Codigo Fallas S60 Epa 07 10 Ingles PDF

EPA07/10 DETROIT DIESEL ELECTRONICS AND TROUBLESHOOTING MANUAL
ENGINE EXHAUST
Consider the following before servicing engines:
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.
TRADEMARK INFORMATION
DDC, Detroit Diesel, DDEC, Diagnostic Link, Optimized Idle, andPro-Link are
registered trademarks of Detroit Diesel Corporation. All other trademarks used are the property
of their respective owners.
ACM2/MCM/CPC WARNING
All information subject to change without notice.

DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION i
SOFTWARE UPGRADES
NOTE:
These engines are equipped with Daimler software. This software generally assures
optimal engine performance. The installation of software upgrades may cause minor
changes in features and engine performance.
ABSTRACT
This manual provides instruction for troubleshooting engines controlled by DDECVI & DDEC10.
Specifically covered in this manual are troubleshooting and repair steps that apply to the Detroit
Diesel Electronic Controls.
SAFETY INSTRUCTIONS
To reduce the chance of personal injury and/or property damage, the instructions contained in this
troubleshooting manual must be carefully observed. Proper service and repair are important to the
safety of the service technician and the safe, reliable operation of the engine.
If part replacement is necessary, the part must be replaced with one of the same part number or
with an equivalent part number. Do not use a replacement part of lesser quality. The service
procedures recommended and described in this manual are effective methods of performing
repair. Some of these procedures require the use of specially designed tools. Accordingly, anyone
who intends to use a replacement part, procedure or tool which is not recommended, must first
determine that neither personal safety nor the safe operation of the engine will be jeopardized by
the replacement part, procedure or tool selected.
It is important to note that this manual contains various Warnings, Cautions and Notices that
must be carefully observed in order to reduce the risk of personal injury during repair, or the
possibility that improper repair may damage the engine or render it unsafe. It is also important
to understand that these Warnings, Cautions and Notices are not exhaustive, because it is
impossible to warn personnel of the possible hazardous consequences that might result from
failure to follow these instructions.
A LETTER TO THE TECHNICIANS
Technicians today are required to have computer skills, excellent comprehension of the written
word and possess an extensive diagnostic understanding of the various technological systems and
components. Technicians today must perform at a higher level of efficiency and competency than
their predecessors and at the same time furnish professional quality support.
As the leader in engine computer systems and technology, Detroit Diesel Corporation remains
focused on providing excellence in products, service support and training. As products become
more and more advanced, technicians must become specialized in multiple areas. This manual
is designed with that thought in mind. The Detroit Diesel DD Series Engine Troubleshooting
Guide will provide you with concentrated information that will allow you to excel in electronics
controls technology.

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REVISION NOTIFICATION
Modifications to this manual are announced in the form of Service Information Bulletins.

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TABLE OF CONTENTS
1 INTRODUCTION
1.1 INTRODUCTION ...................................................................................... 1- 3
1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1- 4
1.3 SAFETY PRECAUTIONS ........................................................................ 1- 6
2 ELECTRICAL SYSTEM
2.1 ELECTRONIC ENGINE CONTROL ......................................................... 2- 3
2.2 MOTOR CONTROL MODULE (MCM) ..................................................... 2- 4
2.3 REMOVAL OF THE MOTOR CONTROL MODULE ................................ 2- 6
2.4 INSPECTION OF THE MOTOR CONTROL MODULE ............................ 2- 7
2.5 INSTALLATION OF THE MOTOR CONTROL MODULE ......................... 2- 8
2.6 MCM-MCM2 TO ENGINE HARNESS ...................................................... 2-10
2.7 MCM-MCM2 21PIN AND 31PIN CONNECTORS ................................ 2-14
2.8 COMMON POWERTRAIN CONTROLLER ............................................. 2-16
2.9 WIRES AND WIRING .............................................................................. 2-25
2.10 CONDUIT AND LOOM ............................................................................. 2-37
2.11 TAPE AND TAPING ................................................................................. 2-38
2.12 INSTRUMENT PANEL LAMPS ................................................................ 2-39
3 ENGINE SENSORS
3.1 OVERVIEW .............................................................................................. 3- 3
3.2 EPA07 TURBOCHARGER INLET AIR TEMPERATURE SENSOR ........ 3- 6
3.3 EPA07 CHARGE AIR COOLER OUTLET AIR TEMPERATURE
SENSOR .................................................................................................. 3- 8
3.4 INTAKE MANIFOLD AIR TEMPERATURE SENSOR .............................. 3- 9
3.5 INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR ................ 3-10
3.6 CRANKSHAFT POSITION SENSOR ...................................................... 3-12
3.7 CAMSHAFT POSITION SENSOR ........................................................... 3-13
3.8 FUEL RAIL PRESSURE SENSOR .......................................................... 3-16
3.9 SUPPLY FUEL TEMPERATURE SENSOR ............................................. 3-18
3.10 TURBOCHARGER SPEED SENSOR ..................................................... 3-19
3.11 TURBOCHARGER COMPRESSOR INLET TEMPERATURE SENSOR 3-21
3.12 WATER-IN-FUEL SENSOR ..................................................................... 3-23
3.13 DELTA P SENSOR ................................................................................... 3-25
3.14 OIL PRESSURE SENSOR ...................................................................... 3-27
3.15 ENGINE OIL TEMPERATURE SENSOR ................................................. 3-28
3.16 ENGINE COOLANT INLET TEMPERATURE SENSOR .......................... 3-29
3.17 ENGINE COOLANT OUTLET TEMPERATURE SENSOR ...................... 3-30
3.18 AMBIENT AIR TEMPERATURE SENSOR .............................................. 3-31
3.19 ENGINE COOLANT LEVEL SENSOR ..................................................... 3-33
3.20 VEHICLE SPEED SENSOR .................................................................... 3-36
3.21 MAGNETIC PICKUP ................................................................................ 3-38
3.22 SAE J1939 DATA LINK ............................................................................ 3-39

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3.23 VSS ANTI-TAMPER ................................................................................. 3-40

4 DIAGNOSTIC TESTS
4.1 LOW PRESSURE FUEL SYSTEM - LEAK TEST .................................... 4- 3
4.2 HIGH PRESSURE FUEL SYSTEM - LEAK TEST ................................... 4- 5
4.3 LOW PRESSURE FUEL SYSTEM - PRESSURE TEST ......................... 4- 8
4.4 AERATED FUEL TEST ............................................................................ 4-11
4.5 HIGH AMPLIFIER/NEEDLE RETURN FLOW TEST ............................... 4-13
4.6 FUEL SYSTEM LEAK DETECTION TEST .............................................. 4-18
4.7 FUEL INJECTION SYSTEM (FIS) LEAK DETECTION - RAIL
PRESSURE BLEED OFF ........................................................................ 4-23
4.8 PRESSURE LIMITING VALVE FLOW TEST ........................................... 4-28
4.9 IDLE SPEED BALANCE (ISB) TEST ....................................................... 4-29
4.10 FUEL FILTER PRESSURE TEST ............................................................ 4-33
4.11 DRAINING FUEL SYSTEM PRIOR TO REPAIRS ................................... 4-34
4.12 FUEL SYSTEM CHECKS ........................................................................ 4-35
4.13 CHECKING DIESEL EXHAUST FLUID QUALITY ................................... 4-37
4.14 RELATIVE CYLINDER COMPRESSION TEST ....................................... 4-39
4.15 MECHANICAL CYLINDER COMPRESSION TEST ................................ 4-41
4.16 CRANKCASE PRESSURE TEST ............................................................ 4-44
4.17 POWER VERIFICATION WITH CHASSIS DYNAMOMETER ................. 4-45
5 STARTING DIFFICULTY
5.1 ENGINE WILL ROTATE ........................................................................... 5- 3
5.2 ENGINE WILL ONLY START USING AN EXTERNAL PRIMING
SOURCE .................................................................................................. 5- 9
5.3 ENGINE WILL NOT ROTATE .................................................................. 5-11
6 EXCESSIVE OIL CONSUMPTION
6.1 CHECK FOR EXCESSIVE OIL CONSUMPTION .................................... 6- 3
7 ENGINE COOLANT TEMPERATURE
7.1 HIGH ENGINE COOLANT TEMPERATURE ........................................... 7- 3
7.2 LOW ENGINE COOLANT TEMPERATURE ............................................ 7- 5
8 EXCESSIVE EXHAUST SMOKE
8.1 EXCESSIVE BLACK OR GREY SMOKE ................................................ 8- 3
8.2 EXCESSIVE BLUE SMOKE .................................................................... 8- 5
8.3 EXCESSIVE WHITE SMOKE .................................................................. 8- 7
9 ROUGH RUNNING OR STALLING
9.1 CHECK FOR ROUGH RUNNING OR STALLING ................................... 9- 3
10 LOW WHEEL HORSEPOWER
10.1 CHECKING FOR LOW WHEEL HORSEPOWER ................................... 10- 3
10.2 ENGINE DIAGNOSTIC QUESTIONNAIRE ............................................. 10-10
10.3 BAROMETRIC PRESSURE VS ALTITUDE CHART ............................... 10-11
11 EXCESSIVE NOISE
11.1 DIFFERENT ENGINE NOISE .................................................................. 11- 3
11.2 BELT NOISE ............................................................................................ 11- 4

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12 POOR ENGINE BRAKE PERFORMANCE

12.1 CHECKING FOR POOR ENGINE BRAKE .............................................. 12- 3
13 SPN 51 (MCM2) (EPA10)
13.1 SPN 51/FMI 2 ........................................................................................... 13- 3
13.2 SPN 51/FMI 3 ........................................................................................... 13- 4
13.3 SPN 51/FMI 4 ........................................................................................... 13- 5
14 SPN 70 (CPC)
14.1 SPN 70/FMI 13 ......................................................................................... 14- 3
14.2 SPN 70/FMI 19 ......................................................................................... 14- 4
15 SPN 84
15.1 SPN 84/FMI 0 ........................................................................................... 15- 3
15.2 SPN 84/FMI 2 ........................................................................................... 15- 4
15.3 SPN 84/FMI 3 ........................................................................................... 15- 5
15.4 SPN 84/FMI 4 ........................................................................................... 15- 6
15.5 SPN 84/FMI 6 ........................................................................................... 15- 7
15.6 SPN 84/FMI 8 ........................................................................................... 15- 8
15.7 SPN 84/FMI 9 ........................................................................................... 15- 9
15.8 SPN 84/FMI 10 ......................................................................................... 15-10
15.9 SPN 84/FMI 11 ......................................................................................... 15-11
15.10 SPN 84/FMI 13 ......................................................................................... 15-12
15.11 SPN 84/FMI 14 ......................................................................................... 15-13
15.12 SPN 84/FMI 19 ......................................................................................... 15-14
15.13 SPN 84/FMI 21 ......................................................................................... 15-15
16 SPN 84 (MCM) (EPA10)
16.1 SPN 84/FMI 3 ........................................................................................... 16- 3
16.2 SPN 84/FMI 4 ........................................................................................... 16- 4
17 SPN 91 (CPC)
17.1 SPN 91/FMI 2 ........................................................................................... 17- 3
17.2 SPN 91/FMI 3 ........................................................................................... 17- 5
17.3 SPN 91/FMI 4 ........................................................................................... 17- 6
18 SPN 94 (MCM) (EPA07)
18.1 SPN 94/FMI 3 ........................................................................................... 18- 3
18.2 SPN 94/FMI 4 ........................................................................................... 18- 4
19 SPN 97
19.1 SPN 97/FMI 3 ........................................................................................... 19- 3
19.2 SPN 97/FMI 4 ........................................................................................... 19- 5
19.3 SPN 97/FMI 15 ......................................................................................... 19- 7
20 SPN 100
20.1 SPN 100/FMI 1 ......................................................................................... 20- 3
20.2 SPN 100/FMI 3 ......................................................................................... 20- 5
20.3 SPN 100/FMI 4 ......................................................................................... 20- 7
20.4 SPN 100/FMI 18 ....................................................................................... 20- 9

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21 SPN 103
21.1 SPN 103/FMI 0 ........................................................................................ 21- 3
21.2 SPN 103/FMI 1 ........................................................................................ 21- 4
21.3 SPN 103/FMI 4 ......................................................................................... 21- 5
22 SPN 108 (MCM)
22.1 SPN 108/FMI 3 ......................................................................................... 22- 3
22.2 SPN 108/FMI 4 ......................................................................................... 22- 4
22.3 SPN 108/FMI 13 ....................................................................................... 22- 5
23 SPN 110 (EPA10)
23.1 SPN 110/FMI 0 ......................................................................................... 23- 3
23.2 SPN 110/FMI 2 ......................................................................................... 23- 4
23.3 SPN 110/FMI 3 ......................................................................................... 23- 5
23.4 SPN 110/FMI 4 ......................................................................................... 23- 7
23.5 SPN 110/FMI 9 ......................................................................................... 23- 8
23.6 SPN 110/FMI 14 ....................................................................................... 23- 9
24 SPN 111 (CPC)
24.1 SPN 111/FMI 1 ......................................................................................... 24- 3
24.2 SPN 111/FMI 3 ......................................................................................... 24- 5
24.3 SPN 111/FMI 4 ......................................................................................... 24- 7
25 SPN 132
25.1 SPN 132/FMI 1 ......................................................................................... 25- 3
26 SPN 157
26.1 SPN 157/FMI 2 ......................................................................................... 26- 3
27 SPN 157 (MCM) (EPA10)
27.1 SPN 157/FMI 16 ....................................................................................... 27- 3
28 SPN 158
28.1 SPN 158/FMI 2 ......................................................................................... 28- 3
29 SPN 158 (EPA10)
29.1 SPN 158/FMI 7 ......................................................................................... 29- 3
30 SPN 164
30.1 SPN 164/FMI 0 ......................................................................................... 30- 3
30.2 SPN 164/FMI 1 ......................................................................................... 30- 5
30.3 SPN 164/FMI 2 ......................................................................................... 30- 6
30.4 SPN 164/FMI 3 ......................................................................................... 30- 8
30.5 SPN 164/FMI 4 ......................................................................................... 30-10
30.6 SPN 164/FMI 5 ......................................................................................... 30-12
30.7 SPN 164/FMI 7 ......................................................................................... 30-13
30.8 SPN 164/FMI 20 ....................................................................................... 30-14
30.9 SPN 164/FMI 21 ....................................................................................... 30-16
31 SPN 168 (EPA07)
31.1 SPN 168/FMI 0 ......................................................................................... 31- 3
31.2 SPN 168/FMI 1 ......................................................................................... 31- 4

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31.3 SPN 168/FMI 14 (CPC) ............................................................................ 31- 6

32 SPN 168 (EPA10)
32.1 SPN 168/FMI 1 ......................................................................................... 32- 3
33 SPN 171 (CPC) (EPA07)
33.1 SPN 171/FMI 3 ......................................................................................... 33- 3
33.2 SPN 171/FMI 4 ......................................................................................... 33- 4
33.3 SPN 171/FMI 9 ......................................................................................... 33- 5
33.4 SPN 171/FMI 14 ....................................................................................... 33- 6
34 SPN 171 (ACM2) (EPA10)
34.1 SPN 171/FMI 3 ......................................................................................... 34- 3
34.2 SPN 171/FMI 4 ......................................................................................... 34- 4
34.3 SPN 171/FMI 13 ....................................................................................... 34- 5
35 SPN 174
35.1 SPN 174/FMI 0 ......................................................................................... 35- 3
35.2 SPN 174/FMI 3 ......................................................................................... 35- 4
35.3 SPN 174/FMI 4 ......................................................................................... 35- 6
36 SPN 175
36.1 SPN 175/FMI 3 ......................................................................................... 36- 3
36.2 SPN 175/FMI 4 ......................................................................................... 36- 5
36.3 SPN 175/FMI 14 ....................................................................................... 36- 6
37 SPN 175 (MCM) (EPA10)
37.1 SPN 175/FMI 0 ......................................................................................... 37- 3
37.2 SPN 175/FMI 15 ....................................................................................... 37- 4
38 SPN 188 (MCM) (EPA10)
38.1 SPN 188/FMI 31 ....................................................................................... 38- 3
39 SPN 190 (EPA10)
39.1 SPN 190/FMI 2 ......................................................................................... 39- 3
39.2 SPN 190/FMI 9 ......................................................................................... 39- 4
40 SPN 191 (CPC)
40.1 SPN 191/FMI 9 ......................................................................................... 40- 3
40.2 SPN 191/FMI 13 ....................................................................................... 40- 4
40.3 SPN 191/FMI 19 ....................................................................................... 40- 5
41 SPN 247 (CPC)
41.1 SPN 247/FMI 0 ......................................................................................... 41- 3
41.2 SPN 247/FMI 1 ......................................................................................... 41- 4
41.3 SPN 247/FMI 9 ......................................................................................... 41- 5
42 SPN 411 (EPA07)
42.1 SPN 411/FMI 0 ......................................................................................... 42- 3
42.2 SPN 411/FMI 1 ......................................................................................... 42- 5
42.3 SPN 411/FMI 3 ......................................................................................... 42- 8
42.4 SPN 411/FMI 4 ......................................................................................... 42-11
42.5 SPN 411/FMI 13 ....................................................................................... 42-14

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43 SPN 411 (MCM2) (EPA10)

43.1 SPN 411/FMI 0 ......................................................................................... 43- 3
43.2 SPN 411/FMI 1 ......................................................................................... 43- 5
43.3 SPN 411/FMI 2 ......................................................................................... 43- 8
43.4 SPN 411/FMI 3 ......................................................................................... 43-11
43.5 SPN 411/FMI 4 ......................................................................................... 43-13
44 SPN 513 (ACM2) (EPA10)
44.1 SPN 513/FMI 9 ......................................................................................... 44- 3
45 SPN 523 (CPC)
45.1 SPN 523/FMI 19 ....................................................................................... 45- 3
45.2 SPN 523/FMI 13 ....................................................................................... 45- 4
46 SPN 524 (CPC)
46.1 SPN 524/FMI 9 ......................................................................................... 46- 3
47 SPN 527 (CPC)
47.1 SPN 527/FMI 9 ......................................................................................... 47- 3
48 SPN 558 (CPC)
48.1 SPN 558/FMI 1 ......................................................................................... 48- 3
48.2 SPN 558/FMI 3 ......................................................................................... 48- 4
48.3 SPN 558/FMI 4 ......................................................................................... 48- 5
49 SPN 596 (CPC)
49.1 SPN 596/FMI 13 ....................................................................................... 49- 3
49.2 SPN 596/FMI 19 ....................................................................................... 49- 4
50 SPN 597 (CPC)
50.1 SPN 597/FMI 13 ....................................................................................... 50- 3
50.2 SPN 597/FMI 19 ....................................................................................... 50- 4
51 SPN 599 (CPC)
51.1 SPN 599/FMI 4 ......................................................................................... 51- 3
52 SPN 600 (CPC)
52.1 SPN 600/FMI 13 ....................................................................................... 52- 3
52.2 SPN 600/FMI 19 ....................................................................................... 52- 4
53 SPN 602 (CPC)
53.1 SPN 602/FMI 13 ....................................................................................... 53- 3
53.2 SPN 602/FMI 19 ....................................................................................... 53- 4
54 SPN 609
54.1 SPN 609/FMI 12 ....................................................................................... 54- 3
54.2 SPN 609/FMI 14 ....................................................................................... 54- 4
55 SPN 615 (CPC)
55.1 SPN 615/FMI 3 ........................................................................................ 55- 3
55.2 SPN 615/FMI 4 ........................................................................................ 55- 4
55.3 SPN 615/FMI 5 ........................................................................................ 55- 5
55.4 SPN 615/FMI 9 ......................................................................................... 55- 6

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55.5 SPN 615/FMI 14 ....................................................................................... 55- 7

56 SPN 625 (EPA07)
56.1 SPN 625/FMI 2 ......................................................................................... 56- 3
56.2 SPN 625/FMI 4 ......................................................................................... 56- 5
56.3 SPN 625/FMI 9 ......................................................................................... 56- 7
57 SPN 625 (CPC) (EPA10)
57.1 SPN 625/FMI 9 ......................................................................................... 57- 3
58 SPN 628 (CPC)
58.1 SPN 628/FMI 13 (ALL FAULT DESCRIPTIONS) ..................................... 58- 3
58.2 SPN 628/FMI 14 ....................................................................................... 58- 4
59 SPN 629 (CPC)
59.1 SPN 629/FMI 2 ......................................................................................... 59- 3
59.2 SPN 629/FMI 12 ....................................................................................... 59- 4
60 SPN 630 (CPC)
60.1 SPN 630/FMI 14 ....................................................................................... 60- 3
61 SPN 636
61.1 SPN 636/FMI 1 ......................................................................................... 61- 3
61.2 SPN 636/FMI 2 ......................................................................................... 61- 5
61.3 SPN 636/FMI 3 ......................................................................................... 61- 6
61.4 SPN 636/FMI 4 ......................................................................................... 61- 8
61.5 SPN 636/FMI 8 ......................................................................................... 61-10
61.6 SPN 636/FMI 14 ....................................................................................... 61-11
62 SPN 639
62.1 SPN 639/FMI 14 ...................................................................................... 62- 3
63 SPN 647
63.1 SPN 647/FMI 3 ......................................................................................... 63- 3
63.2 SPN 647/FMI 4 ......................................................................................... 63- 4
63.3 SPN 647/FMI 5 ......................................................................................... 63- 5
64 SPN 651
64.1 SPN 651/FMI 14 ....................................................................................... 64- 3
65 SPN 651 (EPA10)
65.1 SPN 651/FMI 6 ......................................................................................... 65- 3
66 SPN 652
66.1 SPN 652/FMI 14 ....................................................................................... 66- 3
67 SPN 652 (EPA10)
67.1 SPN 652/FMI 6 ......................................................................................... 67- 3
68 SPN 653
68.1 SPN 653/FMI 14 ....................................................................................... 68- 3
69 SPN 653 (EPA10)
69.1 SPN 653/FMI 6 ......................................................................................... 69- 3

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70 SPN 654
70.1 SPN 654/FMI 14 ....................................................................................... 70- 3
71 SPN 654 (EPA10)
71.1 SPN 654/FMI 6 ......................................................................................... 71- 3
72 SPN 655
72.1 SPN 655/FMI 14 ....................................................................................... 72- 3
73 SPN 655 (EPA10)
73.1 SPN 655/FMI 6 ......................................................................................... 73- 3
74 SPN 656
74.1 SPN 656/FMI 14 ....................................................................................... 74- 3
75 SPN 656 (EPA10)
75.1 SPN 656/FMI 6 ......................................................................................... 75- 3
76 SPN 677
76.1 SPN 677/FMI 2 ......................................................................................... 76- 3
76.2 SPN 677/FMI 3 ......................................................................................... 76- 4
76.3 SPN 677/FMI 4 ......................................................................................... 76- 5
76.4 SPN 677/FMI 5 ......................................................................................... 76- 6
76.5 SPN 677/FMI 7 ......................................................................................... 76- 7
76.6 SPN 677/FMI 14 ....................................................................................... 76- 8
76.7 SPN 677/FMI 18 ....................................................................................... 76- 9
76.8 SPN 677/FMI 31 ....................................................................................... 76-10
77 SPN 679
77.1 SPN 679/FMI 7 ......................................................................................... 77- 3
78 SPN 698
78.1 SPN 698/FMI 5 ......................................................................................... 78- 3
79 SPN 704 (CPC)
79.1 SPN 704/FMI 3 ......................................................................................... 79- 3
79.2 SPN 704/FMI 4 ......................................................................................... 79- 4
80 SPN 705 (CPC)
80.1 SPN 705/FMI 3 ......................................................................................... 80- 3
80.2 SPN 705/FMI 4 ......................................................................................... 80- 4
81 SPN 709 (CPC)
81.1 SPN 709/FMI 3 ......................................................................................... 81- 3
81.2 SPN 709/FMI 4 ......................................................................................... 81- 4
82 SPN 710
82.1 SPN 710/FMI 3 ......................................................................................... 82- 3
82.2 SPN 710/FMI 4 ......................................................................................... 82- 4
83 SPN 711 (CPC)
83.1 SPN 711/FMI 3 ......................................................................................... 83- 3
83.2 SPN 711/FMI 4 ......................................................................................... 83- 4

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84 SPN 713 (CPC)

