of Flywheel Ring Gear...368
Installation...369
Flywheel Housing and Rear Engine Mounting Brackets...369
Rear Oil Seal...371
Crankshaft Timing Disk...372
Flywheel Assembly...373
Flexplate (Automatic Transmissions)...374
Allison 2000 Series Transmissions...374
MD-3000 Series World Transmissions...375
Table of Contents...377
Exploded View and Description...379
Removal...380
Piston Cooling Tubes...380
Piston Protrusion Measurement – Preliminary Check...380
Piston and Connecting Rod Assembly...381
Piston Pin and Rings...383
Cylinder Sleeve...384
Cleaning, Inspecting, and Measuring...385
Cleaning and Inspecting...385
Measuring Pistons...386
Top Compression Ring Grooves...386
Intermediate and Oil Control Ring Groove...387
Piston-to-Cylinder Sleeve Running Clearance...387
Measuring Piston Rings...388
Measuring Piston Pins...388
Measuring and Inspecting Connecting Rods...389
Piston Pin Bushing...389
Connecting Rod Bolt Holes Inspection...389
Connecting Rod Bearing Bore (Big End)...390
Connecting Rod Bend and Twist...390
Bearing Fitting Procedures...391
Measuring Bearing Running Clearance...391
Measuring Connecting Rod Side Clearance...392
Measuring Cylinder Sleeves...393
Telescoping Gauge Method...393
Dial Bore Gauge Method...394
Feeler Gauge Method...394
Measuring Counterbore Depth...395
Cylinder Liner Height Gauge Method...395
Depth Micrometer Method...395
Measuring Cylinder Sleeve Protrusion...396
Reconditioning...398
Resurfacing Counterbore...398
Preparation...398
Mounting the Counterbore Reconditioning Tool...399
Tool Settings...400
Cutting Counterbore Ledge...401
Tool Care and Maintenance...402
Installation...403
Cylinder Sleeve...403
Piston Rings...404
Piston Pin...405
Piston and Connecting Rod Assembly...406
Torque-to-yield Procedure for Connecting Rods...408
Piston Cooling Tubes...409
Engine Run-in Procedure...410
Table of Contents...415
Exploded Views and Description...417
Centrifuge Oil Filter...417
Crankcase Breather Assembly with Turbine...418
Crankcase, Crankshaft, and Camshaft...419
Removal...421
Centrifuge Oil Filter...421
Crankcase Ventilation System...422
Oil Level Gauge Assembly...425
Coolant Heater Assembly (optional)...425
Crankcase Ladder Assembly...425
Camshaft Gear...426
Camshaft Assembly...427
Camshaft Bearings...428
Main Bearing Caps, Crankshaft, and Main Bearings...430
Oil Pump Spline Drive and Crankshaft Gear...431
Cleaning, Inspection, and Measurement...432
Camshaft Assembly...432
Centrifuge Oil Filter Cleaning and Inspection...432
Crankcase Breather Assembly...433
Crankcase, Cup Plugs, and Piston Cooling Tubes...433
Crankshaft and Main Bearings...434
Camshaft End Play Measurement...435
Camshaft Lobes and Journals Measurement...435
Crankshaft End Play Measurement...436
Installation...437
Camshaft Bearings...437
Camshaft Assembly...440
Camshaft Gear...440
Crankshaft Gear and Oil Pump Spline Drive...441
Upper Main Bearings and Crankshaft Assembly...442
Main Bearing Fit Procedure...444
Main Bearings and Caps...446
Torque Procedure for Torque-to-yield Main Bearing Cap Bolts...447
Crankcase Ladder Assembly...448
Coolant Heater Assembly (optional)...449
Oil Level Gauge Assembly...450
Crankcase Ventilation System...451
Centrifuge Oil Filter...453
Table of Contents...455
Abbreviations and Acronyms...457
Abbreviations and Acronyms...457
Table of Contents...463
Terminology...465
Terms...465
Table of Contents...475
Specifications...477
Fuel and High-Pressure Oil Systems...477
Engine Brake...477
Air Compressor and Power Steering Pump...477
Oil System Module Assembly...477
Oil Pan and Oil Suction Tube...477
Front Cover, Cooling System, and Related Components...478
Cylinder Head and Valve Train...480
Flywheel and Flywheel Housing...482
Power Cylinders...483
Crankcase, Crankshaft, and Camshaft...486
Table of Contents...491
General Torque...493
Bolt Identification...493
General Torque Guidelines...494
Standard Torque Charts...495
Using a Torque Wrench Extension...496
Special Torque...497
Mounting Engine on Engine Stand...497
Engine Electrical...497
Down Stream Injection (DSI) & Related Components...497
Dual Stage Turbocharger and Exhaust Brake...498
Exhaust Gas Recirculation (EGR) System...498
Intake, Inlet and Exhaust Manifolds...498
Fuel and High-pressure Oil Systems...499
Engine Brake...500
Air Compressor and Power Steering Pump...500
Oil System Module Assembly...501
Oil Pan and Oil Suction Tube...501
Front Cover, Cooling System, and Related Components...501
Cylinder Head and Valve Train...502
Flywheel and Flywheel Housing...502
Power Cylinders...502
Crankcase, Crankshaft, and Camshaft...502
Table of Contents...503
Tool Ordering Information...505
Special Tools...505
Mounting Engine on Engine Stand...505
Dual Stage Turbocharger and Exhaust Brake...505
Exhaust Gas Recirculation (EGR) System...505
Intake, Inlet and Exhaust Manifolds...506
Fuel and High-pressure Oil Systems...506
Engine Brake...506
Oil System Module Assembly...506
Oil Pan and Oil Suction Tube...506
Front Cover, Cooling System, and Related Components...507
Cylinder Head and Valve Train...507
Flywheel and Flywheel Housing...508
Power Cylinders...509
Crankcase, Crankshaft, and Camshaft...509
Photos of Essential Tools...510
tables...12
N9 and N10 Diesel Engines...12
Engine Component Locations...19
Component...19
Location...19
Valve Seat Insert Selection Chart...330
Piston Ring Gauge Pin Selection...386
Water Pump Pulley Diameters and Spin Ratios...478
Fan Drive Configurations Diameters and Ratios (DriveMaster®) — Dual Drive Belt...479
Valve Specifications...480
Valve Spring Specifications...481
Cylinder Head and Valve Train Specifications...481
Flywheel Housing...482
Crankshaft Pilot...483
Flywheel...483
Flywheel Resurfacing Specifications...483
Connecting Rod Specifications...483
Piston Specifications – N9 and N10...484
Piston Ring Specifications (in 116.573 mm diameter gage ring)...484
Piston Pin Specifications...484
Cylinder Sleeve Specifications...485
Crankcase Specifications ...486
Camshaft Specifications ...487
Camshaft Bearing Specifications...487
Crankshaft Specifications...488
Crankshaft Specifications (continued)...489
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs...495
International/Navistar N9, N10, N13 Diesel Engines Workshop Repair & Service Manual