84.1 SPN 713/FMI 3 ......................................................................................... 84- 3
84.2 SPN 713/FMI 4 ......................................................................................... 84- 4
84.3 SPN 713/FMI 5 ......................................................................................... 84- 5
84.4 SPN 713/FMI 7 ......................................................................................... 84- 6
85 SPN 714 (CPC)
85.1 SPN 714/FMI 3 ......................................................................................... 85- 3
85.2 SPN 714/FMI 4 ......................................................................................... 85- 4
85.3 SPN 714/FMI 5 ......................................................................................... 85- 5
86 SPN 715 (CPC)
86.1 SPN 715/FMI 3 ......................................................................................... 86- 3
86.2 SPN 715/FMI 4 ......................................................................................... 86- 4
86.3 SPN 715/FMI 5 ......................................................................................... 86- 5
87 SPN 723
87.1 SPN 723/FMI 3 ......................................................................................... 87- 3
87.2 SPN 723/FMI 4 ......................................................................................... 87- 4
87.3 SPN 723/FMI 8 ......................................................................................... 87- 5
87.4 SPN 723/FMI 10 ....................................................................................... 87- 7
87.5 SPN 723/FMI 11 ....................................................................................... 87- 8
87.6 SPN 723/FMI 14 ....................................................................................... 87-10
87.7 SPN 723/FMI 31 ....................................................................................... 87-11
88 SPN 729
88.1 SPN 729/FMI 0 ......................................................................................... 88- 3
88.2 SPN 729/FMI 4 ......................................................................................... 88- 4
88.3 SPN 729/FMI 7 ......................................................................................... 88- 5
89 SPN 904 (CPC)
89.1 SPN 904/FMI 9 ......................................................................................... 89- 3
89.2 SPN 904/FMI 13 ....................................................................................... 89- 4
89.3 SPN 904/FMI 19 ....................................................................................... 89- 5
90 SPN 973 (CPC)
90.1 SPN 973/FMI 9 ......................................................................................... 90- 3
90.2 SPN 973/FMI 13 ....................................................................................... 90- 4
90.3 SPN 973/FMI 19 ....................................................................................... 90- 5
91 SPN 986 (CPC)
91.1 SPN 986/FMI 9 ......................................................................................... 91- 3
92 SPN 986 (CPC) (EPA10)
92.1 SPN 986/FMI 13 ....................................................................................... 92- 3
92.2 SPN 986/FMI 19 ....................................................................................... 92- 4
93 SPN 1037 (ACM2) (EPA10)
93.1 SPN 1037/FMI 0 ....................................................................................... 93- 3
93.2 SPN 1037/FMI 16 ..................................................................................... 93- 4

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94 SPN 1071
94.1 SPN 1071/FMI 3 ....................................................................................... 94- 3
94.2 SPN 1071/FMI 4 ....................................................................................... 94- 4
94.3 SPN 1071/FMI 5 ....................................................................................... 94- 5
95 SPN 1072
95.1 SPN 1072/FMI 3 ....................................................................................... 95- 3
95.2 SPN 1072/FMI 4 ....................................................................................... 95- 4
95.3 SPN 1072/FMI 5 ....................................................................................... 95- 6
96 SPN 1073
96.1 SPN 1073/FMI 3 ....................................................................................... 96- 3
96.2 SPN 1073/FMI 4 ....................................................................................... 96- 4
96.3 SPN 1073/FMI 5 ....................................................................................... 96- 6
97 SPN 1077
97.1 SPN 1077/FMI 5 ....................................................................................... 97- 3
97.2 SPN 1077/FMI 7 ....................................................................................... 97- 4
97.3 SPN 1077/FMI 14 ..................................................................................... 97- 6
97.4 SPN 1077/FMI 15 ..................................................................................... 97- 7
97.5 SPN 1077/FMI 31 ..................................................................................... 97- 8
98 SPN 1172
98.1 SPN 1172/FMI 2 ....................................................................................... 98- 3
98.2 SPN 1172/FMI 3 ....................................................................................... 98- 4
98.3 SPN 1172/FMI 4 ....................................................................................... 98- 5
99 SPN 1323
99.1 SPN 1323/31 ............................................................................................ 99- 3
100 SPN 1324
100.1 SPN 1324/FMI 31 ..................................................................................... 100- 3
101 SPN 1325
101.1 SPN 1325/FMI 31 ..................................................................................... 101- 3
102 SPN 1326
102.1 SPN 1326/31 ............................................................................................ 102- 3
103 SPN 1327
103.1 SPN 1327/31 ............................................................................................ 103- 3
104 SPN 1328
104.1 SPN 1328/31 ............................................................................................ 104- 3
105 SPN 1590 (CPC)
105.1 SPN 1590/FMI 9 ....................................................................................... 105- 3
106 SPN 1624 (CPC)
106.1 SPN 1624/FMI 9 ....................................................................................... 106- 3
106.2 SPN 1624/FMI 13 ..................................................................................... 106- 4
106.3 SPN 1624/FMI 19 ..................................................................................... 106- 5

xiv DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
107 SPN 1636

107.1 SPN 1636/FMI 2 ....................................................................................... 107- 3
107.2 SPN 1636/FMI 3 ....................................................................................... 107- 4
107.3 SPN 1636/FMI 4 ....................................................................................... 107- 6
107.4 SPN 1636/FMI 20 ..................................................................................... 107- 7
108 SPN 1636 (MCM) (EPA10)
108.1 SPN 1636/FMI 0 ....................................................................................... 108- 3
109 SPN 1659 (MCM) (EPA10)
109.1 SPN 1659/FMI 18 .................................................................................... 109- 3
110 SPN 1716 (CPC)
110.1 SPN 1716/FMI 9 ....................................................................................... 110- 3
111 SPN 1761 (ACM2) (EPA10)
111.1 SPN 1761/FMI 1 ....................................................................................... 111- 3
111.2 SPN 1761/FMI 3 ....................................................................................... 111- 4
111.3 SPN 1761/FMI 4 ....................................................................................... 111- 6
111.4 SPN 1761/FMI 17 ..................................................................................... 111- 7
111.5 SPN 1761/FMI 18 ..................................................................................... 111- 8
111.6 SPN 1761/FMI 31 ..................................................................................... 111- 9
112 SPN 1845 (CPC)
112.1 SPN 1845/FMI 9 ....................................................................................... 112- 3
113 SPN 2623 (CPC)
113.1 SPN 2623/FMI 4 ....................................................................................... 113- 3
113.2 SPN 2623/FMI 14 ..................................................................................... 113- 4
114 SPN 2630
114.1 SPN 2630/FMI 2 ....................................................................................... 114- 3
114.2 SPN 2630/FMI 3 ....................................................................................... 114- 4
114.3 SPN 2630/FMI 4 ...................................................................................... 114- 6
114.4 SPN 2630/FMI 20 .................................................................................... 114- 7
114.5 SPN 2630/FMI 16 ..................................................................................... 114- 8
114.6 SPN 2630/FMI 21 .................................................................................... 114- 9
115 SPN 2630 (EPA10)
115.1 SPN 2630/FMI 2 ....................................................................................... 115- 3
116 SPN 2631
116.1 SPN 2631/FMI 3 ....................................................................................... 116- 3
116.2 SPN 2631/FMI 4 ....................................................................................... 116- 4
117 SPN 2659
117.1 SPN 2659/FMI 0 ....................................................................................... 117- 3
117.2 SPN 2659/FMI 1 ....................................................................................... 117- 4
118 SPN 2659 (EPA10)
118.1 SPN 2659/FMI 18 ..................................................................................... 118- 3

DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION xv
119 SPN 2791

119.1 SPN 2791/FMI 3 ....................................................................................... 119- 3
119.2 SPN 2791/FMI 4 ....................................................................................... 119- 4
119.3 SPN 2791/FMI 5 ....................................................................................... 119- 5
119.4 SPN 2791/FMI 7 ....................................................................................... 119- 6
119.5 SPN 2791/FMI 8 ....................................................................................... 119-10
119.6 SPN 2791/FMI 9 ....................................................................................... 119-13
119.7 SPN 2791/FMI 11 ..................................................................................... 119-17
119.8 SPN 2791/FMI 14 ..................................................................................... 119-21
119.9 SPN 2791/FMI 15 ..................................................................................... 119-25
119.10SPN 2791/FMI 16 ..................................................................................... 119-26
119.11SPN 2791/FMI 31 ..................................................................................... 119-27
120 SPN 2791 (MCM) (EPA10)
120.1 SPN 2791/FMI 10 .................................................................................... 120- 3
121 SPN 2797
121.1 SPN 2797/FMI 3 ....................................................................................... 121- 3
121.2 SPN 2797/FMI 4 ....................................................................................... 121- 4
122 SPN 2798
122.1 SPN 2798/FMI 3 ....................................................................................... 122- 3
122.2 SPN 2798/FMI 4 ....................................................................................... 122- 4
123 SPN 2900 (CPC)
123.1 SPN 2900/FMI 9 ....................................................................................... 123- 3
124 SPN 3031 (ACM2) (EPA10)
124.1 SPN 3031/FMI 3 ....................................................................................... 124- 3
124.2 SPN 3031/FMI 4 ....................................................................................... 124- 4
125 SPN 3056 (ACM2) (EPA10)
125.1 SPN 3056/FMI 2 ....................................................................................... 125- 3
126 SPN 3057 (ACM2) (EPA10)
126.1 SPN 3057/FMI 2 ....................................................................................... 126- 3
127 SPN 3058
127.1 SPN 3058/FMI 13 ..................................................................................... 127- 3
128 SPN 3064
128.1 SPN 3064/FMI 13 ..................................................................................... 128- 3
129 SPN 3216 (ACM2) (EPA10)
129.1 SPN 3216/FMI 2 ....................................................................................... 129- 3
129.2 SPN 3216/FMI 3 ....................................................................................... 129- 4
129.3 SPN 3216/FMI 4 ....................................................................................... 129- 5
129.4 SPN 3216/FMI 13 ..................................................................................... 129- 6
129.5 SPN 3216/FMI 21 ..................................................................................... 129- 8
130 SPN 3226 (ACM2) (EPA10)
130.1 SPN 3226/FMI 2 ....................................................................................... 130- 3
130.2 SPN 3226/FMI 3 ....................................................................................... 130- 4

xvi DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
130.3 SPN 3226/FMI 4 ....................................................................................... 130- 5

130.4 SPN 3226/FMI 13 ..................................................................................... 130- 6
130.5 SPN 3226/FMI 21 ..................................................................................... 130- 9
131 SPN 3236 (ACM2) (EPA10)
131.1 SPN 3236/FMI 13 ..................................................................................... 131- 3
132 SPN 3242 (EPA07)
132.1 SPN 3242/FMI 2 ....................................................................................... 132- 3
132.2 SPN 3242/FMI 3 ....................................................................................... 132- 9
132.3 SPN 3242/FMI 4 ....................................................................................... 132-11
132.4 SPN 3242/FMI 8 ....................................................................................... 132-12
132.5 SPN 3242/FMI 10 ..................................................................................... 132-15
133 SPN 3242 (ACM2) (EPA10)
133.1 SPN 3242/FMI 3 ....................................................................................... 133- 3
133.2 SPN 3242/FMI 4 ....................................................................................... 133- 5
133.3 SPN 3242/FMI 8 ....................................................................................... 133- 6
133.4 SPN 3242/FMI 20 ..................................................................................... 133- 7
134 SPN 3246 (EPA07)
134.1 SPN 3246/FMI 0 ....................................................................................... 134- 3
134.2 SPN 3246/FMI 2 ....................................................................................... 134- 7
134.3 SPN 3246/FMI 3 ....................................................................................... 134-13
134.4 SPN 3246/FMI 4 ....................................................................................... 134-15
134.5 SPN 3246/FMI 10 ..................................................................................... 134-16
134.6 SPN 3246/FMI 14 ..................................................................................... 134-17
134.7 SPN 3246/FMI 16 ..................................................................................... 134-23
135 SPN 3246 (ACM2) (EPA10)
135.1 SPN 3246/FMI 3 ....................................................................................... 135- 3
135.2 SPN 3246/FMI 4 ....................................................................................... 135- 5
135.3 SPN 3246/FMI 8 ....................................................................................... 135- 6
135.4 SPN 3246/FMI 20 ..................................................................................... 135- 7
136 SPN 3250 (EPA07)
136.1 SPN 3250/FMI 0 ....................................................................................... 136- 3
136.2 SPN 3250/FMI 2 ....................................................................................... 136- 7
136.3 SPN 3250/FMI 3 ....................................................................................... 136-14
136.4 SPN 3250/FMI 4 ....................................................................................... 136-16
136.5 SPN 3250/FMI 8 ....................................................................................... 136-17
136.6 SPN 3250/FMI 10 ..................................................................................... 136-20
136.7 SPN 3250/FMI 14 ..................................................................................... 136-21
136.8 SPN 3250/FMI 31 ..................................................................................... 136-28
137 SPN 3250 (ACM2) (EPA10)
137.1 SPN 3250/FMI 3 ....................................................................................... 137- 3
137.2 SPN 3250/FMI 4 ....................................................................................... 137- 5
137.3 SPN 3250/FMI 8 ....................................................................................... 137- 6
137.4 SPN 3250/FMI 14 ..................................................................................... 137- 7

DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION xvii
138 SPN 3251 (EPA07)

138.1 SPN 3251/FMI 0 ....................................................................................... 138- 3
138.2 SPN 3251/FMI 1 ....................................................................................... 138- 5
138.3 SPN 3251/FMI 16 ..................................................................................... 138- 7
139 SPN 3251 (ACM2) (EPA10)
139.1 SPN 3251/FMI 0 ....................................................................................... 139- 3
139.2 SPN 3251/FMI 2 ....................................................................................... 139- 4
140 SPN 3361 (ACM2) (EPA10)
140.1 SPN 3361/FMI 0 ....................................................................................... 140- 3
140.2 SPN 3361/FMI 1 ....................................................................................... 140- 6
140.3 SPN 3361/FMI 3 ....................................................................................... 140- 7
140.4 SPN 3361/FMI 4 ....................................................................................... 140- 8
140.5 SPN 3361/FMI 5 ....................................................................................... 140- 9
141 SPN 3363 (ACM2) (EPA10)
141.1 SPN 3363/FMI 0 ....................................................................................... 141- 3
141.2 SPN 3363/FMI 1 ....................................................................................... 141- 4
141.3 SPN 3363/FMI 3 ....................................................................................... 141- 5
141.4 SPN 3363/FMI 4 ....................................................................................... 141- 6
141.5 SPN 3363/FMI 5 ....................................................................................... 141- 7
142 SPN 3464 (EPA07)
142.1 SPN 3464/FMI 14 ..................................................................................... 142- 3
143 SPN 3364 (ACM2) (EPA10)
143.1 SPN 3364/FMI 1 ....................................................................................... 143- 3
143.2 SPN 3364/FMI 2 ....................................................................................... 143- 6
143.3 SPN 3364/FMI 17 ..................................................................................... 143- 9
144 SPN 3471 (MCM) (EPA10)
144.1 SPN 3471/FMI 1 ....................................................................................... 144- 3
144.2 SPN 3471/FMI 3 ....................................................................................... 144- 4
144.3 SPN 3471/FMI 4 ....................................................................................... 144- 5
144.4 SPN 3471/FMI 5 ....................................................................................... 144- 6
145 SPN 3480 (MCM) (EPA10)
145.1 SPN 3480/FMI 1 ....................................................................................... 145- 3
145.2 SPN 3480/FMI 2 ....................................................................................... 145- 5
145.3 SPN 3480/FMI 14 ..................................................................................... 145- 7
145.4 SPN 3480/FMI 16 ..................................................................................... 145- 8
145.5 SPN 3480/FMI 31 ..................................................................................... 145- 9
146 SPN 3482 (MCM) (EPA10)
146.1 SPN 3482/FMI 3 ....................................................................................... 146- 3
146.2 SPN 3482/FMI 4 ....................................................................................... 146- 4
146.3 SPN 3482/FMI 5 ....................................................................................... 146- 5
146.4 SPN 3482/FMI 7 ....................................................................................... 146- 6
147 SPN 3509 (MCM) (EPA07)
147.1 SPN 3509/FMI 3 ....................................................................................... 147- 3

xviii DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
147.2 SPN 3509/FMI 4 ....................................................................................... 147- 4

148 SPN 3509 (ACM2) (EPA10)
148.1 SPN 3509/FMI 3 ...................................................................................... 148- 3
148.2 SPN 3509/FMI 4 ...................................................................................... 148- 4
149 SPN 3510 (EPA07)
149.1 SPN 3510/FMI 2 ....................................................................................... 149- 3
149.2 SPN 3510/FMI 3 ....................................................................................... 149- 5
149.3 SPN 3510/FMI 4 ....................................................................................... 149- 7
150 SPN 3510 (ACM2) (EPA10)
150.1 SPN 3510/FMI 3 ....................................................................................... 150- 3
150.2 SPN 3510/FMI 4 ....................................................................................... 150- 4
151 SPN 3511
151.1 SPN 3511/FMI 3 ....................................................................................... 151- 3
152 SPN 3511 (MCM) (EPA10)
152.1 SPN 3511/FMI 4 ....................................................................................... 152- 3
153 SPN 3512
153.1 SPN 3512/FMI 3 ....................................................................................... 153- 3
154 SPN 3512 (MCM) (EPA10)
154.1 SPN 3512/FMI 4 ....................................................................................... 154- 3
155 SPN 3536
155.1 SPN 3536/FMI 18 ..................................................................................... 155- 3
156 SPN 3556
156.1 SPN 3556/FMI 1 ....................................................................................... 156- 3
156.2 SPN 3556/FMI 18 ..................................................................................... 156- 5
157 SPN 3563
157.1 SPN 3563/FMI 20 ..................................................................................... 157- 3
158 SPN 3563 (MCM) (EPA10)
158.1 SPN 3563/FMI 3 ....................................................................................... 158- 3
158.2 SPN 3563/FMI 4 ....................................................................................... 158- 4
159 SPN 3597 (EPA07)
159.1 SPN 3597/FMI 4 ....................................................................................... 159- 3
160 SPN 3597 (EPA10)
160.1 SPN 3597/FMI 3 ....................................................................................... 160- 3
160.2 SPN 3597/FMI 4 ....................................................................................... 160- 4
161 SPN 3598
161.1 SPN 3598/FMI 4 ...................................................................................... 161- 3
162 SPN 3598 (MCM) (EPA10)
162.1 SPN 3598/FMI 3 ....................................................................................... 162- 3
163 SPN 3599 (MCM) (EPA10)
163.1 SPN 3599/FMI 3 ....................................................................................... 163- 3

DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION xix
163.2 SPN 3599/FMI 4 (MCM) (ACM) ............................................................... 163- 4

164 SPN 3603 (CPC)
164.1 SPN 3603/FMI 9 ....................................................................................... 164- 3
165 SPN 3609 (EPA07)
165.1 SPN 3609/FMI 2 ....................................................................................... 165- 3
165.2 SPN 3609/FMI 3 ....................................................................................... 165- 5
165.3 SPN 3609/FMI 4 ....................................................................................... 165- 7
165.4 SPN 3609/FMI 8 ....................................................................................... 165- 9
165.5 SPN 3609/FMI 10 ..................................................................................... 165-12
165.6 SPN 3609/FMI 20 ..................................................................................... 165-14
165.7 SPN 3609/FMI 21 ..................................................................................... 165-16
166 SPN 3609 (ACM2) (EPA10)
166.1 SPN 3609/FMI 3 ....................................................................................... 166- 3
166.2 SPN 3609/FMI 4 ....................................................................................... 166- 4
167 SPN 3610 (EPA07)
167.1 SPN 3610/FMI 2 ....................................................................................... 167- 3
167.2 SPN 3610/FMI 3 ....................................................................................... 167- 6
167.3 SPN 3610/FMI 4 ....................................................................................... 167- 8
167.4 SPN 3610/FMI 10 ..................................................................................... 167-10
167.5 SPN 3610/FMI 14 ..................................................................................... 167-11
167.6 SPN 3610/FMI 20 ..................................................................................... 167-13
168 SPN 3610 (ACM2) (EPA10)
168.1 SPN 3610/FMI 2 ....................................................................................... 168- 3
168.2 SPN 3610/FMI 3 ....................................................................................... 168- 4
168.3 SPN 3610/FMI 4 ....................................................................................... 168- 5
169 SPN 3659 (EPA07)
169.1 SPN 3659/FMI 14 ..................................................................................... 169- 3
170 SPN 3659 (EPA10)
170.1 SPN 3659/FMI 6 ....................................................................................... 170- 3
171 SPN 3660 (EPA07)
171.1 SPN 3660/FMI 14 ..................................................................................... 171- 3
172 SPN 3660 (EPA10)
172.1 SPN 3660/FMI 6 ....................................................................................... 172- 3
173 SPN 3661 (EPA07)
173.1 SPN 3661/FMI 14 ..................................................................................... 173- 3
174 SPN 3661 (EPA10)
174.1 SPN 3661/FMI 6 ....................................................................................... 174- 3
175 SPN 3662 (EPA07)
175.1 SPN 3662/FMI 14 ..................................................................................... 175- 3
176 SPN 3662 (EPA10)
176.1 SPN 3662/FMI 6 ....................................................................................... 176- 3

xx DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
177 SPN 3663 (EPA07)

177.1 SPN 3663/FMI 14 ..................................................................................... 177- 3
178 SPN 3663 (EPA10)
178.1 SPN 3663/FMI 6 ....................................................................................... 178- 3
179 SPN 3664 (EPA07)
179.1 SPN 3664/FMI 14 ..................................................................................... 179- 3
180 SPN 3664 (EPA10)
180.1 SPN 3664/FMI 6 ....................................................................................... 180- 3
181 SPN 3695 (CPC)
181.1 SPN 3695/FMI 9 ....................................................................................... 181- 3
181.2 SPN 3695/FMI 13 ..................................................................................... 181- 4
181.3 SPN 3695/FMI 14 ..................................................................................... 181- 5
181.4 SPN 3695/FMI 19 ..................................................................................... 181- 6
182 SPN 3711 (EPA07)
182.1 SPN 3711/FMI 31 ..................................................................................... 182- 3
183 SPN 3711 (ACM2) (EPA10)
183.1 SPN 3711/FMI 31 ..................................................................................... 183- 3
184 SPN 3713 (EPA07)
184.1 SPN 3713/FMI 31 ..................................................................................... 184- 3
185 SPN 3713 (ACM2) (EPA10)
185.1 SPN 3713/FMI 31 ..................................................................................... 185- 3
186 SPN 3716 (EPA07)
186.1 SPN 3716/FMI 31 ..................................................................................... 186- 3
187 SPN 3716 (MCM2) (EPA10)
187.1 SPN 3716/FMI 31 ..................................................................................... 187- 3
188 SPN 3719 (MCM-EPA07) (ACM2-EPA10)
188.1 SPN 3719/FMI 0 ....................................................................................... 188- 3
188.2 SPN 3719/FMI 15 ..................................................................................... 188- 4
188.3 SPN 3719/FMI 16 ..................................................................................... 188- 5
188.4 SPN 3719/FMI 31 ..................................................................................... 188- 6
189 SPN 3720
189.1 SPN 3720/FMI 15 ..................................................................................... 189- 3
189.2 SPN 3720/FMI 16 ..................................................................................... 189- 4
190 SPN 3936 (ACM2) (EPA10)
190.1 SPN 3936/FMI 18 ..................................................................................... 190- 3
191 SPN 4076
191.1 SPN 4076/FMI 3 ....................................................................................... 191- 3
191.2 SPN 4076/FMI 4 ....................................................................................... 191- 5
192 SPN 4077 (MCM-EPA07) (ACM2-EPA10)
192.1 SPN 4077/FMI 0 ....................................................................................... 192- 3

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192.2 SPN 4077/FMI 1 ....................................................................................... 192- 5

192.3 SPN 4077/FMI 3 ....................................................................................... 192- 7
192.4 SPN 4077/FMI 4 ....................................................................................... 192- 8
192.5 SPN 4077/FMI 14 ..................................................................................... 192- 9
193 SPN 4100
193.1 SPN 4100/FMI 13 ..................................................................................... 193- 3
194 SPN 4193 (MCM) (EPA10)
194.1 SPN 4193/FMI 2 ....................................................................................... 194- 3
194.2 SPN 4193/FMI 3 ....................................................................................... 194- 4
194.3 SPN 4193/FMI 4 ....................................................................................... 194- 6
194.4 SPN 4193/FMI 10 ..................................................................................... 194- 7
195 SPN 4258
195.1 SPN 4258/FMI 3 ....................................................................................... 195- 3
195.2 SPN 4258/FMI 4 ....................................................................................... 195- 5
196 SPN 4257 (EPA10)
196.1 SPN 4257/FMI 3 ....................................................................................... 196- 3
196.2 SPN 4257/FMI 4 ...................................................................................... 196- 5
197 SPN 4259
197.1 SPN 4259/FMI 3 ....................................................................................... 197- 3
197.2 SPN 4259/FMI 4 ....................................................................................... 197- 5
198 SPN 4334 (ACM2) (EPA10)
198.1 SPN 4334/FMI 2 ....................................................................................... 198- 3
198.2 SPN 4334/FMI 3 ....................................................................................... 198- 4
198.3 SPN 4334/FMI 4 ....................................................................................... 198- 5
198.4 SPN 4334/FMI 7 ....................................................................................... 198- 6
199 SPN 4335 (ACM2) (EPA10)
199.1 SPN 4335/FMI 1 ....................................................................................... 199- 3
199.2 SPN 4335/FMI 2 ....................................................................................... 199- 4
199.3 SPN 4335/FMI 3 ....................................................................................... 199- 5
199.4 SPN 4335/FMI 4 ....................................................................................... 199- 6
199.5 SPN 4335/FMI 7 ....................................................................................... 199- 7
199.6 SPN 4335/FMI 14 ..................................................................................... 199- 9
199.7 SPN 4335/FMI 31 .................................................................................... 199-10
200 SPN 4336 (ACM2) (EPA10)
200.1 SPN 4336/FMI 3 ....................................................................................... 200- 3
200.2 SPN 4336/FMI 4 ....................................................................................... 200- 4
200.3 SPN 4336/FMI 5 ....................................................................................... 200- 5
201 SPN 4337 (ACM2) (EPA10)
201.1 SPN 4337/FMI 2 ....................................................................................... 201- 3
201.2 SPN 4337/FMI 3 ....................................................................................... 201- 4
201.3 SPN 4337/FMI 4 ....................................................................................... 201- 6

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202 SPN 4353 (ACM2) (EPA10)

202.1 SPN 4353/FMI 3 ....................................................................................... 202- 3
202.2 SPN 4353/FMI 4 ....................................................................................... 202- 4
202.3 SPN 4353/FMI 5 ....................................................................................... 202- 5
203 SPN 4354 (ACM2) (EPA10)
203.1 SPN 4354/FMI 3 ....................................................................................... 203- 3
203.2 SPN 4354/FMI 4 ...................................................................................... 203- 4
203.3 SPN 4354/FMI 5 ....................................................................................... 203- 5
204 SPN 4355 (ACM2) (EPA10)
204.1 SPN 4355/FMI 3 ....................................................................................... 204- 3
204.2 SPN 4355/FMI 4 ....................................................................................... 204- 4
204.3 SPN 4355/FMI 5 ...................................................................................... 204- 5
205 SPN 4356 (ACM2) (EPA10)
205.1 SPN 4356/FMI 3 ....................................................................................... 205- 3
205.2 SPN 4356/FMI 4 ...................................................................................... 205- 4
205.3 SPN 4356/FMI 5 ....................................................................................... 205- 5
206 SPN 4358 (ACM2) (EPA10)
206.1 SPN 4358/FMI 3 ....................................................................................... 206- 3
206.2 SPN 4358/FMI 4 ....................................................................................... 206- 4
206.3 SPN 4358/FMI 5 ....................................................................................... 206- 5
207 SPN 4360 (ACM2) (EPA10)
207.1 SPN 4360/FMI 3 ....................................................................................... 207- 3
207.2 SPN 4360/FMI 4 ....................................................................................... 207- 5
207.3 SPN 4360/FMI 20 ..................................................................................... 207- 6
208 SPN 4363 (ACM2) (EPA10)
208.1 SPN 4363/FMI 0 ....................................................................................... 208- 3
208.2 SPN 4363/FMI 3 ....................................................................................... 208- 4
208.3 SPN 4363/FMI 4 ....................................................................................... 208- 6
208.4 SPN 4363/FMI 20 ..................................................................................... 208- 7
209 SPN 4364 (ACM2) (EPA10)
209.1 SPN 4364/FMI 1 ....................................................................................... 209- 3
209.2 SPN 4364/FMI 18 ..................................................................................... 209- 5
210 SPN 4375 (ACM2) (EPA10)
210.1 SPN 4375/FMI 3 ....................................................................................... 210- 3
210.2 SPN 4375/FMI 4 ....................................................................................... 210- 4
210.3 SPN 4375/FMI 5 ....................................................................................... 210- 5
210.4 SPN 4375/FMI 6 ....................................................................................... 210- 6
211 SPN 4752 (MCM)
211.1 SPN 4752/FMI 0 ....................................................................................... 211- 3
211.2 SPN 4752/FMI 31 ..................................................................................... 211- 4
212 SPN 5016 (EPA10)
212.1 SPN 5016/FMI 3 (ACM) ........................................................................... 212- 3

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212.2 SPN 5016/FMI 4 (ACM) ........................................................................... 212- 4

213 SPN 5298 (ACM) (EPA10)
213.1 SPN 5298/FMI 14 ..................................................................................... 213- 3
214 SPN 5397 ACM (EPA10)
214.1 SPN 5397/FMI 31 ..................................................................................... 214- 3
215 SPN 5444 (MCM)
215.1 SPN 5444/FMI 1 ....................................................................................... 215- 3
216 SPN 520231 (EPA10)
216.1 SPN 520231/FMI 13 ................................................................................. 216- 3
217 SPN 520232 (EPA10)
217.1 SPN 520232/FMI 9 ................................................................................... 217- 3
218 SPN 520249 (EPA10)
218.1 SPN 520249/FMI 4 ................................................................................... 218- 3
219 VERIFY REPAIRS
219.1 VERIFY REPAIRS .................................................................................... 219- 3

xxiv DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
1 INTRODUCTION
Section Page
1.1 INTRODUCTION ...................................................................................... 1- 3

1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1- 4
1.3 SAFETY PRECAUTIONS ........................................................................ 1- 6
1-2 DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION
1.1 INTRODUCTION
Detroit Diesel is the world leader in diesel engines and diesel engine electronics. Detroit Diesel
has made technological leaps in engine performance and fuel economy. Today, we build the most
dependable electronically controlled diesel engine in the industry.
2010 Electronic Controls, DDEC10, provides two industry standard serial data links: SAE
Standards J1587 and J1939. SAE Standard J1587 provides two way communications for the
diagnostic equipment and vehicle displays. SAE Standard J1939 provides control data to other
vehicle systems such as transmissions and traction control devices.
As the leader in engine computer systems and technology, Detroit Diesel remains focused on
providing excellence in products, service support and training. As products become more and
more advanced, todays technicians must become specialized in multiple areas. This manual is
designed with that thought in mind.
Our goal at Detroit Diesel is to be the most customer focused and most responsive engine
manufacturer in the world.

DDC-SVC-MAN-0084 Copyright 2010 DETROIT DIESEL CORPORATION 1-3
1.2 SCOPE AND USE OF THIS GUIDE
1.2 SCOPE AND USE OF THIS GUIDE
The first half of the manual contain mechanical troubleshooting procedures. The second half
contains instructions for troubleshooting the electronic controls.
This manual is divided into numbered chapters. Each chapter begins with a table of contents.
Pages and illustrations are numbered consecutively within each chapter.
Information can be located by using the table of contents at the front of the manual or the table
of contents at the beginning of each chapter.
Instructions to "Contact Detroit Diesel Customer Support Center" indicate that at the time of this
publication, all known troubleshooting checks have been included. Review any recent Service
Information Bulletins (SIB) or Service Information letters before calling.
It is also suggested that other Detroit Diesel outlets be contacted. E.g. if you are a dealer or
user, contact your closest DDC Distributor.
Ensure you have the engine serial number when you call. The phone number for the Detroit
Diesel Customer Support Center is 313-592-5800.
Instructions in this manual may suggest replacing a non Detroit Diesel component. It may be
required to contact the supplier of the component, e.g. truck manufacturer for a TPS concern,
to obtain approval to replace the component.
Important: Service Information Bulletins are issued via the Detroit Diesel website. Visit
http://www.ddcsn.com.
NOTE:
It is absolutely critical that you understand the EGR system to be qualified to offer any
type of proper diagnostics. Do not waste time trying to troubleshoot a DDC product, you
are not qualified to troubleshoot. Your company may incur wasted labor hours. If you are
qualified to perform a troubleshooting task and have spent more than one hour on that
task, STOP, and contact the Detroit Diesel Customer Support Center at (313) 5925800.
Once you have discussed your options with a customer support center person, you can
perform the required tests and evaluations. Please keep in contact with your customer
support person. Doing so allows you to stay on track.
1.2.1 Mechanical Troubleshooting
Each chapter has a fault as the title (i.e. Excessive White Smoke). The next level within the
chapter is the probable cause/symptom of the fault. Following this are the resolution and
verification of the resolution. The mechanical troubleshooting should be used before the
electronic troubleshooting.
1.2.2 Electronic Troubleshooting
The 2010 Electronic Controls system allows for an increased processor speed and increased
memory.

Instructions for repair in this manual are generic. For example, "Repair Open" is used to advise
the technician that a particular wire has been determined to be broken. In some cases it may
not be best to try and locate the open. It may be that the best repair technique is to replace a
complete harness. The technician should make the determination of the proper repair, with the
best interest of the customer in mind.
Instructions to check terminals and connectors should include checking for proper contact tension.
Using a mating terminal, a modest force should be required to remove a terminal from its mate.
Replace terminals with poor tension.
After completing any repair, always clear fault codes that may have been generated during the
troubleshooting process.
NOTE:
Be aware that troubleshooting in this manual is mostly concerned with DDEC related
codes. Codes associated with other components, e.g. transmissions, ECUs, ABS, etc.
can be found in the related publication.

1.3 SAFETY PRECAUTIONS
The following safety precautions must be observed when working on a Detroit Diesel engine:
PERSONAL INJURY
area.
PERSONAL INJURY
To avoid injury from accidental engine startup while
servicing the engine, disconnect/disable the starting
system.
All engine installations, especially those within enclosed spaces, should be equipped with an
exhaust discharge pipe so that exhaust gases are delivered into the outside air.
PERSONAL INJURY
To avoid injury from the sudden release of a high-pressure
hose connection, wear a face shield or goggles. Bleed the
air from the air starter system before disconnecting the air
supply hose.

1.3.1 Ether Start
The DDEC Ether Start System is a fully-automatic engine starting fluid system used to assist
a DDEC equipped diesel engine in cold starting conditions. The amount of ether is properly
controlled to optimize the starting process and prevent engine damage. DDEC will control ether
injection using standard sensors to control the ether injection hardware.
FIRE AND TOXICITY

Some pressurized fluid may be trapped in the system. To
avoid personal injury, loosen all connections slowly to
avoid contact with fluid. When required, spray fluid into a
proper container. The engine starting fluid used in DDEC
Ether Start Systems contains extremely flammable and
toxic substances.
FIRE AND TOXICITY

To avoid personal injury, spray the fluid from the bottom of
the valve into an appropriate container. The engine starting
fluid used in DDEC Ether Start Systems contains extremely
flammable and toxic substances.

1.3.2 Exhaust (Start/Run Engine)
Before starting and running an engine, adhere to the following safety precautions:
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
PERSONAL INJURY
area.
1.3.3 Glasses
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when
using tools such as hammers, chisels, pullers or punches.
EYE INJURY
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 276 kPa (40 psi) air pressure.

1.3.4 Welding
Wear welding goggles and gloves when welding or using an acetylene torch. Ensure that a metal
shield separates the acetylene and oxygen tanks. These must be securely chained to a cart.
PERSONAL INJURY
To avoid injury from arc welding, gas welding, or
cutting, wear required safety equipment such as an arc
welders face plate or gas welders goggles, welding
gloves, protective apron, long sleeve shirt, head
protection, and safety shoes. Always perform welding
or cutting operations in a well ventilated area. The gas
in oxygen/acetylene cylinders used in gas welding and
cutting is under high pressure. If a cylinder should fall
due to careless handling, the gage end could strike an
obstruction and fracture, resulting in a gas leak leading
to fire or an explosion. If a cylinder should fall resulting
in the gage end breaking off, the sudden release of
cylinder pressure will turn the cylinder into a dangerous
projectile. Observe the following precautions when using
oxygen/acetylene gas cylinders:
Always wear required safety shoes.
Do not handle tanks in a careless manner or with greasy
gloves or slippery hands.
Use a chain, bracket, or other restraining device at all
times to prevent gas cylinders from falling.
Do not place gas cylinders on their sides, but stand
them upright when in use.
Do not drop, drag, roll, or strike a cylinder forcefully.
Always close valves completely when finished welding
or cutting.

FIRE
To avoid injury from fire, check for fuel or oil leaks before
welding or carrying an open flame near the engine.

EXPLOSION / FIRE
To avoid injury from an explosion or fire when using
a welder, torch, or other spark generating device near
the engine, make certain no flammable materials or
combustible vapors are within a distance to allow
unwanted ignition. Volatile penetrating fluids or aerosol
cleaners used to assist in the removal of fasteners could
collect in the engine intake, exhaust, combustion chamber
or crankcase and create an explosive mixture. These
penetrating fluids should be used sparingly and only when
absolutely necessary. Excess fluid should be removed
from the engine before any work with a spark generating
device takes place. Operate the tool in accordance with the
manufacturers recommendations and heed their cautions.
Similarly, heed any cautions relating to the volatile fluids
sprayed on or near the engine.
EXPLOSION / FIRE
To avoid injury from an explosion or fire, check for fuel
leaks, oil leaks or ignitable vapors (such as penetrating
fluids or aerosol based cleaners) before welding or
working near the engine with an open flame or other spark
generating device.
1.3.5 Pressurized Fluids
Be extremely careful when dealing with fluids under pressure. Fluids under pressure can have
enough force to penetrate the skin. These fluids can infect a minor cut or opening in the skin. If
injured by escaping fluid, see a doctor at once. Serious infection or reaction can result without
immediate medical treatment.

PERSONAL INJURY
To avoid injury from the sudden release of a high-pressure
hose connection, wear a face shield or goggles.
PERSONAL INJURY
To avoid injury from penetrating fluids, do not put your
hands in front of fluid under pressure. Fluids under
pressure can penetrate skin and clothing.

1.3.6 Fuel
Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank
when refueling.
FIRE
To avoid injury from fire, keep all potential ignition sources
away from diesel fuel, including open flames, sparks, and
electrical resistance heating elements. Do not smoke when
refueling.
The following cautions should be followed when filling a fuel tank:
FIRE
To avoid injury from fire caused by heated diesel-fuel
vapors:
Keep those people who are not directly involved in
servicing away from the engine.
Stop the engine immediately if a fuel leak is detected.
Do not smoke or allow open flames when working on
an operating engine.
Wear adequate protective clothing (face shield,
insulated gloves and apron, etc.).
To prevent a buildup of potentially volatile vapors, keep
the engine area well ventilated during operation.

FIRE
To avoid injury from fire, contain and eliminate leaks of
flammable fluids as they occur. Failure to eliminate leaks
could result in fire.
1.3.7 Batteries
Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to
do so for some time after receiving a steady charge.
Battery Explosion and Acid Burn

To avoid injury from battery explosion or contact with
battery acid, work in a well ventilated area, wear protective
clothing, and avoid sparks or flames near the battery. If
you come in contact with battery acid:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water.
Get medical attention immediately.
Always disconnect the battery cable before working on the electrical system.
PERSONAL INJURY
To avoid injury from accidental engine startup while
servicing the engine, disconnect/disable the starting
system.

1.3.8 Fire
Keep a charged fire extinguisher within reach. Ensure you have the proper type of extinguisher on
hand.
FIRE
To avoid injury from fire, keep a fire extinguisher near the
grinding machine in case excessive heat should ignite the
oil.
1.3.9 Cleaning Agent
Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it
releases. Ensure the work area is adequately ventilated. Use protective gloves, goggles or face
shield, and apron.
PERSONAL INJURY
To avoid injury from harmful vapors or skin contact, do not
use carbon tetrachloride as a cleaning agent.
1.3.10 Diagnostic Equipment
For mobile applications, Detroit Diesel Diagnostic Link (DDDL) must be used by personnel other
than the vehicle operator. The vehicle operator must maintain control of the vehicle while an
assistant performs the diagnostic evaluations.
PERSONAL INJURY
To avoid injury from loss of vehicle/vessel control, the
operator of a DDEC equipped engine must not use or read
any diagnostic tool while the vehicle/vessel is moving.

1.3.11 Working on a Running Engine
When working on an engine that is running, accidental contact with the hot exhaust manifold
can cause severe burns. Remain alert to the location of the rotating fan, pulleys and belts.
Avoid making contact across the two terminals of a battery which can result in severe arcing,
or battery explosion.
PERSONAL INJURY
To avoid injury from rotating belts and fans, do not remove
and discard safety guards.
PERSONAL INJURY
To avoid injury when working near or on an operating
engine, remove loose items of clothing and jewelry. Tie
back or contain long hair that could be caught in any
moving part causing injury.

1.3.12 Optimized Idle
Optimized Idle must be turned on by the factory via order entry or mainframe setup.
UNEXPECTED ENGINE START

To avoid injury from an unexpected startup of an engine
equipped with the Optimized Idle system, remove the
starter relay from the relay holder.
PERSONAL INJURY
To avoid injury from accidental engine startup, replace a
defective ECM with an ECM programmed with identical
inputs and outputs.
1.3.13 Fluoroelastomer
Fluoroelastomer (Viton) parts such as O-rings and seals are perfectly safe to handle under
normal design conditions.
CHEMICAL BURNS
To avoid injury from chemical burns, wear a face
shield and neoprene or PVC gloves when handling
fluoroelastomer O-rings or seals that have been degraded
by excessive heat. Discard gloves after handling degraded
fluoroelastomer parts.
A potential hazard may occur if these components are raised to a temperature above 600F (316C)
(in a fire for example). Fluoroelastomer will decompose (indicated by charring or the appearance
of a black, sticky mass) and produce hydrofluoric acid. This acid is extremely corrosive and, if
touched by bare skin, may cause severe burns (the symptoms could be delayed for several hours).


2 ELECTRICAL SYSTEM
Section Page
2.1 ELECTRONIC ENGINE CONTROL ......................................................... 2- 3

2.2 MOTOR CONTROL MODULE (MCM) ..................................................... 2- 4
2.3 REMOVAL OF THE MOTOR CONTROL MODULE ................................ 2- 6
2.4 INSPECTION OF THE MOTOR CONTROL MODULE ............................ 2- 7
2.5 INSTALLATION OF THE MOTOR CONTROL MODULE ......................... 2- 8
2.6 MCM-MCM2 TO ENGINE HARNESS ...................................................... 2-10
2.7 MCM-MCM2 21PIN AND 31PIN CONNECTORS ................................ 2-14
2.8 COMMON POWERTRAIN CONTROLLER ............................................. 2-16
2.9 WIRES AND WIRING .............................................................................. 2-25
2.10 CONDUIT AND LOOM ............................................................................. 2-37
2.11 TAPE AND TAPING ................................................................................. 2-38
2.12 INSTRUMENT PANEL LAMPS ................................................................ 2-39
2.1 ELECTRONIC ENGINE CONTROL
The Detroit Diesel Electronic Control System (DDEC) controls fuel injection timing and output
by the Common Rail fuel injector on the engine. The system also monitors several engine
functions using electrical sensors which send electrical signals to the Motor Control Module
(MCM). The MCM then computes the incoming data and determines the correct fuel output and
timing for optimum power, fuel economy and emissions. The MCM also has the ability to display
warnings or shut down the engine completely (depending on option selection) in the case of
damaging engine conditions, such as low oil pressure, low coolant, or high oil temperature.
The DDEC system also has a cab-mounted control unit for vehicle engine management, the
Common Powertrain Controller (CPC). The connection to the vehicle is made via a CAN interface
which digitally transmits the nominal values (e.g. torque, engine speed specifications, etc.) and
the actual values (e.g. engine speed, oil pressure, etc.).
The Exhaust Gas Recirculation (EGR) engines will use the sixth generation of the DDEC system,
DDEC10 Motor Control Module (MCM).
The replacement of DDEC components is based on indicated diagnostic codes leading to faulty
components.
2.1.1 Harnesses
There are two major harness: the Engine Harness (EH) and the Vehicle Interface Harness (VIH).
The Engine Harness is installed at the factory and is delivered connected to all engine sensors, the
fuel injection system, and the MCM-MCM2.
The OEM supplied Vehicle Interface Harness connects the CPC-CPC2 to other vehicle systems.

2.2 MOTOR CONTROL MODULE (MCM)
2.2 MOTOR CONTROL MODULE (MCM)
The Motor Control Module (MCM-MCM2) is located on the left side of the cylinder block. The
Motor Control Module (MCM-MCM2) serves primarily as an interface between the electrical or
electronic components located on the engine side and the Common Powertrain Controller (CPC)
located on the vehicle side. Both control units are on a network together with the Controller Area
Network CAN. The MCM-MCM2 takes on a number of tasks; it controls and regulates processes
for systems such as engine control or the Exhaust Gas Recirculation (EGR) system, and also
monitors information for oil level in the engine. The MCM-MCM2 also has the ability to display
warnings or shut down the engine completely (depending on option selection) in the case of
damaging engine conditions, such as low oil pressure, low coolant, or high oil temperature.
1. 21pin Connector (OEM Responsibility) 2. 120pin Connector (Detroit Diesel Responsibility)
The following is a summary of the tasks the MCM-MCM2 monitors:

Exhaust gas recirculation (EGR)
Intake air preheating system
Turbocharger
Diesel particulate filter (DPF)
Instrument cluster
Engine brake
Amplified Pressure Common Rail System (APCRS)
Thermal management

DDEC10 provides an indication of engine and vehicle malfunctions. The MCM-MCM2

continually monitors the DDEC10 system.
Any faults that occur are stored as codes. These codes can be accessed in any of three ways:
1. A DDDL 7.X for DDEC10 can be used to read the codes.
2. A personal computer (PC) connected to the Motor Control Module (MCM-MCM2)
through a translator device using SAE J1939 Data Link+, are used as the communication
link, to Common Powertrain Controller (CPC) and CAN link to (MCM-MCM2).
3. The Amber Warning Lamp (AWL) (check engine) or the Red Stop Lamp (RSL) is
illuminated.
The AWL (check engine) (panel mounted yellow indicator light) illuminated diagnose
condition as soon as convenient, lights are CPC controlled.
The RSL (panel mounted red indicator light) and AWL (check engine) illuminated, a
major fault occurred and immediate attention required to avoid engine damage.
Automatic engine shutdown or rampdown is available as an option. A shutdown
override switch is required to allow the vehicle to be moved to a safe location during
automatic shutdown or rampdown.
The MCM-MCM2 tells the light when to activate.

2.3 REMOVAL OF THE MOTOR CONTROL MODULE
2.3 REMOVAL OF THE MOTOR CONTROL MODULE
Perform the following steps for Motor Control Module (MCM-MCM2) removal:
1. Release latch on harness connector to remove the 21 and 120-pin connectors from Motor
Control Module (MCM-MCM2).
2. Disconnect the vehicle battery power to prevent failure of the MCM-MCM2.
3. On a rear sump oil pan, disconnect the oil dipstick tube from the MCM-MCM2.
4. Remove two harness retaining bolts.
5. Remove the four bolts holding the MCM-MCM2 to the engine, remove the MCM-MCM2
from engine.

2.4 INSPECTION OF THE MOTOR CONTROL MODULE
Inspect the MCM-MCM2 as follows:

1. Inspect the MCM-MCM2 for damage and replace if required. Refer to section 2.3
2. Inspect the ISO mounts for damage and replace if required.

2.5 INSTALLATION OF THE MOTOR CONTROL MODULE
2.5 INSTALLATION OF THE MOTOR CONTROL MODULE
Perform the following steps for MCM-MCM2 installation:
NOTE:
If installing a new MCM-MCM2; after installation program to proper settings using the
programming station.
NOTE:
Do not ground the MCM-MCM2 housing. This can result in false codes being logged.
NOTICE:
Ensure the MCM-MCM2 metal housing does not come in contact
with the chassis.
1. Mount the MCM-MCM2 to the engine.
NOTICE:
Ensure MCM-MCM2 is not contaminated with diesel fuel.
2. Install the MCM-MCM2 to the engine with four bolts and isolators. Torque the
MCM-MCM2-to-engine bolts to 34 Nm (25 lbft).
NOTICE:
Ensure the connectors are not contaminated with diesel fuel.
3. Connect the 21 and 120-pin engine harness connectors to the MCM-MCM2 close and lock
latch on the connectors.
4. Install bracket onto fuel line; install bracket and line to MCM-MCM2 with two bolts.
5. Install the fuel line to the MCM-MCM2 and fuel filter module. Torque bolts to 55 Nm
(40.57 lbft).
6. Install the fuel line to the fuel filter module and MCM-MCM2. Torque bolts to 55 Nm
(40.57 lbft).
7. Reconnect vehicle battery power.
8. Turn the ignition to the "ON" position. Observe the DDDL 7.X for any diagnostic code(s).
If any code(s) are logged, refer to the DDEC10 Troubleshooting Guide, 6SE569.

ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area. Engine
exhaust is toxic.
9. Start the engine, and check for leaks.

2.6 MCM-MCM2 TO ENGINE HARNESS
The MCM-MCM2 has a 120pin connector Engine Harness which is factory installed. It also has
a 21pin connector which is the responsibility of the OEM. The pinouts for the 120pin connector
are listed in Table 2-1, Table 2-2, Table 2-3, and Table 2-4.
The pinout for the 21pin connector is listed in Table 2-5.
Pin Function Connector

1 Quality Control Valve
2 Quality Control Valve
3 NC
4 Spill Amplifier Control Valve (cyl 4) - pin 2
5 NC
7 Spill Amplifier Control Valve Common (cyl 4, 5, 6) - pin 1
9 NC
11 NC
13 Spill Amplifier Control Valve Common (cyl 1, 2, 3) pin 1
15 NC
16 Needle Control Valve (cyl 4) - pin 4
17 NC
19 Needle Control Valve Common (cyl 4,5,6) - pin 3
21 NC
23 NC
25 Needle Control Valve Common (cyl 1,2,3) - pin 3
26 Needle Control Valve (cyl 1) - pin4
27 NC
28 NC
29 DOC Outlet Temp sensor
30 DPF Outlet Pressure sensor
Table 2-1 MCM-MCM2 Connector DD15 Engine (1 of 4)


31 NC
32 Jake 1
33 Two-speed Fan or Variable Speed Fan
34 NC
35 NC
36 NC
37 NC
38 Ground
39 NC
40 NC
41 Grid heater
42 NC
43 CKP/TRS (+)
44 NC
45 CMP/SRS (+)
46 NC
47 Fan Speed
48 CMP/SRS (-)
49 NC
50 Sensor Ground
51 Turbo Speed sensor
52 Sensor Ground
53 NC
54 Sensor Ground
55 Sensor Ground
56 NC
57 Water-in-Fuel-sensor
58 Sensor Power Supply
59 HDMS Fan Thermal Switch
60 EGR Valve Position


61 EGR Valve
62 Power Supply
63 NC
64 Power Supply
65 Doser
66 Jake 2
67 Sensor Ground
68 NC
69 Fuel Cutoff Valve
70 Ground
71 Sensor Supply
72 NC
73 CKP (-)
74 CAN (-)
75 CAN (+)
76 NC
77 Supply Fuel Temperature sensor
78 Fuel Rail Pressure sensor
79 Grid heater
80 Engine coolant inlet temperature sensor
81 NC
82 Sensor Supply
83 NC
84 Fuel Compensation Pressure sensor
85 Sensor Supply
86 Turbo Compressor In Temp
87 Intake manifold pressure sensor
88 Sensor Ground
89 DOC Inlet Temp sensor
90 Intake Air Throttle Valve


91 Power Supply
92 Grid heater
93 Air Seal Pressure Regulator Valve
94 NC
95 Ground
96 NC
97 NC
98 Single-speed Fan or Two-speed Fan
99 NC
100 Intake Air Throttle (+)
101 Intake Air Throttle (-)
102 Sensor Ground
103 Sensor Ground
104 Sensor Ground
105 Engine Oil Pressure sensor
106 Intake Air Temperature sensor
107 NC
108 Engine Oil Temperature sensor
109 EGR Delta Pressure sensor
110 Coolant Outlet Temp sensor
111 Fuel Line Pressure sensor
112 Turbo Compressor Out Temp
113 NC
114 Sensor Ground
115 DPF Outlet Temp sensor
116 NC
117 Sensor Power Supply
118 DPF Inlet Pressure sensor
119 Intake manifold pressure sensor
120 NC

2.7 MCM-MCM2 21PIN AND 31PIN CONNECTORS
2.7 MCM-MCM2 21PIN AND 31PIN CONNECTORS
The wiring for the VIH 21pin to the MCM-MCM2 is listed in Table 2-5. The side of the
connector shown is looking into the pins.
Pin Signal Type Function Connector

21/1 CAN2L Not Used
21/2 CAN2GND Not Used
21/3 CAN2H Not Used
21/4 CAN2GND Not Used
21/5 KL31 Battery (-)
21/7 KL15 IGN
21/10 CAN1GND Engine CAN Shield
21/11 KL30 Battery (+)
21/13 CAN1H Engine CAN +
21/16 CAN1GND Not Used Front
Looking into the Pins on the Harness
21/17 BOOT Not Used
21/18 KDiag_S Not Used
21/19 CAN1L Engine CAN
21/20 KL50 Crank Start Input
21/21 START_B Crank Activation Output
Table 2-5 21Pin Connector to the MCM-MCM2
The pinout for the 31pin pigtail on the Engine Harness is listed in Table 2-6. The OEM is
responsible for wiring to this connector.
31pin 120pin Function DD15 Engine

31/1 Spare
31/2 Power Supply (IGN)* X
31/3 Fuel Heater Supply #1 X
31/4 Spare
31/5 Full Heater Supply #2 X
31/6 Spare

31pin 120pin Function DD15 Engine

31/7 Power Supply Ground* X
31/8 120/70 Ether Start
31/9 120/33 Fan Control #2 High of Two-speed Fan or Variable Speed Fan X
31/10 120/98 Single Speed Fan or Low for Two-speed Fan X
31/11 Fuel Heater Ground #1 X
31/12 Spare
31/13 Spare
31/14 120/71 Water-in-Fuel sensor Supply X
31/15 120/67 Water-in-Fuel sensor Ground X
31/16 120/96 Engine Brake Solenoid Control
DOC Outlet Temp sensor (Exhaust Gas Temperature
31/17 120/29 X
in Front of Particulate Trap)
31/18 120/89 DOC Inlet Temp sensor X
DPF Outlet Temp sensor ( Exhaust Gas Temperature
31/19 120/115 X
After Particulate Trap)
31/20 Full Heater Ground #2 X
31/21 Spare
31/22 120/91 Power Supply (Eng Brk, Fan, Ether) X
31/23 120/47 Fan Speed X
31/24 120/88 Sensor Ground X
31/25 HDMS Fan Thermal Switch X
31/26 120/57 Water-in-Fuel sensor X
31/27 120/86 TCI Temp X
31/28 120/114 Sensor Ground X
31/29 120/85 Sensor Supply X
DPF Outlet Pressure sensor (Exhaust Gas Pressure
31/30 120/30 X
After Particulate Filter)
DPF Inlet Pressure sensor (Exhaust Gas Pressure
31/31 120/118 X
Before Particulate Filter)
*Fused at 15 amps
Optional for MBE 900 and DD Platform Engine. Must use 14 AWG wire and fuse at 20A.
Table 2-6 31pin MCM-MCM2 Pigtail Connector

2.8 COMMON POWERTRAIN CONTROLLER
The Common Powertrain Controller (CPC-CPC2) has three 18pin connectors and one 21pin
connector. The following sections contain the connector pin-outs for truck, vocational, transit
bus and crane applications.
The CPC-CPC2 is the interface between the MCM-MCM2 and the vehicle/equipment for engine
control and manages other vehicle/equipment functions. See Figure .

The OEM is responsible for mounting this part in an enclosed, protected environment. The
mounting bracket is the responsibility of the OEM. There must be maximum physical separation
of the VIH from other vehicle/equipment electrical systems. Other electrical system wires should
ideally be at least three feet away from the VIH and should not be parallel to the VIH. This
will eliminate coupling electromagnetic energy from other systems into the VIH.See Figure for
the CPC-CPC2 dimensions.
NOTE:
The CPC-CPC2 should be mounted with the connectors pointing down.
The CPC-CPC2 communicates over the J1587 and J1939 Data Links to the vehicle.
Within the CPC-CPC2, sets of data for specific applications are stored. These include idle
speed, maximum running speed, and speed limitation. Customer programmable parameters
are also stored here.
The CPC-CPC2 receives data from the operator (accelerator pedal position, switches, various
sensors) and other electronic control units (for example, synchronization controllers for more than
one genset, air compressor controls).
From this data, instructions are computed for controlling the engine and transmitted to the
MCM-MCM2 via the proprietary data link.
2.8.1 Environmental Conditions
Temperature, vibration, and water intrusion must be considered.

2.8.1.1 Temperature
The ambient operating temperature range is 40F to 185F (-40C to 85C).
2.8.1.2 Water Intrusion
The CPC-CPC2 is not water tight and cannot be subject to water spray. It must be mounted in an
enclosed, protected environment.
2.8.2 CPC-CPC2 Vehicle Interface Harness
The OEM supplied Vehicle Interface Harness (VIH) connects the CPC-CPC2 to the MCM-MCM2
and other vehicle systems.
The following criteria are to be used when designing the VIH:
The four vehicle connectors are designed to accept 18 AWG wires for all circuits.
The conductor must be annealed copper, not aluminum, and must comply with the industry
standard SAE J1128 document.
Color code the wires as shown in the schematics. If the wires used are the same color,
hot stamp the cavity number on the wires.
NOTE:
The Vehicle Speed sensor (VSS) must be a twisted pair. The twists are a minimum of 12
turns per foot (305 mm) and are required to minimize electromagnetic field coupling.
NOTE:
J1939 cable is required for the J1939 datalink wires. Refer to SAE J193911 spec
for specific requirements.
The low speed propriety Engine-CAN link between the MCM-MCM2 and the CPC-CPC2 must
be a twisted shielded cable with 0.75 mm diameter wire (approximately 20 AWG), bundle
shielded with drain wire and 30 twists per meter. The insulation is rated to 105C. Termination
resistors for the Engine-CAN link are located in the CPC-CPC2 and MCM-MCM2.
2.8.2.1 Frequency Input
The CPC-CPC2 has one frequency input on the VIH that can accept a variable reluctance sensor.
A typical frequency input functions is the Vehicle Speed sensor (VSS). Requirements for a
variable reluctance signal interface are listed in Table 2-7.
Parameter Range
Input Amplitude Range V Peak to Peak
Input Frequency Range 0 to 10,000 Hz
Table 2-7 Variable Reluctance Signal Interface

2.8.3 Power Supply 12 Volt System
Normal operating voltage on a 12 V system for the CPC-CPC2 and MCM-MCM2 is 11-16 VDC.
NOTICE:
Operating the CPC-CPC2 or MCM-MCM2 over the voltage limits
of 16 volts will cause damage to the CPC-CPC2 or MCM-MCM2.
Operating the CPC-CPC2 and/or MCM-MCM2 between 8 and 11 volts may result in degraded
engine operation. (Transient operation in this range during engine starting is considered normal
for 12 volt systems.)
NOTICE:
Reversing polarity will cause damage to the CPC-CPC2 and/or
MCM-MCM2 if the Power Harness is not properly fused.
NOTE:
All output loads, ignition and CPC-CPC2 power must be powered from the same battery
voltage source.
2.8.3.1 Average Current Draw
The maximum average current draw is listed in Table 2-8. This information should be used
to size the alternator.
Maximum Average Current Draw

System (12 V Nominal Supply)
Crank Idle Full Load/Rated Speed
MCM-MCM2 Engine
1.0 A avg 21.0 A avg 25.0 A avg
Loads
CPC-CPC2 Vehicle
18.0 A peak 55.0 A peak 55.0 A peak
Loads*
* Vehicle loads are controlled by the OEMs who can best determine the total maximum current draw for their installation.
Table 2-8 Maximum Average Current Draw
The current draw for a CPC-CPC2 configuration is listed in Table 2-9.
Configuration Condition Current

Ignition Off <1 mA
CPC-CPC2
Ignition On and Engine Stopped 120 mA
Table 2-9 Current Draw for CPC-CPC2 Configuration

The current draw for a MCM-MCM2 is listed in Table 2-10.
Configuration Condition Current

Ignition Off <1 mA
MCM-MCM2
Ignition On and Engine Stopped 400 mA
Table 2-10 Current Draw for MCM-MCM2 Configuration
2.8.3.2 Battery Isolator
A battery isolator is not required. However, some applications require a battery that is dedicated
to the engine and completely isolated from the rest of the vehicle. Commercially available battery
isolators can be used.

2.8.3.3 Main Power Shutdown
The main power supply shutdown schematic shows the DDC approved method for main power
switch implementation. See Figure .
NOTE:
Switches must remain closed for 30 seconds after ignition is off for the MCM-MCM2 and
to write non-volatile data.
NOTE:
CPC-CPC2 It is recommended that both the positive (+) and negative (-) battery leads be
disconnected.
NOTE:
Disconnecting positive power is not sufficient to isolate the CPC-CPC2 for welding
purposes.

NOTICE:
When welding, the following must be done to avoid damage to
the electronic controls or the engine:
Both the positive (+) and negative (-) battery leads must be
disconnected before welding.
The welding ground wire must be in close proximity to
welding location - the engine must never be used as a
grounding point.
Welding on the engine or engine mounted components is
NEVER recommended.
NOTE:
The alternator should be connected directly to the battery for isolation purposes.
2.8.4 Fuses
A Battery (+) fuse and an ignition circuit fuse must be provided by the vehicle wiring harness.
Blade-type automotive fuses are normally utilized; however, manual or automatic reset circuit
breakers which meet the following requirements are also acceptable. The fuse voltage rating must
be compatible with the CPC-CPC2 MCM-MCM2's maximum operating voltage of 16 volts.
FIRE
To avoid injury from fire, additional loads should not be
placed on existing circuits. Additional loads may blow the
fuse (or trip the circuit breaker) and cause the circuit to
overheat and burn.
FIRE
To avoid injury from fire, do not replace an existing fuse
with a larger amperage fuse. The increased current
may overheat the wiring, causing the insulation and
surrounding materials to burn.
The ignition fuse current rating must be sized for the loads utilized in each application; however,
a rating of between 5 and 10 amps is usually sufficient.
The Battery (+) fuse current rating must satisfy two criteria:
Must not open during normal operation
Must open before the MCM-MCM2 or CPC-CPC2 is damaged during a reverse battery
condition

Bussmann ATC-30 and Delphi Packard Electric Systems MaxiFuse 30 amp rated fuses or
equivalent will satisfy these requirements. Acceptable blow times versus current and temperature
derating characteristics are listed in Table 2-11 and Table 2-12.
% of Rated Fuse Current Minimum Blow Time Maximum Blow Time

100% 100 hours -
135% 1 minutes 30 minute
200% 6 seconds 40 seconds
Table 2-11 Fuse Current and Blow Time
Temperature % of Rated Fuse Current

-40C 110% max
+25C 100%
+120C 80% min
Table 2-12 Fuse Temperature and Current
2.8.5 Connectors
There are three 18pin connectors and one 21pin connector to the CPC-CPC2. The OEM is
responsible for the four connectors at the CPC-CPC2, the 21pin connector at the MCM-MCM2,
the 31pin MCM-MCM2 pigtail connector and the 10pin DPF connector.
NOTE:
The CPC-CPC2 connectors are not water tight and cannot be subject to water spray.
2.8.5.1 Data Link Connector
The SAE J1708/J1587 nine-pin data link connector is required. DDC recommends that
the OEM-supplied Data Link Connector be conveniently positioned in a well protected
location facilitating subsequent Detroit Diesel Diagnostic Link 7.X (DDDL 7.X) usage (i.e.,
reprogramming, diagnostics, etc.).
NOTE:
REQUIRED: The J1939 data link must be wired to this connector.

The following illustration shows the wiring for the nine-pin connector (see see Figure ).
The SAE J1587/J1708 Data Link must be twisted pairs. The twists are a minimum of 12 turns per
foot (305 mm). The maximum length for the SAE J1587/J1708 Data Link is 130 ft. (40 m).

2.9 WIRES AND WIRING
Detroit Diesel Corporation recommends color coding and hot stamping wire numbers in
contrasting colors at intervals of four inches or less.
2.9.1 General Requirements
NOTE:
Avoid renumbering DDC circuits since all troubleshooting guides reference the circuit
numbers shown in the schematic. DDC suggests including a prefix or suffix with the
DDC circuit numbers when conflicts exist.
2.9.2 General Wire
All wires used in conjunction with Detroit Diesel Electronic Control (DDEC) must meet the
following criteria:
NOTICE:
DDC does not recommend using any type of terminal lubricant
or grease compounds. These products may cause dirt or other
harmful substances to be retained in the connector. DDC has
not tested these products and cannot stand behind their use.
NOTICE:
Insulation must be free of nicks.
2.9.2.1 Criteria for Wire
Tape, conduit, loom or a combination thereof must be used to protect the wires. Refer to sections
2.10 and 2.11.
All wires must be annealed copper wire (not aluminum).
All wires must comply with SAE J1128.
All wires must be insulated with cross-link polyethylene (XLPE) such as GXL, or any
self-extinguishing insulation having a minimum rating of -40C (-40F) to 125C (257F).

2.9.3 Crimp Tools
The part numbers for the crimp tools for working with the MCM-MCM2 and DDEC-VCU
connectors are listed in Table 2-13.
Description Part Number

Extraction Tool 7265031
Hand Crimp Tool 1694000
Crimp Dies for 0.5 mm 1.0 mm Terminals 7342620
Crimp Dies for 1.0 mm 2.5 mm Terminals 1699170
Table 2-13 Crimp Tools
2.9.4 Deutsch Terminal Installation And Removal
The method of terminal installation and removal varies. The following sections cover Deutsch
terminal installation and removal.
2.9.4.1 Deutsch Terminal Installation Guidelines
Deutsch connectors have cable seals molded into the connector. These connectors are push-to-seat
connectors with cylindrical terminals. The diagnostic connector terminals are gold plated for
clarity.
NOTICE:
Improper selection and use of crimp tools have varying adverse
effects on crimp geometry and effectiveness. Proper installation
of terminals require specialized tools. Do not attempt to use
alternative tools.
The crimp tool to use in Deutsch terminal installation is J34182 (Kent-Moore part number).
NOTICE:
Terminal crimps must be made with the Deutsch crimp tool
P/N: HDT-48-00 to assure gas tight connections.
NOTICE:
If a separate seal is required, be sure to install the seal onto the
wire before stripping the insulation.
Use the following instructions for installing Deutsch terminals:

1. Strip approximately .25 inch (6 mm) of insulation from the cable.

2. Remove the lock clip, raise the wire gage selector, and rotate the knob to the number
matching the gage wire that is being used.
3. Lower the selector and insert the lock clip.
4. Position the contact so that the crimp barrel is 1/32 of an inch above the four indenters.
See Figure . Crimp the cable.
5. Grasp the contact approximately one inch behind the contact crimp barrel. Hold the
connector with the rear grommet facing you. See Figure .

6. Push the contact into the grommet until a positive stop is felt. See Figure . A slight tug
will confirm that it is properly locked into place. See Figure .
2.9.4.2 Deutsch Terminal Removal
The appropriate size removal tool should be used when removing cables from connectors. The
proper removal tools are listed in Table 2-14.
Tool Kent-Moore Part Number

Removing (12 AWG) J 37451
Removing (16-18 AWG) J 34513-1
Table 2-14 Removal Tools for Deutsch Terminals
Remove Deutsch terminals as follows:

1. With the rear insert toward you, snap the appropriate size remover tool over the cable of
contact to be removed. See Figure .

2. Slide the tool along the cable into the insert cavity until it engages and resistance is felt.
Do not twist or insert tool at an angle. See Figure .
3. Pull contact cable assembly out of the connector. Keep reverse tension on the cable and
forward tension on the tool.
2.9.5 Splicing Guidelines
The following are guidelines which may be used for splices. The selection of crimpers and
splice connectors is optional. Select a high quality crimper equivalent to the Kent-Moore tool, J
38706, and commercially available splice clips.
The recommended technique for splicing and repairing circuits (other than power and ignition
circuits) is a clipped and soldered splice. Alternatively, any method that produces a high quality,
tight (mechanically and electronically sound) splice with durable insulation is considered to
be acceptable.
2.9.5.1 Clipped and Soldered Splicing Method
The tools required are listed in Table 2-15.
Tool Part Number

Heat Gun --
Sn 60 solder with rosin core flux --
Wire Stripper Kent-Moore J 35615 or equivalent
Splice Clips (commercially available) Wire size dependent
Heat Shrink Tubing Raychem HTAT or equivalent
Table 2-15 Recommended Splicing Tools
The criteria for splicing straight leads is:

No more than one strand in a 16 strand wire may be cut or missing.

Use Sn 60 solder with rosin core flux.
The exposed wire must be clean before the splice is soldered.
Soldering splice connectors is optional. To solder splice connectors:
1. Position the leads, so one overlaps the other. See Figure .
2. Secure the leads with a commercially available clip and hand tool. See Figure .
3. Use a suitable electronic soldering iron to heat the wires. Apply the solder to the heated
wire and clip (not to the soldering iron) allowing sufficient solder flow into the splice joint.

4. Pull on wire to assure crimping and soldering integrity. The criteria listed in Table 2-16
must be met.
Wire Gage Must Withstand Applied Load

14 AWG 45 lb (200 N)
16 AWG 27 lb (120 N)
18 AWG 20 lb (90 N)
Table 2-16 Applied Load Criteria for Terminals
5. Loop the lead back over the spliced joint and tape. See Figure .
2.9.5.2 Splicing and Repairing Straight Leads-Alternate Method 1
The tools required are listed in Table 2-17.
Tool Part Number

Heat Gun --
Terminal Crimper for Metri-Pack 280 (12 AWG) Kent-Moore J 38125-6
Terminal Crimper for Metri-Pack 280 (18 AWG) Kent-Moore J 39848
Terminal Crimper for Weather Pack Kent-Moore J 35606
Terminal Crimper for Deutsch Kent-Moore J 34182
Terminal Crimper for Metri-Pack 150 Kent-Moore J 35123
NOTE:

The recommended method to splice straight leads follows:

1. Locate broken wire.
2. Remove insulation as required; be sure exposed wire is clean and not corroded.
3. Insert one wire into the splice clip until it butts against the clip. Stop and crimp (see
Figure , A).
4. Insert the other wire into the splice clip until it butts against the clip stop (see Figure , B).
NOTICE:
Any terminal that is cracked or ruptured is unacceptable as
malfunctions may occur.
5. Visually inspect the splice clip for cracks, rupture, or other crimping damage. Remove and
replace damaged clips before proceeding.
6. Pull on wire to ensure the splice integrity. The criteria listed in Table 2-18 must be met.
Wire Gage Must Withstand Applied Load

14 AWG 45 lb (200 N)
16 AWG 27 lb (120 N)
18 AWG 20 lb (90 N)
Table 2-18 Applied Load Criteria for Terminals
7. Shrink the splice clip insulative casing with a heat gun to seal the splice.

NOTICE:
Splices may not be closer than 12 in. (.3 m) apart to avoid
degradation in circuit performance. Replace wire to avoid having
splices closer than 12 in. (.3 m) apart.
8. Loop the lead back over the spliced joint and tape.

2.9.5.3 Splicing and Repairing Straight Leads - Alternate Method 2
This method is not allowed or recommended for power or ignition circuits. The tools required are
listed in Table 2-19.
Tool Part Number

Heat Gun --
Terminal Crimper for Metri-Pack 280 (12 AWG) Kent-Moore J 38125-6
Terminal Crimper for Metri-Pack 280 (18 AWG) Kent-Moore J 39848
Terminal Crimper for Weather Pack Kent-Moore J 35606
Terminal Crimper for Deutsch Kent-Moore J 34182
Terminal Crimper for Metri-Pack 150 Kent-Moore J 35123
NOTE:
An acceptable option for splicing straight leads is:

1. Locate broken wire.
2. Remove insulation as required; be sure exposed wire is clean and not corroded.
3. Slide a sleeve of glue lined, shrink tubing (Raychem HTAT or equivalent) long enough to
cover the splice clip on the wire and overlap the wire insulation, about .25 in. (6 mm) on
both sides (see Figure , A).
4. Insert one wire into splice clip until it butts against the splice clip. Stop and crimp (see
Figure , B).
5. Insert the remaining wires into the splice clip one at a time until each butts against the
splice clip; stop and crimp (see Figure , B).
NOTICE:
Any terminal that is cracked or ruptured is unacceptable as
malfunctions may occur.
6. Visually inspect the terminal for cracks, rupture, or other crimping damage. Remove and
turbocharger compressor inlet temperature damaged terminal before proceeding.
7. Slide the shrink tubing over the crimped splice clip (see Figure , C).
8. Shrink tubing with a heat gun to seal the splice (see Figure , D).

NOTICE:
A minimum of two layers of heat shrink tubing must be applied
to splices that have more than one lead in or out.
9. Loop the lead back over the spliced joint and tape. See Figure .
2.9.5.4 Shrink Wrap
Shrink wrap is required when splicing non insulated connections. Raychem HTAT or any
equivalent heat shrink dual wall epoxy encapsulating adhesive polyolefin is required. Shrink wrap
must extend at least .25 in. (6 mm) over wire insulation past splice in both directions.
To heat shrink wrap a splice:

NOTICE:
The heat shrink wrap must overlap the wire insulation about
.25 in. (6 mm) on both sides of the splice.
1. Select the correct diameter to allow a tight wrap when heated.

2. Heat the shrink wrap with a heat gun; do not concentrate the heat in one location, but
apply the heat over the entire length of shrink wrap until the joint is complete.
3. Repeat step 2 to apply a second layer of protection (if required by splicing guidelines).
2.9.5.5 Staggering Wire Splices
Position spliced wires properly as follows:
NOTICE:
You must stagger positions to prevent a large bulge in the
harness and to prevent the wires from chafing against each
other.
1. Stagger the position of each splice (see Figure ) so there is at least a 2.5 in. (65 mm)
separation between splices.
NOTICE:
A minimum of two layers of heat shrink tubing extending .25 in.
(6 mm) past the splice must be used to complete the splice.
2. Heat shrink a minimum of two layers of heat shrink tubing.

3. Tape the spliced wires to each other. Refer to section2.10.

2.10 CONDUIT AND LOOM
Conduit must be used to protect the harness cable and cable splices.
NOTICE:
The conduit must not cover any connectors, switches, relays,
fuses, or sensors.
The following guidelines should be used when designing a harness:
NOTICE:
Wires should be sized and cut to near equal length prior to
installing conduit.
The distance between the back of the connector or other listed devices to the end of the
conduit should not exceed:
0.5 in. (12.7 mm) for a single connector/device
1.0 in. (25.4 mm) for a double connector/device
1.5 in. (38.1 mm) for multiple (three or more) connectors/devices
All cable breakouts and conduit ends must be secured in place with conduit outlet rings or
tape.
2.10.1 Criteria for Conduit and Loom
Due to the wide variety of operating conditions and environments, it is the responsibility of the
OEM to select a conduit that will survive the conditions of the specific applications. Flame
retardant convoluted polypropylene conduit or equivalent may be used for most installations.
Heat retardant nylon conduit or oil, water, acid, fire, and abrasion resistant non-metallic loom
conforming to SAE J562A* is also acceptable. The diameter of conduit should be selected based
on the number of wires being protected.
* If non-metallic loom is used, secure the ends with tightly wrapped nylon straps to prevent
unraveling.
Conduit should cover the wires without binding and without being excessively large.

2.11 TAPE AND TAPING
2.11 TAPE AND TAPING
Tape must be used when conduit is utilized. Be sure to follow the tape manufacturers' guidelines.
The harness manufacturer may use tape under the harness covering (conduit or loom) to facilitate
harness building. Tape must be tightly wrapped at all conduit interconnections with a minimum of
two layers (refer to section2.10). Be sure to firmly secure the start and finish ends of tape.
2.11.1 Tape Criteria
In applications where the temperature doesn't exceed 176F (80C), black vinyl electrical tape
that is flame retardant and weather resistant may be used.
NOTICE:
Black vinyl electrical tape should not be used in applications
where the temperature exceeds 176F (80C).
In applications where temperature exceeds 176F (80C), vinyl electrical tape should not be used.
For these applications, adhesive cloth backed, flame retardant polyethylene or fiber glass tape
(Delphi #PM-2203, Polikan #165 or equivalent) is recommended.
2.11.2 Taping Criteria
The tape must extend a minimum of 1 in. (25 mm) past the conduit.
The tape must be crossed over butted conduit ends.
The tape must be extended a minimum of 1 in. (25 mm) in each direction at all branches.

2.12 INSTRUMENT PANEL LAMPS
The instrument panel lamps are listed in Table 2-20.
Lamp Lamp Name Description Driver Action
Amber Warning Lamp Indicates a fault with the Truck can be driven to end
(AWL) engine controls. of shift. Call for service.
Indicates a major engine

fault that may result in Move the truck to the
engine damage nearest safe location and
Red Stop Lamp (RSL)
Engine derate and / or shutdown the engine. Call
shutdown sequence will be for service
initiated.
Solid yellow indicates a

manual regeneration is
required.
Truck may be driven to end
Blinking yellow and
of shift. Call for service.
DPF Regeneration Lamp derate or shutdown are
Blinking light indicates
possible if back pressure
attention required now.
exceeds limits. Blinking
yellow during stationary
regeneration
Lamp may be red or
yellow. Indicates exhaust
temperature is above a
preset limit. Illuminates
Truck may be driven. If
during regeneration
lamp remains illuminated
High Exhaust System process if speed below
for an extended period
Temperature Lamp (HEST) 5 m.p.h. and during
longer than 40 minutes call
stationary regeneration.
for service.
When rpm is elevated for
a parked regen, the lamp
will flash once every ten
seconds.
Yellow lamp Indicates a

failure of an Emission
Malfunction Indicator Control device. May Truck may be driven to end
Lamp (MIL) illuminate at the same time of the shift. Call for service
as the Amber Warning
Lamp
Table 2-20 Instrument Panel Lamps

2.12 INSTRUMENT PANEL LAMPS

3 ENGINE SENSORS
3.1 OVERVIEW
DDEC is designed to operate with several types of sensors as listed in Table 3-1.
Sensor Type Description

Used to monitor the crankshaft position, engine speed,
Variable Reluctance/Magnetic Pick-up
turbocharger speed, and vehicle speed.
Thermistor Used to monitor temperatures.
Variable Capacitance Used to monitor manifold, and oil gallery pressures.
Variable Resistance (Potentiometer) Used to sense throttle position.
Switch Used to signal coolant level.
Table 3-1 Sensor Types
The sensors integrated into the Engine Harness are factory-installed (refer to section
3.1.1). The sensors integrated into the Vehicle Interface Harness are installed by the OEM
(refer to section3.1.2).
3.1.1 Factory-installed sensors
The sensors integrated into the factory-installed Engine Harness are listed in Table 3-2.

3.1 OVERVIEW
Sensor Function
Camshaft Position sensor (camshaft
Indicates a specific cylinder in the firing order.
position sensor)
Crankshaft Position sensor Senses crankshaft position and engine speed for functions such
(CKP sensor) as fuel control strategy.
Sensor measures pressure between the Diesel Oxidation Catalyst
DPF Inlet Pressure sensor (DOC) and the Diesel Particulate Filter (DPF) in the aftertreatment
assembly located in the exhaust system of the vehicle.
Sensor measures pressure on the outlet of the after-treatment
DPF Outlet Pressure sensor device in the exhaust system of the vehicle. Located after the DPF
that is within the aftertreatment device.
Temperature measured at the outlet of the after-treatment system
DPF Outlet Temperature sensor that is installed within the exhaust system of the vehicle. It's
located after the DPF that is within the aftertreatment unit.
DOC Temperature In - Temperature measured at the inlet of
DOC Inlet Temperature the after-treatment device in the exhaust system of the vehicle.
Located before the DOC that is within the after-treatment device.
Temperature measured between the DOC and the DPF in the
DOC Outlet Temperature aftertreatment assembly located in the exhaust system of the
vehicle.
EGR Delta Pressure sensor
Senses EGR pressure for EGR control.
EGR Delta P sensor
Senses EGR exhaust temperature after EGR cooler. Used for
EGR Temperature sensor
EGR system diagnosis.
Engine Coolant Temperature sensor Senses coolant temperature for functions such as engine
(ECT sensor) protection, fan control and engine fueling.
Engine Oil Pressure sensor
Senses gallery oil pressure for functions such as engine protection.
(EOP sensor)
Engine Oil Temperature sensor Senses oil temperature for functions such as reducing variation
(EOT sensor) in fuel injection and fan control.
Fuel Line Pressure sensor Senses fuel line pressure
Fuel Compensation Pressure sensor Compensates fuel line pressure
Intake manifold pressure sensor Senses turbocharger boost for functions such as smoke control
(IMP sensor) and engine protection.
Intake manifold Temperature sensor
Senses boost temperature
(IMT sensor)
Supply Fuel Temperature sensor (supply
Senses fuel temperature for functions such as engine fueling.
fuel temperature sensor)
Turbocharger Compressor Temperature
Senses turbocharger out air temperature.
Out sensor
Turbocharger Speed sensor (TSS) Monitors turbocharger speed.
Detects water in the fuel filter that alerts the owner/driver that the
Water-in-Fuel sensor
fuel filter needs to be dried out.
Table 3-2 Function of Factory-installed sensors
3.1.2 OEM-installed sensors
All sensors must be of the proper type and continuously monitor vehicular and environmental
conditions, so the MCM-MCM2 can react to changing situations.

The OEM is responsible for installing the sensors listed in Table 3-3.
Sensor Function
Ambient Air Temperature sensor Senses ambient air temperature specifically for the Ambient
(AAT sensor) Air Temperature Override Disable feature or for OI.
Engine Coolant Level sensor
Senses coolant level for engine protection.
(ECL sensor)
Turbocharger Compressor In Senses the temperature of the turbocharger compressor
Temperature sensor inlet.
Senses vehicle speed for Cruise Control and Vehicle Speed
Vehicle Speed sensor (VSS)
Limiting.
* Available in some applications
Table 3-3 Function and Guidelines for OEM-installed sensors
NOTE:
The OEM harness must be securely fastened every six (6) inches. It is required that the
harness be fastened within six (6) inches of the sensor.

3.2 EPA07 TURBOCHARGER INLET AIR TEMPERATURE SENSOR
3.2 EPA07 TURBOCHARGER INLET AIR TEMPERATURE SENSOR
The Motor Control Module (MCM-MCM2) uses the signal from the turbocharger inlet air
temperature sensor to monitor inlet air temperature at the turbocharger for EPA07 DD Platform
engines.
1. Turbocharger Inlet Air 2. Gasket 3. Inlet Pipe

Temperature sensor
3.2.1 Removal of the EPA07 Turbocharger Inlet Air Temperature sensor
Remove as follows:
1. Release the sensor harness connector by pulling the gray tab to unlock the connector.
Remove harness connector from sensor.
2. Remove compressor elbow and charge air plumbing.
3. Using the appropriate tool, remove the turbocharger inlet Air Temperature sensor from
the inlet pipe.
3.2.2 Installation of the EPA07 Turbocharger Inlet Air Temperature

Sensor
Install as follows:

NOTICE:
When installing the Air Temperature sensor into the compressor
elbow, the elbow must first be removed from the engine and be
at ambient temperature. Failure to remove elbow to install the
sensor could result in an air leak at the temperature sensor.
1. Using the appropriate tool, install the turbocharger inlet Air Temperature sensor and new
gasket into the compressor elbow. Torque to 35 Nm (26 lbft).
2. Install compressor elbow and charge air compressor plumbing. Torque clamps to 6 Nm
(4 lbft).
3. Install harness connector onto the turbocharger inlet Air Temperature sensor and push the
gray tab to lock harness connector to sensor.

3.3 EPA07 CHARGE AIR COOLER OUTLET AIR TEMPERATURE SENSOR
3.3 EPA07 CHARGE AIR COOLER OUTLET AIR TEMPERATURE SENSOR
The removal and installation procedures are as follows:
3.3.1 Removal of the EPA07 Charge Air Cooler Outlet Air Temperature
Sensor
Remove as follows:
1. Remove electrical harness connector from the sensor.
2. Remove the charge air cooler outlet air temperature sensor from the throttle valve adaptor .
3.3.2 Installation of the EPA07 Charge Air Cooler Outlet Air Temperature
Sensor (EPA07)
Install as follows:
1. Install the charge air cooler outlet air temperature sensor. Torque to 35 Nm (26 lbft).
2. Install the electrical harness connection.

3.4 INTAKE MANIFOLD AIR TEMPERATURE SENSOR
The removal and installation procedures are as follows:
3.4.1 Removal of the Intake Manifold Air Temperature Sensor
Remove as follows:
1. Remove electrical harness connector from the sensor.
2. Remove the intake manifold air temperature sensor from the intake manifold.
3.4.2 Installation of the Intake Manifold Air Temperature Sensor
Install as follows:
1. Install the intake manifold air temperature sensor. Torque to 35 Nm (26 lbft).
2. Install the electrical harness connection.

3.5 INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR
3.5 INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR
The intake manifold pressure/temperature sensor is mounted to the top intake manifold on the
left side of the engine.
The motor control module (MCM-MCM2) determines the air pressure and air temperature of
the air entering the engine from a signal received from the intake manifold pressure/temperature
sensor .
1. Pin 1 = 0.5 v to 4.5v 3. NTC Output

2. Pin2 = =4.75v to 5.25v 4. Ground
3.5.1 Removal of the Intake Manifold Pressure/Temperature Sensor
Remove as follows:
1. Release harness connection from sensor by pulling the gray tab up to unlock and remove
harness connection from sensor.
2. Using the appropriate wrench on the hex end of the intake manifold pressure/temperature
sensor unscrew the sensor from the intake manifold.
3.5.2 Installation of the Intake Manifold Pressure/Temperature Sensor
Install as follows:
1. Lubricate the seal ring from the sensor with grease.
2. Install the intake manifold pressure/temperature sensor to the intake manifold with the
appropriate wrench on the hex end of the sensor.

3. Install the harness connection onto the sensor and push down on the gray tab to lock
the harness onto sensor.

3.6 CRANKSHAFT POSITION SENSOR
3.6 CRANKSHAFT POSITION SENSOR
The crankcase position sensor is mounted on the left side of the flywheel housing. The crankshaft
position sensor sends a signal to the Motor Control Module (MCM-MCM2) to determine
rotational speed and crankshaft position.
3.6.1 Removal of the Crankshaft Position Sensor
Remove as follows:
1. Pull back on the gray tab to release harness connector from sensor.
2. Remove harness connection from sensor.
3. Remove one bolt from sensor and remove sensor from flywheel housing.
3.6.2 Installation of the Crankshaft Position Sensor
Install as follows:
1. Lubricate the seal ring from the sensor with grease.
2. Install the crankshaft position sensor to the flywheel housing with one bolt and tighten.
3. Install harness connection to sensor and push up on the gray tab to lock harness connector
to sensor.
4. Turn the engine to the ON position. Observe DDDL for any diagnostic code(s).

3.7 CAMSHAFT POSITION SENSOR
The Camshaft Position sensor (CMP) (2) is mounted through the camshaft housing near cylinder
number six. The sensor is fixed to the camshaft housing with a bolt (1).
The CMP is an active Hall sensor that consists of a permanent magnet and an electronic analysis
system. Hall sensors create a signal that is the same strength at all engine speeds. The magnet in
the sensor generates a magnetic field. When a groove in the rotating camshaft tone wheel nears
the sensor, a fluctuation occurs in the magnetic field. This fluctuation is converted by the CMP
electronics into a square-wave signal that is sent to the MCM-MCM2. The MCM-MCM2 uses
this signal to determine engine speed, crankshaft position, and therefore, the compression cycle of
cylinder number one. If the CMP fails, the engine reverts to limp-home mode.

3.7 CAMSHAFT POSITION SENSOR
The camshaft position sensor sends a signal to the Motor Control Module (MCM-MCM2) which
senses engine rotation and the compression cycle of cylinder number one, engine speed or
crankshaft position can then be determined. (If the crankshaft position sensor fails the engine
reverts to limp home mode)
3.7.1 Removal of the Camshaft Position Sensor
Remove as follows:
1. Remove harness connector from camshaft position sensor by pulling up the gray tab on
the connector to unlock and remove harness connection.
2. Remove the bolt retaining the sensor to the camshaft frame.
3. Remove camshaft position sensor from camshaft frame.
3.7.2 Installation of the Camshaft Position Sensor
Install as follows:
1. Lubricate the seal ring on the sensor with clean engine oil.
2. Install camshaft position sensor into camshaft frame.

NOTICE:
The camshaft position sensor is held into the cam frame by an
M 6X16; 8.8 bolt. Use of any longer bolt will force the end of
the bolt into the cup plug that is used to seal the hole from the
oil return passage. The correct length bolt MUST be used or
damage could occur to the cam tone wheel, cam frame, and gear
train.
3. Install the bolt to the sensor and camshaft frame and torque 10 Nm (7 lbft).
4. Install harness connector to the camshaft position sensor and push gray tab down to lock
connector to sensor.
3.7.3 Intake Camshaft Tone Wheel Run-out Measurement
Measure the tone wheel run-out as follows:

1. Remove the rocker cover. Refer to section .
2. Mount a dial indicator to a suitable location on the engine, ensuring that the dial indicator
does not move, and is secure.
3. Locate the tip on the dial indicator against the inner face of the tone wheel and zero out
the dial indicator. Ensure that the dial indicator tip does not fall into any intake camshaft
tone wheel slots.
4. Using the Engine Barring Tool (J-46392), bar the engine over and watch the movement
of the dial indicator.
5. The dial indicator should not move more than 0.008 in

3.8 FUEL RAIL PRESSURE SENSOR
3.8 FUEL RAIL PRESSURE SENSOR
The fuel rail pressure sensor (1) uses a sensor element and a hybrid element. As pressure increases
the sensor membrane will distort. There are four pressure-dependent resistances (strain measuring
resistors) on the sensor membrane. Its bridge circuit is supplied with voltage by an electronic
analysis system which also serves for signal amplification and signal correction. The electronic
analysis system itself is supplied a 5 V DC voltage by the MCM-MCM2. The resistors in the
sensor membrane are arranged in a way that when deforming the sensor membrane two resistors
will contract and two resistors will expand. Contracting and expanding changes the electrical
resistance and in turn has effects upon the measurement voltage, which is being applied to the
electronic analysis system. The electronic analysis system amplifies the measurement voltage,
compensating for possible temperature fluctuations or balancing out possible manufacturing
tolerances and passes the cleaned measurement voltage to MCM-MCM2.
1. Fuel rail pressure sensor 3. Fuel injector

2. Fuel Rail 4. Pressure Limiting Valve

3.8.1 Removal of the Fuel Rail Pressure sensor
Remove as follows:
PERSONAL INJURY
To prevent the escape of high pressure fuel that can
penetrate skin, ensure the engine has been shut down for
a minimum of 10 minutes before servicing any component
within the high pressure circuit. Residual high fuel
pressure may be present within the circuit.
1. Remove connector.
2. Remove the fuel rail pressure sensor using the appropriate wrench on the hex end of the
sensor and unscrew the sensor from the fuel rail.
3.8.2 Installation of the Fuel Rail sensor
Install as follows:
1. Install the fuel rail pressure sensor using the appropriate wrench on the hex end of the
sensor and screw the sensor to the fuel rail. Torque sensor to 65-70 Nm (48-52 lbft).
2. Install connector.

3.9 SUPPLY FUEL TEMPERATURE SENSOR
3.9 SUPPLY FUEL TEMPERATURE SENSOR
The supply fuel temperature sensor is located on the left side of the crankcase on the fuel filter
module (1). The Motor Control Module (MCM-MCM2) detects the current temperature of the
fuel via the supply fuel temperature sensor. There is an NTC resistor inside the supply fuel
temperature sensor. NTC stands for "Negative Temperature Coefficient" and means that the
electrical resistance falls as the temperature increases. The supply fuel temperature sensor is a
passive sensor (i.e., it is not supplied with voltage).

3.10 TURBOCHARGER SPEED SENSOR
The turbocharger speed sensor is mounted in the center housing of the of the turbocharger. The
motor control module (MCM-MCM2) receives a signal from the turbocharger speed sensor to
monitor turbocharger speed and prevent overspeed conditions.
NOTE:
The turbocharger speed sensor is only used on certain DD15 engine models; check the
engine to see if your engine requires the turbocharger speed sensor.
3.10.1 Removal of the Turbocharger Speed Sensor
Remove as follows:
NOTE:
If the turbocharger speed sensor is difficult to access, removal of the turbocharger may
be necessary.
1. Clean the center housing area around the base of the turbocharger speed sensor.
2. Disconnect the sensor wire from the main harness.
NOTICE:
Ensure the turbocharger shaft is secured and not rotated when
the turbocharger speed sensor is removed from the bearing
spacer. Turning the shaft without the sensor in place can rotate
the bearing spacer. If the sensor is not properly positioned in
the opening of the bearing spacer, the sensor and turbocharger
bearings will be damaged during sensor installation.
3.10.2 Installation of the Turbocharger Speed Sensor
Install as follows.
NOTE:
Ensure O-ring is located in sensor to prevent oil leaks.
1. Inspect the hole for the turbocharger speed sensor and ensure the hole in the bearing
spacer is aligned and the rotor shaft is visible.
2. Manually insert the turbocharger speed sensor into the hole of the center housing wall.
Push the sensor until the sealing lip on the underside of the sensor seats against the flat on
the center housing and the sensor is finger tight.
3. Turn the turbocharger rotor to ensure it spins freely with minimal resistance. If binding
occurs, repeat speed sensor installation.

3.10 TURBOCHARGER SPEED SENSOR
NOTICE:
Ensure the turbocharger rotor turns freely. If the shaft binds, the
speed sensor is not aligned with the bearing spacer and damage
can occur to the shaft and speed sensor.
4. Tighten the turbocharger speed sensor.

5. Turn the turbocharger rotor to ensure it spins freely. If binding occurs it is not aligned
properly. Refer to step 3.

3.11 TURBOCHARGER COMPRESSOR INLET TEMPERATURE SENSOR
The turbocharger compressor inlet temperature sensor produces a signal representing the inlet air
temperature. See Figure and Figure .

3.11 TURBOCHARGER COMPRESSOR INLET TEMPERATURE SENSOR
Label 31pin Connector Cavity (1) Turbocharger Compressor In

Temp Connector (2) Cavity*
Turbocharger Compressor In Temp 27/31 (120/86) 2
Sensor Return 24/31 (120/88) 1
Turbocharger Compressor In Temp Connector sensor (3), 3/818 NPT Short Thread (4)
* Wire length determined by OEM installation

3.12 WATER-IN-FUEL SENSOR
The Water-in-Fuel sensor determines the electrical resistance between the two sensor electrodes.
If the water level increases in the water separator up to the sensor electrodes the electrical
resistance drops. This change of resistance is detected by the MCM-MCM2. If the critical water
level is reached, an indicator light on the sensor will illuminate. In order to avoid electrolysis
(corrosion of the electrodes), AC voltage is used.
1. Water-in-Fuel sensor 2. Sensor Electrode
3.12.1 Removal of the Water-in-Fuel Sensor
The Water-in-Fuel sensor is located on the left side of the engine mounted on the fuel filter module.
Remove as follows:
1. Drain the fuel filter module using the water drain valve located on the bottom of the
fuel filter module.
2. Pull gray tab down and disconnect the harness connector.
3. Remove two screws from sensor; remove sensor.
3.12.2 Installation of the Water-in-Fuel Sensor
Install as follows:
1. Lubricate the seal ring on the new sensor with clean fuel.
2. Install water-in-fuel sensor to fuel filter module.
3. Install two screws to the water-in-fuel sensor and fuel filter module and tighten bolts
9-13 Nm (6.5-9.5 lbft).

3.12 WATER-IN-FUEL SENSOR
4. Install harness connector to sensor and push in the gray tab on the connector to lock
harness connector.
5. Prime fuel system.

3.13 DELTA P SENSOR
The Delta P sensor is mounted on the Exhaust Gas Recirculation (EGR) venturi pipe. The
Motor Control Module (MCM-MCM2) receives a signal from the Delta P sensor which senses
pressure and drop across the EGR venturi. The MCM-MCM2 uses this signal to calculate the
EGR flow rate.
1. Signal 3. Supply Voltage

2. Ground
3.13.1 Removal of the Delta P Sensor
Remove as follows:
1. Release harness connector on sensor by pushing the orange tab up to unlock the connector,
depress the thumb tab and remove the harness connector .
2. Remove two bolts from Delta P sensor securing it to the Exhaust Gas Recirculation
(EGR) venturi pipe.
3. Remove the two hose clamps and the hose that connects the delivery pipe to the venturi.
Slide the hose onto the delivery pipe.
4. Remove the two bolts from the venturi to the crossover tube and remove the venturi pipe.
3.13.2 Cleaning of the Exhaust Gas Recirculation (EGR) Venturi Pipe

Delta P Sensor Ports
Clean as follows:

3.13 DELTA P SENSOR
1. Using a suitable wire brush, clean out any debris from the Delta P sensor ports (1).
2. Clean EGR venturi pipe Delta P flange with clean diesel fuel.
EYE INJURY
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 276 kPa (40 psi) air pressure.
3. Dry of EGR venturi pipe with shop air.
3.13.3 Installation of the Delta P Sensor
Install as follows:
1. Install the venturi onto the crossover tube and install the two bolts. Torque to 30 Nm
(22 lbft).
2. Tighten the clamps on the rubber hose to 3.0 Nm - 3.5 Nm (26-26.5 lbin).
3. Install the Delta P sensor to the EGR venturi pipe with two bolts and tighten. Torque to
30 Nm (22 lbft).
4. Install harness connector to sensor and push orange tab down to lock harness connector
to sensor.

3.14 OIL PRESSURE SENSOR
The oil pressure sensor is mounted below the water pump in the cylinder block. The motor control
module (MCM-MCM2) receives a signal from the oil pressure sensor to ensure that the oil is at
the correct pressure levels. Senses gallery oil pressure for functions such as engine protection.
3.14.1 Removal of the Oil Pressure Sensor
Remove as follows:
1. Release harness connection from sensor by pushing the gray tab to unlock and remove
2. Using the appropriate tool on the oil pressure sensor unscrew the sensor from the cylinder
block.
3.14.2 Installation of the Oil Pressure Sensor
Install as follows:
1. Install the oil pressure sensor and new gasket to the cylinder block using the appropriate
tool.
2. Install harness connector to oil pressure sensor and push the gray tab forward to lock the
connector onto the sensor

3.15 ENGINE OIL TEMPERATURE SENSOR
3.15 ENGINE OIL TEMPERATURE SENSOR
The oil temperature sensor is mounted below the water pump in the cylinder block. The motor
control module (MCM-MCM2) receives a signal from the oil temperature sensor to ensure that
the oil temperature is at the correct temperature levels.
3.15.1 Removal of the Engine Oil Temperature Sensor
Remove as follows:
1. Release harness connection from sensor by pushing the gray tab to unlock and remove
2. Using the appropriate tool on the oil temperature sensor unscrew the sensor from the
cylinder block.
3.15.2 Installation of the Engine Oil Temperature Sensor
Install as follows:
1. Install the oil temperature sensor and new gasket to the cylinder block using the
appropriate tool. Torque sensor to 35-45 Nm (26-33 lbft)
2. Install harness connector to oil temperature sensor and push the gray tab forward to lock
the connector onto the sensor.

3.16 ENGINE COOLANT INLET TEMPERATURE SENSOR
The coolant inlet temperature sensor is mounted on the oil cooler module. The motor control
module (MCM-MCM2) receives a signal from the coolant inlet temperature sensor which senses
the coolant temperature and alerts the driver if the coolant temperature is high.
3.16.1 Removal of the Engine Coolant Inlet Temperature Sensor
Remove as follows:
1. Remove harness connector from coolant inlet temperature sensor by pulling up on the gray
tab on the connector to unlock and remove harness connection.
2. Drain the coolant.
3. Using the appropriate hex tool unscrew coolant inlet sensor from oil coolant module.
3.16.2 Installation of the Engine Coolant Inlet Temperature Sensor
Install as follows:
1. Using the appropriate hex tool install the coolant inlet temperature sensor and a new
gasket to the oil cooler module.
2. Install harness connector to the coolant inlet temperature sensor by pushing the gray tab
down to lock the connector to the sensor.
3. Fill the cooling system.

3.17 ENGINE COOLANT OUTLET TEMPERATURE SENSOR
3.17 ENGINE COOLANT OUTLET TEMPERATURE SENSOR
The coolant outlet temperature sensor is mounted on the front side of the water manifold
between the camshaft frame exhaust gas recirculation (EGR) cooler. The motor control module
(MCM-MCM2) receives a signal from the coolant outlet temperature sensor and analyzes coolant
temperature for functions such as engine protection, fan control and engine fueling.
3.17.1 Removal of Engine Coolant Outlet Temperature Sensor
Remove as follows
1. Remove harness connector from coolant outlet sensor by pushing the gray tab on the
connector up to unlock and remove harness connection.
2. Drain the coolant system.
3. Using the appropriate tool unscrew coolant outlet sensor from water manifold.
3.17.2 Installation of Engine Coolant Outlet Temperature Sensor
Install as follows:
1. Using the appropriate tool install the coolant outlet temperature sensor and new gasket to
the water manifold. Tighten to 35-45 Nm (26-33 lbft).
2. Install harness connector to the coolant outlet temperature sensor and push gray tab down
to lock connector to sensor.
3. Fill the cooling system.

3.18 AMBIENT AIR TEMPERATURE SENSOR
The AAT sensor is a thermistor type sensor with a variable resistance that produces an analog
signal between 0 and 5 V, representing the temperature of the ambient air. The AAT sensor
(see Figure ) is used with the Idle Shutdown Timer, specifically for the Ambient Air Temperature
Override Disable feature or for Optimized Idle. For additional information on these features
refer to Chapter 5.
NOTE:
This sensor is optional.

3.18 AMBIENT AIR TEMPERATURE SENSOR
3.18.1 Ambient Air Temperature Sensor OEM Installation
Install the AAT sensor where ambient air temperature can be read. A protected location on the
frame rails where it will not be splattered with dirt and grime and is removed from any heat source
such as exhaust is preferred. See Figure for AAT sensor installation.
Label CPC-CPC2 Wire Color Ambient Air

Connector #3, Temperature
21pin (1) Connector (2) Cavity
Sensor Return #1. 3/2 YEL/BLK A
Ambient Air Temp 3/15 TAN/YEL B
The parameter for the AAT sensor are listed in Table 3-4.
Parameter Group Parameter Options Default Access

0 Not Available
1 Hardwired
Ambient Air Temp 2 Reserved for
31 0 Not Available VEPS, DRS 7.X
sensor Enable J1939
3 J1587
4 ECAN
MID for Ambient
31 0 255 0 VEPS, DRS 7.X
Air Temp
Table 3-4 Ambient Air Temperature sensor Parameters

3.19 ENGINE COOLANT LEVEL SENSOR
The ECL sensor provides an input to the engine protection system and warn the operator if a
low coolant level has been reached.
The main component of the ECL sensor consists of a conductivity probe, which connects to the
CPC-CPC2 (see Figure ).
NOTICE:
The probe has an operational temperature range of -40 to 257F
(-40 to 125C). Exposure to temperatures beyond this range
may result in unacceptable component life, or degraded sensor
accuracy.

3.19 ENGINE COOLANT LEVEL SENSOR
The OEM must connect the ECL sensor probe as shown in the next illustration (see Figure ).
Polarity of the ground and signal must be correct for proper operation.
Label CPC-CPC2 Connector Wire Color CLS Connector (3)

#3, 21pin Cavity (2) Cavity
Coolant Level 3/11 ORN A
Ground (1) 3/2 BLK B

The probe should be located in either the radiator top tank or a remote mounted surge tank. It
should be mounted horizontally in the center of the tank and must be in a position to signal low
coolant before aeration occurs. Typically, this is a height representing 98% of the drawdown
quantity. The probe should be located so that it is not splashed by deaeration line, stand pipe or
coolant return line flows. The insulated portion of the probe should be inserted into the coolant
1/2 in or more past the inside wall of the tank. See Figure .
1. Coolant Full Level (cold) 3. Aeration Begins

2. Level Representing 98% of Drawdown Quantity
Determine proper location for low coolant level sensor while running the drawdown test. It must
actuate a warning before the satisfactory drawdown level is reached.
The ECL sensor components are OEM supplied hardware and can be purchased as kits or
individual components, depending on OEM requirements.
The sensor must be enabled with VEPS or the DRS as listed in Table 3-5.
Parameter
Parameter Options Default
Group
0 = Disabled
1 = Dual Level Probe sensor (IMO), fixed threshold*
Cool Level sensor 2 = Single Level Probe sensor, temp dependent
32 2
Input Enable 3 = Dual Level Float sensor (FTL), fixed
threshold/FTL Gentec
4 = Single Level Probe sensor, fixed threshold
Table 3-5 Enabling the Engine Coolant Level sensor

3.20 VEHICLE SPEED SENSOR
3.20 VEHICLE SPEED SENSOR
The CPC-CPC2 can calculate vehicle speed providing that it is properly programmed and
interfaced with a Vehicle Speed sensor (VSS) that meets requirements. The VSS (see Figure
) provides a vehicle speed signal for use in Cruise Control and Vehicle Speed Limiting. The
VSS signal type can be changed v
NOTE:
DDC does not approve of the use of signal generator sensors.

To obtain accurate vehicle mileage, the parameters listed in Table 3-6 must be programmed
with VEPS, DRS, or DDDL 7.X.
Parameter
Parameter Range Default
Group
0 = No sensor
1 = C3 sensor
2 = Square Wave (Hall sensor)
3 = J1939 (ECT1)
8 Vehicle Speed sensor 4 = Magnetic Pickup 4 = Magnetic
5 = J1939 (TCO1)
6 = J1939 (CCVS Source 1)
8 Axle Ratio 1 20.0 5.29
8 Number of Output Shaft Teeth 0 250 16
8 Tire Revs per Unit Distance 160 1599 312

8 Top Gear Ratio 0.1 2.55 1
8 Second Highest Gear Ratio 0.1 5.75 2.54
8 Two Spd Axle Second Axle Ratio 1 20.0 5.29
0 = Disable
1 = Enable VSS Anti Tamper Function via ABS
8 Anti Tamper 0 = Disable
2 = Enable Anti Tamper Function via
Gear Ration
Table 3-6 Vehicle Speed sensor Parameters

3.21 MAGNETIC PICKUP
3.21 MAGNETIC PICKUP
The magnetic pickup requirements are listed in Table 3-7. Magnetic Pickup size is determined by
installation requirements.
Parameters Range
Frequency Range 0 - 10 kHz
Low Threshold Voltage >1.8 Volts Peak to Peak
Table 3-7 Magnetic Pickup Vehicle Speed sensor Requirements
The Vehicle Speed sensor is wired to the 21pin #3 connector of the CPC-CPC2 as listed in Table
3-8.
CPC-CPC2 Connector/Pin Function

3/13 VSS (+)
3/14 VSS (-)
Table 3-8 Vehicle Speed sensor Wiring
See Figure for the installation of the Magnetic VSS.
Label CPC-CPC2 Connector Wire Color Vehicle Speed sensor

#3, 21pin Cavity (1) Connector Cavity
Vehicle Speed sensor (+) 3/13 LT BLU/ORN Signal
Vehicle Speed sensor (-) 3/14 LT BLU/BLK Return

3.22 SAE J1939 DATA LINK
A VSS wired to the CPC-CPC2 is not required if the transmission output shaft speed message
is being transmitted over the SAE J1939 Data Link. To obtain accurate vehicle mileage, the
parameters listed in Table 3-9 must be programmed with VEPS.
Parameter
Parameter Range Default
Group
0 = No sensor
1 = C3 sensor
2 = Square Wave (Hall sensor)
3 = J1939 (ECT1)
8 Vehicle Speed sensor 4 = Magnetic Pickup 4 = Magnetic
5 = J1939 (TCO1)
8 Axle Ratio 1 20.0 5.29
8 Tire Revs per Unit Distance 160 1599 312
8 Top Gear Ratio 0.1 2.55 1
8 Second Highest Gear Ratio 0 5.75 2.54
Two Spd Axle Second
8 1 20.0 5.29
Axle Ratio
0 = Disable
1 = Enable VSS ABS Anti Tampering
8 Anti Tamper Function 0 = Disable
2 = Enable VSS without ABS Anti
Tampering Function
Table 3-9 Vehicle Speed sensor Parameters for Transmission Output Shaft
Speed

3.23 VSS ANTI-TAMPER
3.23 VSS ANTI-TAMPER
If the sensor appears to be working improperly, but the vehicle speed is not zero, VSS
Anti-Tamper will log a VSS fault.

4 DIAGNOSTIC TESTS
Section Page
4.1 LOW PRESSURE FUEL SYSTEM - LEAK TEST .................................... 4- 3

4.2 HIGH PRESSURE FUEL SYSTEM - LEAK TEST ................................... 4- 5
4.3 LOW PRESSURE FUEL SYSTEM - PRESSURE TEST ......................... 4- 8
4.4 AERATED FUEL TEST ............................................................................ 4-11
4.5 HIGH AMPLIFIER/NEEDLE RETURN FLOW TEST ............................... 4-13
4.6 FUEL SYSTEM LEAK DETECTION TEST .............................................. 4-18
4.7 FUEL INJECTION SYSTEM (FIS) LEAK DETECTION - RAIL
PRESSURE BLEED OFF ........................................................................ 4-23
4.8 PRESSURE LIMITING VALVE FLOW TEST ........................................... 4-28
4.9 IDLE SPEED BALANCE (ISB) TEST ....................................................... 4-29
4.10 FUEL FILTER PRESSURE TEST ............................................................ 4-33
4.11 DRAINING FUEL SYSTEM PRIOR TO REPAIRS ................................... 4-34
4.12 FUEL SYSTEM CHECKS ........................................................................ 4-35
4.13 CHECKING DIESEL EXHAUST FLUID QUALITY ................................... 4-37
4.14 RELATIVE CYLINDER COMPRESSION TEST ....................................... 4-39
4.15 MECHANICAL CYLINDER COMPRESSION TEST ................................ 4-41
4.16 CRANKCASE PRESSURE TEST ............................................................ 4-44
4.17 POWER VERIFICATION WITH CHASSIS DYNAMOMETER ................. 4-45
4.1 LOW PRESSURE FUEL SYSTEM - LEAK TEST
Tool J-48710 is required for this testing.

Test as follows:
1. Shut off engine and apply the parking brake, chock the wheels, disconnect vehicle battery
power, and perform any other applicable safety steps.
2. Remove the fuel feed and return lines from the fuel filter module.
3. Install J-48710 fuel pressure test kit onto the module.
4. Insure the shutoff valve (2) is in the OFF position.
5. Turn regulator (1) counterclockwise until it stops. The regulator is now set to zero pressure.
PRESSURIZED AIR AND FLYING PARTICLES

To avoid injury to eye or face, wear a face shield or goggles
when conducting a pressure test.
6. Connect to shop air pressure.

7. Turn the shut-off valve to the ON position.
8. Turn the regulator clockwise to increase pressure in the fuel system to 75 psi.

4.1 LOW PRESSURE FUEL SYSTEM - LEAK TEST
9. Once the system pressure has reached 75 psi, let the system pressure stabilize for one
minute then turn the shutoff valve to the OFF position and disconnect shop air from
the regulator.
NOTE:
The fuel cooler and feed line for the amplifier circuit is located behind the fuel filter
module. Ensure this area is not overlooked.
10. Wait 30 minutes, then check the pressure. The system pressure should not drop over 30
minutes.
[a] If the pressure does not drop (still 75 psi), there are no low pressure fuel leaks.
Continue troubleshooting elsewhere.
[b] If the system pressure drops off over 30 minutes, go to step 11.
11. Reconnect shop air and turn on the valve.
12. Use a soapy solution and spray all connectors, fittings, and braided hoses.
[a] If no leaks are found, go to step 13.
[b] If leaks are found, repair as necessary.
13. Remove oil fill cap and listen for internal air leaks.
[a] If internal leaks are heard, remove the rocker cover to locate where the leak is coming
from, fuel injector/pump. If no fuel injectors show signs of leakage, remove the oil
pan and look for leakage coming from behind the fuel pump gear. Refer to section .
[b] If no internal leaks are located, go to step 14.
14. Install cooling system pressure testing tool.
[a] If cooling system pressure increases and there is fuel in the coolant, replace fuel
cooler located behind fuel filter module. Refer to section .
[b] If cooling system pressure does not increase, return to step 12 and retest. If no
problem is found, verify Repairs 219.1.

4.2 HIGH PRESSURE FUEL SYSTEM - LEAK TEST
High pressure fuel system leaks can cause a variety of problems including difficulty starting, fuel
in oil, rough running, low power, and several other issues. If there is a suspected leak in the high
pressure fuel system, follow these steps to find the leak.
FIRE
To avoid injury from fire caused by heated diesel-fuel
vapors:
Keep those people who are not directly involved in
servicing away from the engine.
Stop the engine immediately if a fuel leak is detected.
Do not smoke or allow open flames when working on
an operating engine.
Wear adequate protective clothing (face shield,
insulated gloves and apron, etc.).
To prevent a buildup of potentially volatile vapors, keep
the engine area well ventilated during operation.
1. Steam clean the entire fuel system prior to inspecting for leaks. If there are obvious
external leaks, repair the leak(s) before going to the next step 2.
2. Start engine and allow it to reach operating temperature 140F (60C).
3. Perform a RPBO Test. Refer to section 4.7.
[a] PASS, no problem found.
[b] FAIL, go to step 4.
4. Inspect the high pressure pump to rail feed fittings at the rail and the pump for leakage.
Are any leaks found; are the line fittings loose?
[a] Yes, torque the line fittings, start the engine and recheck. If leaks are still found,
replace the lines. Refer to section .
[b] No, go to next step.

4.2 HIGH PRESSURE FUEL SYSTEM - LEAK TEST
5. Inspect fuel injector fuel line rail connections (1) for external leaks. Are leaks found or
are there any loose lines?
[a] Yes, torque the fuel line rail connections, start the engine and recheck. If leaks are
still found, replace the lines. Refer to section .
[b] No, go to step 6.
6. Inspect the fuel rail pressure sensor for leakage. Is the sensor leaking or is it loose?
[a] Yes, torque the fuel rail pressure sensor, start the engine and recheck. If leaks are still
found, replace the fuel rail pressure sensor. Refer to section 3.8.1.
7. Inspect Pressure Limiting Valve (PLV) for leakage. Is the PLV leaking externally or is
it loose?
[a] Yes, , torque the PLV, start the engine and recheck. If leaks are still found, replace
the Pressure Limiting Valve (PLV). Refer to section .
8. Inspect the high pressure fuel pump for external leaks. Are there any leaks coming from
the high pressure pump?
[a] Yes, replace the high pressure fuel pump. Refer to section .
9. Install fuel test bottle kit (J-48708); fill one container with ultra-low sulfur diesel fuel and
add fuel dye to the fuel in the bottle. Connect the hoses to the fitting on the top of the cap.
This will isolate the engine from the chassis fuel system.
10. Prime the fuel system using the hand primer until there is no air coming out of the return
fuel line. Refer to section .

11. Remove the rocker cover refer to section and install tool (W470589009800) onto the rear
of the cam frame to cover the cam gears.
NOTE:
It will take a few minutes for the dye in the test bottle to make its way into the high
pressure system and up to the fuel injectors.
12. Start engine and allow it to reach operating temperature 140F (60C). To perform the test
run the engine at 900 rpm. Using the black light, inspect the fuel injectors and fuel lines
for signs of leakage. Are there any leaks coming from any of the fuel injectors or lines?
[a] Yes, replace any leaking fuel injector(s) or replace any leaking fuel line(s).
13. Using the black light, inspect the entire high pressure system for leaks. Repair as necessary.

4.3 LOW PRESSURE FUEL SYSTEM - PRESSURE TEST
This procedure will allow the low pressure fuel system to be monitored using pressure gauges.
1. Place a towel or container under the fitting for the low pressure pump out to catch any
draining fuel.
2. Remove four 8mm plug fitting in each of the four lines: low pressure pump inlet (1), low
pressure pump outlet (2), high pressure pump inlet (3), and high pressure pump outlet (4).
Store fittings to be reinstalled when testing is complete.
3. Insert four quick disconnect fittings into each of the four fuel line test ports.
4. Torque each fitting to 8 Nm (6 ft./lb).
5. Install priming port gauge J-48876.
6. Prime the fuel system.
7. Start the engine; Refer to section 4.3.1 and compare the pressures to the tables found there.

8. Remove test equipment
4.3.1 Fuel System Pressures
Normal and abnormal fuel system pressure are listed in the following tables.
Normal System Pressures

Cold Engine Cold Engine Warm Engine Warm Engine
600 RPM 1800 RPM 600 RPM 1800 RPM
LPP Inlet (in Hg -8 to-9 -14 -7.5 -13.5
LPP Outlet (PSI) 78-80 104 73-74 97
HPP Inlet (PSI) 74-76 87 70-71 83
HPP Outlet (PSI) 2.5 4.5 2-2.5 4
Priming Port (PSI) 78-80 101 72-73 94-95
Table 4-1 Normal Fuel System Pressures

Abnormal Fuel System Pressures

Coalescer (at or past its useful life) Final Filter (at or past its useful life)
Warm Engine Warm Engine Warm Engine Warm Engine
600 RPM 1800 RPM 600 RPM 1800 RPM
LPP Inlet (in Hg) -8.5 -13.5 -5.5 -6
LPP Outlet (PSI) 82 122 160+ 160+
HPP Inlet (PSI) 72 90 65 66
HPP Outlet (PSI) 3 4 1-2 2
Priming Port (PSI) 75 105 160+ 160+
Restricted Fuel Feed Line to Module Restricted Fuel Return Line From Module
Warm Engine Warm Engine Warm Engine Warm Engine
600 RPM 1000 RPM 600 RPM 1000 RPM
LPP Inlet (in Hg) -12 -14.5 -4.5 -6.5
LPP Outlet (PSI) 69 80 75 91
HPP Inlet (PSI) 67 75 72 84
HPP Outlet (PSI) 1-2 1-2 4.5 5.5
Priming Port (PSI) 70 80 75 90
Air in System (connector at line
to MCM-MCM2)
Warm Engine
600 RPM
LPP Inlet (in Hg) -1 to -5 (oscillating)
LPP Outlet (PSI) 14
HPP Inlet (PSI) 14
HPP Outlet (PSI) 1-2
Priming Port (PSI) 14
Table 4-2 Abnormal System Pressures

4.4 AERATED FUEL TEST
This condition will exist if there is an external leak of the low pressure fuel system, combustion
pressure entering the fuel system, or a vehicle fuel system concern.
Check as follows
1. Install J-48709 sight glass tools on to fuel filter module.
ENGINE EXHAUST
exhaust is toxic.
2. Start engine and allow it to reach operating temperature (over 140F/60C).

3. At idle and 1800 rpm watch the fuel inlet and outlet sight glasses at the fuel filter module.
[a] If the fuel is aerated, go to next step.
[b] If the fuel is not aerated, move to other troubleshooting procedures.

4.4 AERATED FUEL TEST
4. Install J-48707 and J-48708. This will allow the engine to be isolated from the chassis.
5. Start engine and allow it to reach operating temperature (over 140F/60C).

6. At idle and 1800 rpm watch the fuel inlet and outlet sight glasses at the fuel filter module.
[a] If the fuel is aerated at idle, go to next step.
[b] If the fuel is aerated at 1800 RPM only; go to step 8.
[c] If the fuel is not aerated, inspect the fuel system from the fuel filter module back
to the fuel tanks.
7. Install J-48710 to the fuel filter module. Refer to section 4.1.
[a] If leaks were found, repair as necessary.
[b] If no leaks were found, go to next step.
8. Using DDDL, run the Compression Test. Refer to section 4.14.
9. Note any cylinders that show lower than normal compression
10. Compare the cylinders that show lower than average torque loss to the cylinders that show
lower than normal compression. Example: If cylinder #1 shows low torque loss and
low compression, inspect this cylinder first
11. Remove the suspect fuel injector. Refer to section .
[a] If copper washer and fuel injector show signs of blow-by, replace copper washer and
replace all fuel filters. Fuel Prefilter refer to section , Water Separator/Coalescer
refer to section , Final Filter refer to section .
[b] Before installing new fuel injector, inspect fuel injector cup for corrosion. Replace
if necessary. Refer to section .
12. Retest the system.

4.5 HIGH AMPLIFIER/NEEDLE RETURN FLOW TEST
This condition will exist if there is leakage at the flat seat for the amplifier solenoid valve. At
idle fuel injector amplifiers are not turned on, thus little to no leakage should be noted out the
return line.
NOTE:
When measuring needle/amplifier return flow, both measurements must be completed
at the same time, but in separate containers. If these instructions are not followed,
incorrect return flow measurements will occur.
4.5.1 Amplifier Measurement Setup
Setup as follows:
1. Drain fuel system.

2. Remove banjo bolt attaching the amplifier return line (1) to the fuel filter module.
3. Using the short banjo bolt supplied in J-48708, plug the opening in the fuel filter module.
4. Install the banjo bolt line J-48708-2 to the amplifier return (1) line. The original banjo bolt
and new seal rings must be used.
5. Attach the opposite end of the clear return line to the J-48708 container.
4.5.2 Needle Measurement Setup
Setup as follows:
1. Remove the needle return line from the high pressure manifold located on the high
pressure pump.
2. Using one cap supplied in the J-48708, cap the fitting at the high pressure manifold.
3. Connect needle return line to the clear return line J-48708-4 supplied in kit.

4. Attach opposite end of the clear return line J-48708-4 to the opposite J-48708 container.
4.5.3 Return Flow Test
Test as follows:
1. Prime fuel system.
2. Start engine.
3. Measure the amplifier return flow from the clear return line (J-48707) to the container
(J-48708).
4. The maximum allowable amplifier leakage rate at idle is 15 liters per hour (250 mL per
one minute).
[a] If the volume is within specifications the system passed, return system to original
condition.
[b] If the volume is out of specification, go to next step.
5. Using DDDL 7.X read parameters Idle Speed Balance Values under Instrumentation
section for all six cylinders. Refer to section 4.9.1.
6. Turn engine OFF and wait five minutes to service any components of the high pressure
circuit.
NOTE:
System may contain residual high pressure when engine is turned off. Allow the residual
pressure to bleed off for five minutes.

7. Disconnect #1 (or next one in sequence) fuel injector high pressure line.
8. Install J-48704 rail plug on to the fuel rail and torque to 40 Nm (30 ft./lb).
9. Start engine.

10. Measure the flow from the clear return line to J-48708 container during a one minute time
frame and note the flow rate in the following chart.
Leakage Rate Worksheet

Total Leakage Rate ____________ ML per minute
(from step 4)
____________ Ounces per minute
Was a drop of more than 50 ML
Capped Cylinder Leakage Rate (1.7 ounces) compared to the Total
Leakage Rate noted?
_____________ ML per minute
Cylinder #1 YES NO
_____________ Ounces per minute
Cylinder #2 YES NO

Cylinder #3 YES NO
Cylinder #4 YES NO
Cylinder #5 YES NO
Cylinder #6 YES NO
11. Have all the cylinder flow measurements been recorded?

[a] If Yes, go to next step.
[b] If No, go to step 7.
12. Replace suspect fuel injector refer to section causing a drop of more than 50 ML (1.7
ounces) compared to the Total Leakage Rate value. Once the fuel injector is replaced,
go to step 4 to recheck the system and verify Repairs 219.1.

4.6 FUEL SYSTEM LEAK DETECTION TEST
This screen will allow a technician to monitor the fuel system leakage, current threshold value
and will allow the relearning of the threshold when certain repairs are completed.
When the high pressure fuel system, from the pump to fuel injectors, develops an internal or
external leak, the MCM-MCM2 software compensates for the additional loss. When the leakage
rate is greater than a threshold plus an auxiliary value, a code will set. This screen will help
determine if a leak has occurred and if the repair has fixed the leakage problem. The parameters
within the screen are listed in the following table.
Parameter Description
This counter will decrease by one when the leakage was less than the
learned threshold plus the aux value.
HP Leak Counter This counter will increase by one when:
HP Leak Actual Value > (HP Leak Leaned Value + 0.688 )
When the counter reaches 5, an error code will set.
HP Leak Learned Value This value is stored when an engine goes through a learn cycle for the
leakage threshold. The HP Leak Learned Value will only be stored when a
test has successfully passed.
HP Leak Learned Counter This counter will only increase each time a successful learn cycle is
completed. When the counter reaches 10, the Threshold Learning is
considered complete.
Rail Pressure Governor Compensation (RPG) is displayed in liters per hour.
This value is directly proportional to how the system is compensating for
leakages either internal or external.
A new fuel system with little leakage, RPG Compensation value is
around 1520 l/h (operating around 280650 bar rail pressure and
RPG Compensation
at idle).
A fuel system with a 9 l/h leakage, RPG Compensation is around
2528 l/h (operating around 280650 bar rail pressure and at idle).
A fuel system with a 45 l/h leakage, RPG Compensation is around
66 l/h (operating around 280650 bar rail pressure and at idle).
HP Leak Actual Value This value is updated when a leak down test is performed. This is the actual
leakage value that is calculated by the MCM-MCM2.
NOTE: Due to the accuracy of the test; you may not see this value change
between leakage tests. The number may only change past the 4th decimal
place.
Coolant Temperature Coolant temperature

Fuel Temperature Fuel Temperature

The buttons within the screen are listed in the following table.
Button Description
This button will start and stop a free running timer. This
Start/Stop Timer
timer is used as a reference only.
Read Accumulators This button will refresh the values in the panel.
This button will set the HP Leak Counter to 4. This will
Reset Error Counter allow the technician a chance to rerun the Leak Down
Test. If the test fails again, a leakage code will set.
This button will reset any previously learned
Reset Learned data
leakage/threshold values.
Close Closes the panel.
Check for leaks as follows:

1. Install and connect DDDL 7.X.
2. Navigate to the Service Routines panel.

3. Click on the Actions tab located at the top of the screen.
4. Click on the tab labeled Fuel System and then Leak Detection.

5. The dialog box that appears shows the parameters related to fuel system.
6. While in the Leak Detection screen, click the Reset Error Counter button.
NOTE:
This will change the HP Leak Counter to four (4). If the leak down test fails, a code
will set on next key cycle.
7. Start engine and monitor Coolant Temperature and Fuel Temperature. Both dialog
boxes will turn green when temperature conditions are met.
[a] Coolant temperature must be between 70C (158F) and 100C (212F).
[b] Fuel temperature must be between 35C (95F) and 89C (192F).
8. When temperature entry conditions are met, increase engine speed above idle using the
throttle pedal for a minimum of five minutes. Ensure the Engine State parameter in the

screen indicates Torque Demand. You can use the free running timer located at the
bottom right of the screen to monitor the time above idle.
9. When the five minute time is reached, decrease engine speed to idle.
NOTE:
Do not allow the engine to stay at idle for more than five minutes or the test will need to
be repeated.
10. Turn ignition OFF.

11. Allow system to bleed down for approximately 10 seconds.
12. Turn ignition ON.
13. Reconnect to MCM-MCM2 and CPC.
14. Read the value for HP Leak Actual Value.
[a] If the value is less than HP Leak Learned Value + 0.688, the system leakage is
acceptable. The HP Leak Counter will decrease by one (1).
[b] If the value is greater than HP Leak Learned Value + 0.688, the system leakage
is unacceptable and should be checked. The HP Leak Counter will increase by
one (1).

4.7 FUEL INJECTION SYSTEM (FIS) LEAK DETECTION - RAIL PRESSURE

BLEED OFF
This procedure, the Rail Pressure Bleed Off (RPBO) test will allow a technician to identify a
leak in the high pressure system. A Leakage rate of 280 bar to 10 bar in 35 seconds or more is
acceptable. A leak in one of the following locations will show a fast bleed down rate over time.
For EPA07 Rail Pressure Bleed Off Test Using DDDL refer to section 4.7.1. For EPA10 Fuel
Injection System (FIS) Leak Detection refer to section 4.7.2.
High pressure pump (pumping elements)
Fuel lines from the high pressure pump to fuel rail
Fuel lines to each fuel injector
Leak at the fuel rail pressure sensor
Leaking pressure limiting valve
Internal amplifier or needle leakage to the return
Internal amplifier or needle leakage to the cylinder
4.7.1 Rail Pressure Bleed Off Test Using DDDL (EPA07)
This procedure, the Rail Pressure Bleed Off (RPBO) test will allow a technician to identify a leak
in the high pressure system. A leak in one of the following locations will show a fast bleed down
rate over time. (A leakage rate of 280 bar to 10 bar or 35 seconds or more is acceptable).
Test as follows:
1. Install DDDL hardware.
2. Start DDDL software.
3. Go to Instrumentation, Chart, and select the parameter Rail Pressure.
4. Start engine and bring to operating temperature (over 140F/60C).
5. Turn engine OFF.
6. When the engine has stopped, turn ignition ON (key ON, engine OFF). Do not start.
NOTE:
Failure to turn the ignition back ON will cause the MCM-MCM2 to power down before
completing the test.
7. Monitor rail pressure trace over time.

4.7 FUEL INJECTION SYSTEM (FIS) LEAK DETECTION - RAIL PRESSURE BLEED OFF
8. A normal sealed system should show the characteristics shown in the following illustration.
[a] Note the time at which rail pressure reaches 280 bar.
[b] Note the time at which rail pressure reaches 10 bar.
[c] Subtract the end time (10 bar) from the start time (280 bar). Use the following
worksheet.
Time noted when rail pressure reads 10 bar _______________________________

Time noted when rail pressure reads 280 bar _______________________________
Bleed down rate__________________________
Example:
Time at 10 bar=8:19.32 8:18.28 8:19.32 = 0:01.04
Time at 280 bar=8:18.28 One minute four seconds or 64 seconds.
This engine passes a Rail Pressure Bleed Off Test.
Table 4-3 Rail Pressure Bleed Off Worksheet
NOTE:
A leaking high pressure system will have a bleed rate of less than 35 seconds.

9. A system that developed a leak in the high pressure system will show the following
characteristics.
10. Return to symptom-based diagnostic routine.
4.7.2 Fuel Injection System (FIS) Leak Detection (EPA 2010)
This automated procedure for EPA2010, the Rail Pressure Bleed Off (RPBO) test will allow a
technician to identify a leak in the high pressure system. A leak in one of the following locations
will show a fast bleed down rate over time. (A leakage rate of 280 bar to 10 bar or 35 seconds or
more is acceptable).
Test as follows:

4.7 FUEL INJECTION SYSTEM (FIS) LEAK DETECTION - RAIL PRESSURE BLEED OFF
1. Using DDDL 7.X, go to the Service Routines window and click on the FIS Leak
Detection tab.
NOTE:
Coolant and fuel temp must be over 50F and engine at idle.
2. When both coolant and fuel temperature conditions are met you will see a check mark,
click start test to begin.
NOTE:
Rail Pressure will Ramp up to 900bar. An error message will appear in the text box if the
minimum rail pressure can not be achieved which indicates a leak.

3. Once desired rail pressure is achieved a pop up message will appear. Read the instructions
completely then perform the steps.
4. Test will measure time rail pressure drops from 280 bar to 10 bar and give a pass/fail
result with time.
5. Return to symptom-based diagnostic routine.

4.8 PRESSURE LIMITING VALVE FLOW TEST
4.8 PRESSURE LIMITING VALVE FLOW TEST
Test as follows:
1. Remove the Pressure Limiting Valve (PLV) line to the fuel filter module.
2. Install clear hose and fitting J-48708-4 from J-48708 kit.
3. Cap fitting at module.
4. Connect the opposite end to the J-48708 tank.
5. Crank or start engine and note the return flow to the tank.
[a] If return fuel is noted, replace Pressure Limiting Valve (PLV). Refer to section .
[b] If no return flow is noted, go to next step.
6. Sweep engine speed from idle to 1800 and note the return flow to the tank.
[a] If return fuel is noted, replace Pressure Limiting Valve (PLV). Refer to section .
[b] If no return flow is noted, PLV is not causing the error condition.

4.9 IDLE SPEED BALANCE (ISB) TEST
Incorporated into the MCM-MCM2 is the ISB software which monitors the crank wheel speed
variation per segment and compensates each fuel injector to allow for a smoother running engine.
When the engine is at or around idle speed, the compensation values can be learned and stored
in the EEPROM. ISB values are the percentage of adjustment that the MCM-MCM2 can make
to a fuel injector to adjust for idle stability. It does not represent the total amount of available
fuel per cylinder.
For diagnostic purposes these values can be used to pinpoint a cylinder which is getting close to
or at its maximum/minimum limit. The limit values are set to positive (+100) and negative (-100).
At the positive value, the MCM-MCM2 software is compensating for an injection rate that is low.
On a common rail system this can be caused by a fuel injector fueling issue or failure of a high
pressure supply to a particular fuel injector.
If the ISB values are 0, this indicates no compensation is needed. Values of +40 and -40 are not
uncommon for a new fuel system. If values reach +70 to +80 and -70 to -80, injection quantities
are reaching their limits and should be noted. If values are at +100 or -100, the respective
cylinders should be checked for a failed component.
Example: For a low injection rate (low fueling from fuel injector), the software will try to
compensate for this fuel injector by increasing its pulse width to smooth out the engine. The value
will go positive until the engine is performing properly. If the value reaches (+100), no more
compensation can occur. The fuel injector should be replaced only after a visual inspection of the
fuel supply to the fuel injector is checked. If the value reaches (-100), this would indicate that the
fuel injector is over-fueling to the point that the software cannot take out any more fuel. The fuel
injector should be replaced. Refer to section .
Mechanical failure can also cause a +100 or a -100 reading of ISB. Follow all of the
troubleshooting procedures for the particular system to determine the root cause of the failure.

4.9.1 Checking Idle Speed Balance
Check as follows:
1. Using DDDL 7.X, go to the Service Routines window and click on the Idle Speed
Balance tab.
NOTE:
Fuel temp must be at least 50F and coolant temp must be at least 158F
2. If there are any cylinders with a +100 or -100 Idle Speed Balance (ISB) value, run a
compression test with DDDL 7.X. Refer to section 4.14.
[a] If all cylinders pass the compression test, go to step 3.
[b] If cylinder(s) fail, inspect for mechanical failure.
3. Monitor ISB parameters making note of each cylinder that is showing a positive or
negative 100% value.
4. Clicking on RUN TEST will reset the values for all cylinders to Zero.
NOTE:
During the learning process some cylinders may reach the positive or negative 100%
limit, but will only stay there for a short period of time. Looking at the parameters using
the chart function can help determine an injector that is stuck at the 100% limit compared
to an injector that reached the limit for a short time.

NOTE:
If all cylinders have not updated within three minutes, run the engine to 1200 RPM
for one minute and return to idle. This will cause the MCM-MCM2 software to relearn
the ISB values.

Fill in the following chart with the ISB values. These can be used at a later date or may be
required for another procedure.
ISB Worksheet
Cylinder # ISB Value
Cylinder # 1
Cylinder # 2
Cylinder # 3
Cylinder # 4
Cylinder # 5
Cylinder # 6
5. Continue to monitor cylinder(s) that reached a positive or negative 100%. If the suspect
cylinder is stuck at the limit of positive or negative 100%, check the following components:
Fuel line from rail to injector (kinked or plugged). Repair as necessary. Refer to section
219.1. Go to Step 6.
Fuel line connection at injector or rail (leaking). Repair as necessary. Refer to section
219.1. Go to Step 6.
Cranking compression. Repair as necessary. Refer to section 219.1. Go to Step 6.
6. If a cylinder is constantly higher than +70% or lower than -70% and there are no other
mechanical concerns with the engine, change the injector.

4.10 FUEL FILTER PRESSURE TEST
The fuel system consists of three main filters. The prefilter has the task of filtering material
down to 100 micron. The coalescer or water separator has the function of separating out
emulsified water, and can be considered to be a 10 micron filter. The final filter is rated at 3-5
micron. Generally the final filter is the filter that reaches the pressure limit first. With the current
configuration all filters are changed at the same time. The pressure limits when all fuel filters are
to be replaced are listed in the chart that follows.
Filter Pressure Limits

Replace Filters Using Replace Filters Using
RPM Normal Pressures J-48876 Priming J-48706 Gauge Set
Port Gauge (LPP Outlet Value)
600 RPM 70-115 PSI >115 PSI >115 PSI
1800 RPM 100-150 PSI >150 PSI >150 PSI
4.10.1 Replacing Fuel Filters
Replace as follows:
1. Install J-48876 or J-48706 test gauge(s).
2. Start engine.
3. Monitor pressures at 600 RPM.
[a] If the pressure is >115 psi at the priming port or the LPP Outlet, replace fuel filters.
Fuel Prefilter refer to section , Water Separator/Coalescer refer to section , Final
Filter refer to section .
[b] If the pressure is <115 psi at the priming port or the LPP Outlet, go to next step.
4. Monitor pressures at 1800 RPM.
[a] If the pressure is >150 psi at the priming port or the LPP Outlet, replace fuel filters.
[b] If the pressure is <150 psi at the priming port or the LPP Outlet, filters are OK.
5. Turn OFF engine.
6. Remove J-48876 or J-48706 test gauge(s).

4.11 DRAINING FUEL SYSTEM PRIOR TO REPAIRS
4.11 DRAINING FUEL SYSTEM PRIOR TO REPAIRS
Drain system as follows:

1. Remove the fuel feed line from the fuel filter module.
2. Install J-48710 fuel pressure test kit onto the fuel feed line at the module.
3. Do NOT remove the return line from the module.
4. Use regulator and adjust the system pressure to 50 psi.
5. After one to two minutes the system should be drained of fuel.
6. Remove test equipment.

4.12 FUEL SYSTEM CHECKS
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
1. Check fuel level and correct if necessary.

2. Use DDDL to check for stored or active codes and repair if necessary.
3. Using DDDL, monitor the rail pressure while cranking the engine.
4. During cranking rail pressure should be above 150 bar.
[a] If rail pressure is not above 150 bar, go to next step.
[b] If rail pressure is greater than 150 bar, check for other related engine concerns
causing a no start condition (i.e. Camshaft Position sensor failure).
5. Use DDDL to monitor quantity control valve current while cranking engine.
[a] If the current measures less than 2800 mA, go to next step
[b] If the current measures greater than 2800 mA, check for a short to power between pin
1 of the quantity control valve and pin 1 of the 120pin MCM-MCM2 connector.
6. Crank engine for 20 seconds and monitor LPP Outlet pressure. Refer to Low Pressure
Fuel System Pressures.
[a] If the gauge does not reach 30 psi; go to next step.
[b] If the gauge is above 30 psi, but below 40 psi; go to step 8.
[c] If the gauge is above 40 psi, replace fuel filters. Fuel Prefilter refer to section , Water
Separator/Coalescer refer to section , Final Filter refer to section .
7. Crank engine for 20 seconds and monitor LPP Inlet suction pressure. Refer to Low
Pressure Fuel System Pressures.
[a] If the gauge does not reach -3 in. Hg; go to next step.
[b] If the gauge is less than or equal to -3 in. Hg; go to step 9.
8. Check for external fuel leakage and repair if necessary. Refer to section 4.1.
9. Check flow from the pressure limiting valve (PLV).
[a] If no flow is noted, go to next step.
[b] If flow is noted; replace the PLV. Refer to section .

4.12 FUEL SYSTEM CHECKS
10. Install fuel system tool J-48707 and J-48708. This allows the engine to be isolated from
the chassis.
11. Fill the single container with clean fresh fuel and prime the fuel system using the hand
primer.
12. Crank the engine for 20 seconds.
13. Does the engine start and run?
[a] If yes, check for loose connections, kinked fuel lines, or issues related to the fuel
tank. Repair or replace as necessary.
[b] If no, go to next step.
14. Watch the fuel from the J-48708 tank to the inlet of the fuel filter module. Is fuel reaching
the fuel filter module?
[a] If yes, go to step 16.
[b] If no, go to the next step.
15. Check the following components
[a] Check for kinked LPP inlet and outlet lines between filter module and pump.
[b] Remove and inspect the low pressure pump for wear or broken oldham connection.
[c] Replace fuel filter module and retest system. Refer to section .
16. Watch the return fuel going to the tank.
17. Are there large amounts return fuel as soon as the engine cranks?
[a] If yes, check the three filter caps for proper torque and seating. If this is OK,
go to step 17[b].
[b] Remove prefilter, coalescer, and final filters. Check for damaged or missing seals at
the bottom of the filters. Fuel Prefilter refer to section , Water Separator/Coalescer
refer to section , Final Filter refer to section .
18. If all steps have been followed and a starting difficulty condition still exists, replace high
pressure fuel pump. Refer to section .

4.13 CHECKING DIESEL EXHAUST FLUID QUALITY
To determine if the Diesel Exhaust Fluid (DEF) quality is correct you will need to use the
refactrometer W060589009101 in tool kit W060589001900 (DEF Test kit). Retrieve a sample of
DEF from the DEF tank taking the sample at the highest level. Put 2-3 drops on the refactometer
and check the concentration level. Good quality DEF should read between 31.8 33.2 if the
reading is within specs then the next sample should be taken at the metering unit. Disconnect
the inlet to the metering unit and place the line in the graduated cylinder and perform the SCR
Pressure Test (60 seconds) and retest fluid again.
4.13.1 Checking for Contaminated Diesel Exhaust Fluid
To determine if the Diesel Exhaust Fluid (DEF) has been contaminated multiple things will need
to be checked from color, smell and the use of test strips.
COLOR
Light blue exposed to copper or Brass
Rusty color exposed to steel or Galvanized steel
Diesel fuel and oil will float on the top of DEF after letting it set.
SMELL DEF can have a slight ammonia smell.
4.13.2 Checking for Diesel Fuel/Oil In Diesel Exhaust Fluid
If diesel fuel/oil is suspected to be in the Diesel Exhaust Fluid (DEF) use tests strips A0005850202
and see if they change color when exposed to DEF. If diesel fuel/oil is found in the DEF remove
the DEF filter and check the DEF filter for diesel fuel/oil if the filter is contaminated then the
complete DEF system will need to be replaced.

4.13 CHECKING DIESEL EXHAUST FLUID QUALITY
1-Box refer to section .

2-Box refer to section .

4.14 RELATIVE CYLINDER COMPRESSION TEST
Using DDDL, the relative compression test is carried out through the cranking phase of engine
start-up. The test measures relative compression of each cylinder with the best one shown as
100% and the others displayed as a percentage of the best cylinder. When the results appear
on the screen, look for cylinders that are more than 10% lower than the highest cylinder. This
will be the suspected bad cylinder. Perform the mechanical compression test to verify the test
results. Refer to section 4.15
Test as follows:
1. Turn the ignition ON, (key ON, engine OFF).
2. Connect to DDDL 7.x. For EPA10 engines, connect to DDDL 7.05 or higher.
3. Choose Relative Compression Test from the Actions menu to display the
Compression Test dialog box.
4. Press the RUN TEST button.

5. Follow the instructions given on the screen.

4.14 RELATIVE CYLINDER COMPRESSION TEST
6. Use the results to determine a possible damaged cylinder. If the relative compression test
identifies a bad cylinder, perform the Mechanical Cylinder Compression Test to verify
repairs. Refer to section 4.15.

4.15 MECHANICAL CYLINDER COMPRESSION TEST
Perform the following steps for a mechanical compression test on a DD Platform Engine:
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves,
or allow engine to cool before removing any component.
PERSONAL INJURY
To avoid injury when working on or near an operating
engine, wear protective clothing, eye protection, and
hearing protection.
NOTE:
First perform the electronic cylinder compression test using DDDL 7.X. If results indicate
a weak cylinder, perform this mechanical compression test.
1. Run the engine and bring the engine coolant temperature to normal operating range,
88-96C (190-205F).
2. Disconnect the batteries. Refer to OEM procedures.
3. Drain fuel system. Refer to the appropriate workshop manual.
4. Remove rocker cover. Refer to the appropriate workshop manual.
5. Remove both fuel injector harnesses. Refer to the appropriate workshop manual.
[a] Disconnect electrical contacts at the fuel injectors.
[b] Disconnect the two wiring terminals going to the Jake brake solenoids.
[c] Disconnect 14-pin fuel injector harness connector.
[d] Remove the spring clip holding the fuel injector harness connectors to camshaft
frame.
[e] Remove the fuel injector wiring harnesses.
6. Remove high pressure fuel line from the suspect cylinder. Refer to the appropriate
workshop manual.
7. Remove the fuel injector. Refer to the appropriate workshop manual.
8. Remove excess fuel from cylinder using a vacuum pump.
9. Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder
head.

4.15 MECHANICAL CYLINDER COMPRESSION TEST
10. Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 Nm (14 lbft)
+ 90 degrees.
11. Install the fuel rail plug (J-48404).

12. Install a hold-down bolt onto the Jake Brake solenoid and snug the bolt.
13. Reconnect the batteries.
14. Crank the engine over five compression strokes using the starter motor. Record the
compression reading on the gauge.
NOTE:
Verify that the battery voltage does not go low enough to affect engine cranking speed. If
the cranking speed is affected then the results will be inaccurate. If needed, connect a
battery charger to maintain an acceptable battery voltage.
15. The compression reading should be 3102-3793 kPa (450-550 psi) with no two cylinders
differing by more than 276 kPa (50 psi). If compression readings are below specifications,
repeat step 14 to be certain of the reading.
16. The following are possible causes of low compression:
Jake Brake/piston
Valve lash/valve train damage
Cam timing
Cylinder liner/ring damage
Fuel injector hold downs
Blown head gasket
Cracked liner or head
Valve or seat damage

17. Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the
compression test adaptors.
NOTE:
Fuel injector hold-down bolts are a one-time use.
18. Repeat steps for all suspect cylinders.

19. Repair engine as necessary. Verify Repairs 219.1.

4.16 CRANKCASE PRESSURE TEST
4.16 CRANKCASE PRESSURE TEST
Check the engine crankcase pressure as follows:

ENGINE EXHAUST
exhaust is toxic.
1. Start the engine.

2. Run the engine and bring the engine coolant temperature to normal operating range,
88-96C (190-205F).
3. Install an adapter on to the oil fill opening. Attach a water manometer, calibrated to read
pressure as in. H2O, on to the adaptor.
4. Run the vehicle to full load and rated speed with a loaded trailer or dyno.
5. Measure and record crankcase pressure.
6. Shut down the engine.
7. Remove the adaptor from the oil fill opening.
8. The correct crankcase pressure should be less than 5 in. H2O at full load. If the engine
crankcase pressure is greater than 5 in. H2O, check the crankcase breather system for
blockage or any damage to the breather, inlet, or outlet tubes. Make sure that the spinning
element in the breather is not locked up or broken. If any damage is found, refer to the
appropriate workshop manual.

4.17 POWER VERIFICATION WITH CHASSIS DYNAMOMETER
The chassis dynamometer is a device for applying specific loads to a vehicle to determine if the
vehicle will perform to published specifications and to permit a physical inspection for leaks of
any kind. It is an excellent method for detecting improper tune-up, misfiring fuel injectors, low
compression, and other malfunctions.
4.17.1 Chassis Dynamometer Room Ventilation Recommendations
For safe and accurate dynamometer readings, the chassis dynamometer room must be properly
ventilated.

ENGINE EXHAUST
exhaust is toxic.
If a vehicle is tested on a dynamometer located in an area without proper ventilation, the engine
will be subject to high ambient air temperatures. High air inlet temperatures can result in false
low power readings on the dynamometer.
To help ensure accurate horsepower readings, the dynamometer room should have a
ceiling-mounted fan with a 850 to 1133 m3 /min (30,000 to 40,000 ft3 /min) capacity. This will
provide proper ventilation of exhaust gases and heat radiated by the operating engine.
For direct engine cooling, Detroit Diesel recommends the use of a 368 m3 /min (13,000 ft3 /min)
or greater capacity barrel-type ram air fan. This should be portable so that it can be conveniently
placed three to five feet (approximately one to two meters) in front of the truck and aimed directly
at the radiator/charge air cooler package.
4.17.2 Chassis Dynamometer Test and Run-in Procedure
The function of the dynamometer is to absorb and measure the engine output after it has been
transmitted through the vehicle transmission and driveline to the drive tires.

The vehicle is connected to dynamometer through the roller absorption unit. The load on the
vehicle may be varied from zero to maximum by decreasing or increasing the resistance in the
unit. The amount of power absorbed in a water brake type dynamometer, as an example, is
governed by the volume of fluid within the working system. The fluid offers resistance to a
rotating motion. By controlling the volume of water in the absorption unit, the load may be
increased or decreased as required.
The following are some tips to keep in mind in preparing the vehicle before the dynamometer
run and during the actual testing:
Follow all applicable safety procedures from the chassis dynamometer manufacturer.
Observe the air intake duct and charge air fan shrouding to identify misalignments. Correct
as necessary.
Make sure the differential lock is on.
Make sure the radiator/charge air cooler system fan(s) are locked on.
If the vehicle is equipped with anti-lock brakes (ABS), disable the ABS controller by
unplugging it or removing its power fuse/breaker.
Instrument the engine for fuel pressure, air inlet restriction, exhaust backpressure, and
crankcase pressure, and note these readings during the dynamometer run.
Make sure the vehicle hood is down and locked into its normal position.
Make sure the engine is fully warmed up before placing the vehicle on the dynamometer.
Both oil and coolant temperature should be at least 180 F (82 C).
When loading the vehicle on the dynamometer, make sure the vehicle is positioned onto
the rollers as straight as possible.
For direct engine cooling, Detroit Diesel recommends the use of a 368 m3 /min (13,000
ft3 /min) or greater capacity barrel-type ram air fan. This should be portable so that it
can be conveniently placed three to five feet (approximately one to two meters) in front
of the truck and aimed directly at the charge air cooler. This is especially important at
high altitudes.
During high ambient temperature conditions (90+ F, 32+ C), it may also be necessary to
use a water spray mist fan in front of the vehicle to prevent overheating.
Running the dynamometer in manual mode instead of automatic mode allows for
maximum control of the test process and may result in more consistent test results.
During the horsepower test, make sure percent engine load and torque limiting factor
are 100% by monitoring them with a computer equipped with DDDL 7.X.
Select a transmission gear with a 1:1 gear ratio during the horsepower test.
Take horsepower reading at 1500 rpm and 1750 rpm. Stabilize at rated speed for at least
one minute before taking a final horsepower reading. Compare the recorded horsepower to
the appropriate minimum horsepower tables below for particular ratings.

Note that the following charts are for vehicles with manual transmissions. Vehicles with
automatic transmissions (i.e. equipped with torque converters) will have slightly lower
minimum horsepower values then listed in Table 4-4.
Rated HP Wheel HP @ 1800 RPM Wheel HP @ 1500 RPM

455/1550 374 @ 1800 367 @ 1500
475/1550 390 @ 1800 367 @ 1500
455/1650 374 @ 1800 377 @ 1500
475/1650 390 @ 1800 390 @ 1500
505/1650 415 @ 1800 391 @ 1500
455/1750 374 @ 1800 377 @ 1500
475/1750 390 @ 1800 394 @ 1500
515/1750 423 @ 1800 416 @ 1500
475/1850 390 @ 1800 394 @ 1500
500/1850 411 @ 1800 415 @ 1500
530/1850 436 @ 1800 436 @ 1500
560/1850 460 @ 1800 440 @ 1500
Note: This is wheel HP with the fan locked on, 17.8% parasitic loss @1800 rpm, & 15.5% parasitic loss @ 1500 rpm
Table 4-4 Minimum Acceptable Wheel HP


5 STARTING DIFFICULTY
Section Page
5.1 ENGINE WILL ROTATE ........................................................................... 5- 3

5.2 ENGINE WILL ONLY START USING AN EXTERNAL PRIMING
SOURCE .................................................................................................. 5- 9
5.3 ENGINE WILL NOT ROTATE .................................................................. 5-11
5.1 ENGINE WILL ROTATE
Check as follows:
Engine cranking time depends on battery voltage, cranking speed, engine temperature, ambient air
temperature, fuel type, and oil viscosity. Typical cranking times range from two to five seconds.
BODILY INJURY
To avoid injury from an explosion, do not use ether or
starting fluid on engines equipped with a manifold (grid)
heater.
NOTICE:
To avoid engine damage, do not use ether or starting fluid on
engines equipped with a manifold (grid) heater.
Check as follows:
1. Use DDDL to check for stored or active codes and repair as necessary.
Stored or Active Codes

Stored or Active
codes:____________________________________________________________________________________
2. Did the symptom appear after a fuel filter service, fuel system repair or when the truck
was delivered from the factory?
[a] Yes, refer to section .
FIRE
To avoid injury from fire, keep all potential ignition sources
away from diesel fuel, including open flames, sparks, and
electrical resistance heating elements. Do not smoke when
refueling.
3. Check the fuel level in both fuel tanks to verify sufficient fuel supply.
Fuel Tank Levels

Fuel Tank 1:_____________________ Fuel Tank 2:_____________________

[a] If fuel level is low, add fuel until the fuel level is at least 3 inches over the pickup
tubes in the fuel tank. Drive the vehicle for 15 to 20 minutes to clear any air out
of the fuel system and retest.
[b] Fuel level OK, go to next step.
4. Use DDDL to insure that cranking speed is over 150 RPM.
[a] Cranking speed is over 150 RPM, go to next step.
[b] Cranking speed is under 150 RPM, to determine the cause of low crank speed
Refer to section .
5. Does crank time change based on the time that the engine has been shut down?
How long does the engine need to sit?_____________________

List internal engine issues (if
any)._________________________________________________________________________________________
[a] Yes, go to the next step.

[b] No, check for internal engine issues; battery voltage, crank speed, low compression,
or poor fuel quality.
6. Measure the low pressure fuel system pressure. Refer to section 4.1.
Low Pressure Fuel System Pressures

600 RPM 1800 RPM
Low pressure fuel pump in:
Low pressure fuel pump out:
High pressure fuel pump in:
High pressure fuel pump out:
Priming Port Pressure:
[a] If low pressure fuel system pressures are OK, go to the next step.
[b] If low pressure fuel system pressures are NOT OK, repair as necessary.
7. Check for internal or external low pressure fuel system leaks. Refer to section 4.3.
Leaking YES:_____________________ Leaking NO:_____________________
[a] If NO leaks are found, go to the next step.

[b] If leaks are found, repair as necessary.

8. Check for aerated fuel; refer to section 4.4.

[a] If fuel is aerated, repair as necessary.
[b] If fuel is NOT aerated, go to next step.
9. Remove the bypass valve (1) from the fuel module Refer to section , inspect the valve for
debris. Refer to section .
[a] If debris is found, clean or replace the bypass valve.
[b] If no debris is found, reinstall the valve and go to the next step.
10. Remove the two-stage valve (1) from the high pressure pump refer to section and inspect
for debris, refer to section check if the valve is stuck open.
[a] If debris is found or if the Two-Stage valve is stuck open, replace the Two-Stage
valve refer to section .

11. Remove the pressure relief valve (2) from the high pressure fuel pump refer to section and
inspect for debris, refer to section check if the valve is stuck open.
[a] If debris is found or if the valve is stuck open, replace the pressure relief valve.
Refer to section .
ENGINE EXHAUST
exhaust is toxic.
12. Start the engine. Perform a Rail Pressure Bleed Off test (RPBO) using DDDL.
Refer to section 4.7.
RPBO Time
RPBO Time:__________________________________________
[a] If the RPBO test passes, go to step 16.

[b] If the RPBO test fails, go to next step.

13. Check for internal and external high pressure fuel system leakage. Refer to section 4.2.
Leaking From
Where are the leaks coming
from?____________________________________________________________________________
[a] If leak(s) are found, repair leak(s) and prime the fuel system. Start the engine and
verify repair.
[b] If no leak(s) are found, go to the next step.
14. Check the ISB values, refer to section 4.9.
ISB Values
Cylinder 1%:_____________________ Cylinder 4%:_____________________
[a] If there are NO cylinders above 70% or below -70%, go to the next step.
[b] If there IS a cylinder above 70% or below -70%, remove that fuel injector line and
cap off the rail with J-48704. Run the RPBO test again. If the RPBO test passes,
change the fuel injector that is capped off and verify repairs.
15. Check for leakage from the Pressure Limiting Valve (PLV). Refer to section 4.8.
Leaking From
Where are the leaks coming
from?___________________________________________________________________________________
[a] If the PLV is leaking, replace the PLV and verify repairs. Refer to section .
[b] If the PLV is not leaking, replace the high pressure fuel pump and verify repair.
Refer to section .
16. Install a priming port gauge and start the engine. Turn the engine OFF and watch for fuel
pressure to drop when the engine is shut down.
How many seconds is the bleed

down?___________________________________________________________________________
[a] If the pressure drops to 0 within 3 seconds after engine shut down, inspect the check
ball under the pre-screen filter for proper seating. If the check ball is missing or is not
seating properly, repair or replace the fuel filter module. Refer to section .
[b] If the pressure DOES NOT drop to 0 within 3 seconds, go to the next step.

17. Remove the needle return line and fitting from the fuel filter module. Inspect the check
valve in the fitting for debris. Refer to section .
[a] If there is debris, clean or replace the check valve.
[b] If there is no problem with the check valve, replace the high pressure fuel pump.
Refer to section .

5.2 ENGINE WILL ONLY START USING AN EXTERNAL PRIMING SOURCE
Hard starting with external priming source indicates a system that cannot generate the required
pressure for the high pressure pump.
1. Use DDDL to check for stored or active codes and repair as necessary.
Stored or Active Codes

Stored or Active
codes:____________________________________________________________________________________
2. Check the fuel level in both fuel tanks to verify sufficient fuel supply.
Fuel Tank Levels

Fuel Tank 1:_____________________ Fuel Tank 2:_____________________
[a] If fuel level is low, add fuel until the fuel level is at least 3 inches over the pickup
tubes in the fuel tank. Drive the vehicle for 15 to 20 minutes to clear any air out
of the fuel system and retest.
[b] Fuel level OK, go to next step.
3. Check for external or internal low pressure fuel leaks and repair if necessary.
4. Check all filter caps for proper torque and seating.
5. Start the engine using an external priming source (remove once the engine is running).
ENGINE EXHAUST
exhaust is toxic.
6. Install the priming port gauge J-48876 and note the pressure at 600 rpm and 1800 rpm.
7. If pressure is below 60 psi, turn engine OFF and watch the bleed down rate of the priming
port gauge.

5.2 ENGINE WILL ONLY START USING AN EXTERNAL PRIMING SOURCE
8. Does the pressure bleed down to zero within two seconds after engine OFF?
[a] If yes, remove the high pressure relief valve for the low pressure pump and check
for debris. Refer to section If debris is found, replace high pressure relief valve
refer to section and inspect prefilter for damage or clogging. If debris was not found,
remove all three fuel filters and inspect lower seals for leakage. Replace if necessary.
[b] If no, perform a Pressure Limiting Valve (PLV) leakage flow test. Refer to section
4.8. If flow is noted; replace the PLV. Refer to section .

5.3 ENGINE WILL NOT ROTATE
Check as follows:
1. Using DDDL 7.X, check for stored or active codes. Are codes are present?
[a] Yes; determine cause of code(s).
[b] No; go to step 2.
2. Check all battery cables and connections. Reconnect or replace if necessary.
3. Measure and record the voltage at the battery terminals; refer to OEM guidelines. Was the
battery voltage at or above OEM specifications?
[a] Yes; go to step 6.
Electrical Shock
To avoid injury from electrical shock, use care when
connecting battery cables. The magnetic switch studs are
at battery voltage.
ELECTRICAL SHOCK
To avoid injury from electrical shock, follow OEM furnished
operating instructions prior to usage.
4. Charge the batteries.

5. Load test the batteries according to OEM specifications. Did the batteries pass the load
test?
[b] No; replace the defective battery (or batteries) and verify repair.

6. Check for battery voltage between the positive and negative connections at the starter
motor. Is battery voltage present at the starter motor connections?
[b] No; inspect the wiring between the battery and starter. Repair or replace as necessary.
7. Verify wiring integrity between the starter, start switch, and magnetic switch. Is the wiring
OK?
[b] No; replace start switch, magnetic switch, or repair wiring as necessary.
8. Attempt to manually rotate the engine using Engine Barring Tool J-46392. Does the
engine rotate normally?
9. Remove and bench test the starter; inspect the flywheel and ring gear. Was damage found
to the starter, flywheel, or ring gear?
[a] Yes; repair or replace as necessary.

10. Remove the accessory drive belts.

11. Attempt to rotate the engine with the proper barring tool. Does the engine rotate normally
with the accessory drive belt removed?
[a] Yes; identify and replace the seized accessory components (i.e. alternator, A/C
compressor, water pump, cooling fan, etc.).
12. Inspect the gear driven components (i.e. turbocharger compound, high pressure pump, air
compressor, etc.) for signs of binding or failure. Are all of the gear driven components
OK?
[b] No; replace gear driven components as necessary and verify repair.
13. Begin engine disassembly and inspection.


6 EXCESSIVE OIL CONSUMPTION
Section Page
6.1 CHECK FOR EXCESSIVE OIL CONSUMPTION .................................... 6- 3

6.1 CHECK FOR EXCESSIVE OIL CONSUMPTION
Check as follows:
1. Check first for external oil leaks.
[a] If external leaks are found, repair as needed.
[b] If no external leaks are found, go to step 2.
2. Perform a crankcase pressure test. Refer to section 4.16.
[a] Is excessive crankcase pressure is found, go to step 3.
[b] Is excessive crankcase pressure is not found, go to step 4.
3. Perform the relative compression test with DDDL 7.X or higher. Refer to section 4.14.
[a] If relative compression test shows no cylinders with low compression, inspect the
air compressor refer to section .
[b] If relative compression test reveals a cylinder with low compression, inspect for a
worn or damaged cylinder kit. Repair as necessary.
4. Check the interior of the exhaust S-pipe (DD15) or the exhaust flanged manifold (DD13)
for oil.
[a] If oil is found, go to step 5.
[b] If no oil is found, go to step 8.
5. Remove the turbocharger and inter-stage duct (if equipped), inspect for oil in the exhaust
manifold. For DD13: refer to section For DD15: refer to section .
[a] If oil is found in the inter-stage duct (DD15) or the exhaust flanged manifold (DD13)
and none is found in the exhaust manifold, Go to step 6.
[b] If no oil is found in the inter-stage duct (if equipped), go to step 7.
[c] If oil is found in the exhaust manifold, go to step 8.
6. Inspect the turbocharger for damage.For DD13: Refer to section , For DD15:
refer to section .
[a] If the turbocharger is OK, check for air inlet restrictions.
[b] If the turbocharger appears to be defective, replace the turbocharger. For DD13:
refer to section For DD15: refer to section .
7. Check pressure output of the Axial Power Turbine (APT) air solenoid using an air pressure
gauge. Is the APT air pressure between 3 and 7 psi?
[a] Yes; replace the APT. Refer to section .
[b] No; if the air pressure is out of specification, change the APT air solenoid.

6.1 CHECK FOR EXCESSIVE OIL CONSUMPTION
8. Remove the exhaust manifold to determine if the oil is coming from one cylinder or
multiple cylinders. Refer to section .
[a] If oil is coming out of a particular cylinder, check the valve seals, stems, and guides
for wear. If the valve seals, stems, and guides are OK, go to step 9
[b] If oil is coming from multiple cylinders, look in the air inlet and Charge Air Cooler
(CAC) pipes for oil from the compressor side of the turbocharger. If no oil is found
go to step 9
9. Remove the cylinder head and inspect cylinder(s) for damage. Repair as necessary.
DD13: refer to section .

7 ENGINE COOLANT TEMPERATURE
Section Page
7.1 HIGH ENGINE COOLANT TEMPERATURE ........................................... 7- 3

7.2 LOW ENGINE COOLANT TEMPERATURE ............................................ 7- 5
7.1 HIGH ENGINE COOLANT TEMPERATURE
Check as follows:
1. Check belt conditions for the fan and water pump belts.
[a] If the belts are not in good condition, replace the belts.
[b] If the belts are OK, go to step 2.
2. Check the condition of the belt tensioner.
[a] If the belt tensioner is not in good condition, replace the belt tensioner.
Refer to section .
[b] If the springs are OK, go to step 3.
3. Check the condition of the idler and accessory drive pulleys.
[a] If the idler and accessory drive pulleys are damaged, replace and repair as necessary.
[b] If the idler and accessory drive pulleys are in good condition, go to step 4.
4. Visually inspect the coolant level.
[a] If the coolant level is within an acceptable range, go to step 5.
[b] If the coolant level is not within an acceptable range, fill coolant system to correct
level.
5. Pressure test the radiator cap according to OEM procedure.
[a] If the radiator cap passes the test; go to step 6.
[b] If the radiator cap fails the test, replace the radiator cap.
6. Pressure test the cooling system with a pressure tester according to OEM procedure.
[a] If cooling system passes, go to step 7.
[b] If Cooling system fails, repair according to OEM procedure.
7. Visually examine the radiator and radiator shrouding.
8. Clean the exterior radiator of all clogging, debris, or excessive dirt; refer to OEM
guidelines. Remove winter front (if equipped).
[a] If the radiator is absent of clogging, debris, and dirt, check the radiator shrouding for
damage or incorrect positioning. If there is no damage or clogging to the radiator
go to step 9.
[b] If the radiator shrouding is damaged, incorrectly positioned, or inadequate, Repair or
replace damaged radiator shrouding; refer to OEM guidelines.
9. Visually examine cooling system hoses; refer to OEM guidelines.

7.1 HIGH ENGINE COOLANT TEMPERATURE
10. Check for soft, deteriorated, or collapsed hoses.

[a] If cooling system hoses are not soft, deteriorated, or collapsed, check the fan belts
and tensioner go to step 11.
[b] If cooling system hoses are soft, deteriorated, or collapsed, remove and replace
damaged or worn coolant hoses as necessary; refer to OEM instructions.
11. Test the cooling fan; refer to OEM guidelines.
[a] If the cooling fan is functioning correctly go to step 12.
[b] If the cooling fan is not functioning correctly, replace inoperative cooling fan; refer to
OEM guidelines.
12. Inspect thermostat for correct operation. Three different operating conditions occur due
to the coolant inlet temperature:
Bypass mode: When the coolant inlet temperature is <85C (185F) the circulating
thermostat (3) is closed. The coolant circulates in the engine and coolant can flow
through the vehicle heating heat exchange.
Mixed mode: For a coolant inlet temperature of >85C (185F) to <95C (203F) the
circulating thermostat opens partially and the coolant flows at the same time through
the engine radiator and the short circuit line to the coolant thermostat.
Radiator operation: When the coolant inlet temperature >95C (203F) the
circulating thermostat is completely open. The coolant is freely flowing to the engine
radiator.
[a] If the thermostat is not opening correctly, remove the thermostat housing from the oil
coolant module and replace the thermostat. Refer to section .
[b] If the thermostat is operating correctly, go to step 13.
13. Remove the water pump. Refer to section .
14. Inspect the pulley, shaft, and impeller for damage. If damaged, replace the water pump.
Refer to section .

7.2 LOW ENGINE COOLANT TEMPERATURE
To determine if faulty thermostats are causing low engine coolant temperature, perform the
following:
1. Inspect thermostat for correct operation. Three different operating conditions occur due
to the coolant inlet temperature:
Bypass mode: When the coolant inlet temperature is <85C (185F) the circulating
thermostat (3) is closed. The coolant circulates in the engine and coolant can flow
through the vehicle heating heat exchange.
Mixed mode: For a coolant inlet temperature of >85C (185F) to <95C (203F) the
circulating thermostat opens partially and the coolant flows at the same time through
the engine radiator and the short circuit line to the coolant thermostat.
Radiator operation: When the coolant inlet temperature >95C (203F) the
circulating thermostat is completely open. The coolant is freely flowing to the engine
radiator.
2. Compare the oil and coolant temperatures using DDDL 7.X. If the temperatures relate go
to the next step. If not check the sensors.
3. If the thermostat is not opening correctly, remove the thermostat housing from the oil
cooler and replace the thermostat. Refer to section .
ENGINE EXHAUST
exhaust is toxic.
4. Start and run the engine.

5. Run the engine through its operating range with no-load for approximately 5 minutes,
allowing the engine coolant to reach normal operating range.
[a] If the engine coolant temperature is 85-95C (185-203F), no further troubleshooting
is required. Shut down the engine.
[b] If the engine coolant temperature is below 85-95C (185-203F), shut down the
engine. Contact DDC Customer Support Center (313-592-5800).

7.2 LOW ENGINE COOLANT TEMPERATURE

8 EXCESSIVE EXHAUST SMOKE
Section Page
8.1 EXCESSIVE BLACK OR GREY SMOKE ................................................ 8- 3

8.2 EXCESSIVE BLUE SMOKE .................................................................... 8- 5
8.3 EXCESSIVE WHITE SMOKE .................................................................. 8- 7
8.1 EXCESSIVE BLACK OR GREY SMOKE
To check for excessive black or grey smoke perform the following:
NOTE:
Always check the Aftertreatment Device for internal damage when experiencing exhaust
smoke. The Aftertreatment Device could be a secondary failure.
NOTICE:
Use only Ultra-Low Sulfur Diesel (ULSD) fuel (15 ppm sulfur
content maximum), based on ASTM D2622 test procedure.
1. Verify proper ultra-low sulfur diesel fuel is being used. Is the correct fuel being used?
[a] Yes, go to step 3.
2. Run engine from a known good fuel source go to step 3.
ENGINE EXHAUST
exhaust is toxic.

4. Run the engine at idle with no-load for approximately five minutes, allowing the engine
coolant to reach normal operating range.
5. Visually inspect exhaust pipe for excessive black or grey smoke.
[a] If the engine exhaust smoke emission appears normal, no further troubleshooting is
required. Shut down the engine.
[b] If the engine exhaust smoke is excessively black or gray, shut down the engine.
Go to step 6.
6. Check the air cleaner for restriction.
[a] If the air cleaner is restricted, remove the air filter element from the air cleaner
container; refer to OEM guidelines.
[b] If the air cleaner is not restricted, go to step 7.
7. Attach the air-to-air cooler test kit (J-41473); refer to OEM guidelines.
8. Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing.
9. Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor
connector. Refer to OEM guidelines.

8.1 EXCESSIVE BLACK OR GREY SMOKE
10. Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the
air inlet system to a pressure of 177 kPa (25 psi).
11. Apply a water and soap solution to each hose connection, across the face of the charge
air cooler.
12. Apply a water and soap solution to the air intake manifold and cylinder head mating
surface area.
13. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for
stress cracks.
[a] If air leaks are present around the joints, replace the charge air cooler. Refer to
OEM guidelines.
[b] If air leaks are present around the air intake manifold. Repair as necessary.
[c] If NO air leaks are present go to step 14.
14. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section .
15. Using DDDL 7.X command the EGR valve from full open to full closed. Visually verify
that the EGR valve fully opens and fully closes.
[a] If the EGR valve fully opens and fully closes, go to step 18.
[b] If the EGR valve does not fully open and fully close, go to step 16.
16. With the ignition OFF, manually check the EGR valve and actuator by sweeping for
smoothness. Is binding is present?
[a] If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR
pull rod binds, go to step 17.
[b] If no binding is present, reset the EGR Valve actuator end stops using DDDL 7.X.
17. Check the EGR valve for excessive soot buildup.
[a] If buildup exists, clean or replace as necessary. For the DD15 ONLY: Refer to section
. For the DD13: Refer to section .
[b] If no buildup exists, go to step 18.
18. Check for soot or buildup in the EGR crossover tube.
[a] If soot is found, clean the EGR crossover tube.
[b] If no soot is found, go to step 19.
19. Check the Delta P for leaks and blockage.
[a] If the Delta P leaks or has blockage, clean or replace the Delta P sensor.
[b] If the Delta P does not leak or have blockage, check for a cracked or leaking intake
manifold or gaskets. Repair as necessary.

8.2 EXCESSIVE BLUE SMOKE
Check as follows:
NOTE:
1. Perform a crankcase pressure test. Refer to section 4.16.

[a] Is excessive crankcase pressure is found, go to step 2.
[b] Is excessive crankcase pressure is not found, go to step 3.
2. Perform the relative compression test with DDDL 7.X or higher. Refer to section 4.14.
[a] If relative compression test shows no cylinders with low compression, go to step 3.
[b] If relative compression test reveals a cylinder with low compression, inspect for a
worn or damaged cylinder kit. Repair as necessary.
3. Check the interior of the exhaust S-pipe (DD15) or the exhaust flanged manifold (DD13)
for oil.
[a] If oil is found, go to step 4.
[b] If no oil is found, go to step 7.
4. Remove the turbocharger and inter-stage duct (if equipped), inspect for oil in the exhaust
manifold. For DD13: refer to section For DD15: refer to section .
[a] If oil is found in the inter-stage duct (DD15) or the exhaust flanged manifold (DD13)
and none is found in the exhaust manifold, go to step 5.
[b] If no oil is found in the inter-stage duct (if equipped), go to step 6.
[c] If oil is found in the exhaust manifold, go to step 7.
5. Inspect the turbocharger for damage.For DD13: Refer to section , For DD15:
refer to section .
[a] If the turbocharger is OK, check for air inlet restrictions.
[b] If the turbocharger appears to be defective, replace the turbocharger. For DD13:
refer to section For DD15: refer to section .
6. Check pressure output of the Axial Power Turbine (APT) air solenoid using an air pressure
gauge. Is the APT air pressure between 3 and 7 psi?
[a] Yes; replace the APT. Refer to section .
[b] No; if the air pressure is out of specification, change the APT air solenoid.

8.2 EXCESSIVE BLUE SMOKE
7. Remove the exhaust manifold to determine if the oil is coming from one cylinder or
multiple cylinders. Refer to section .
[a] If oil is coming out of a particular cylinder, check the valve seals, stems, and guides
for wear. If the valve seals, stems, and guides are OK, go to step 8.
[b] If oil is coming from multiple cylinders, look in the air inlet and Charge Air Cooler
(CAC) pipes for oil from the compressor side of the turbocharger. If no oil is found
go to step 8.
8. Remove the cylinder head and inspect cylinder(s) for damage. Repair as necessary.

8.3 EXCESSIVE WHITE SMOKE
Check as follows:
NOTE:
1. Check for water in the exhaust pipe.

[a] If no water is found, go to step 2.
[b] If water is found, drain water and retest. If excessive white smoke is still present,
go to step 2.
2. Check engine coolant level.
[a] If coolant level is low, repair source of coolant loss.
[b] If coolant within specification, go to step 3.
3. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section .
4. Using DDDL 7.X command the EGR valve from full open to full closed. Visually verify
that the EGR valve fully opens and fully closes.
[a] If the EGR valve fully opens and fully closes, go to step 7.
[b] If the EGR valve does not fully open and fully close, go to step 5.
5. With the ignition OFF, manually check the EGR valve and EGR actuator by sweeping for
smoothness. Is binding is present?
[a] If yes, remove the pull rod and sweep the EGR Valve. If the EGR valve or the EGR
pull rod binds, replace as necessary. For the DD15 ONLY: Refer to section . For
the DD13: Refer to section .
[b] If no binding is present, go to step 6.
6. Check the EGR valve for excessive soot buildup.
[a] If buildup exists, clean or replace the EGR valve. For the DD15 ONLY:
Refer to section . For the DD13: Refer to section .
[b] If no buildup exists, reset the EGR Valve actuator end stops using DDDL 7.X.
7. Perform an Idle Speed Balance (ISB) test refer to section 4.9.
[a] If ISB test fails, repair as necessary.
[b] If ISB passes, go to step 8.
8. Verify camshaft and valve timing. Refer to section .
[a] If camshaft and valve timing is OK, contact the Detroit Diesel Customer Support
Center at 3135925800.
[b] If camshaft and valve timing is not OK, repair as necessary.

8.3 EXCESSIVE WHITE SMOKE

9 ROUGH RUNNING OR STALLING
Section Page
9.1 CHECK FOR ROUGH RUNNING OR STALLING ................................... 9- 3

9.1 CHECK FOR ROUGH RUNNING OR STALLING
Check as follows:
ENGINE EXHAUST
exhaust is toxic.

2. Measure the battery voltage; refer to OEM guidelines.
[a] If the battery voltage is greater than or equal to 10.5 volts, go to step 3.
[b] If the battery voltage is less than 10.5 volts, replace the battery. Refer to OEM
procedures.
3. Check for aerated fuel; refer to section 4.4.
[a] If fuel is aerated, repair or replace as necessary.
[b] If fuel is not aerated, go to step 4.
4. Check for loose connections, kinked fuel lines, or issues related to the fuel system.
[a] If fuel system issues were found, repair or replace as necessary.
[b] If fuel system issues were not found, go to step 5.
5. Remove prefilter, coalescer, and final filters. Check for damaged or missing seals at
the bottom of the filters. Fuel Prefilter refer to section , Water Separator/Coalescer
refer to section , Final Filter refer to section . Are there damaged or missing seals at
the bottom of the filters?
[a] If yes, replace the fuel filters as necessary. Fuel Prefilter refer to section , Water
Separator/Coalescer refer to section , Final Filter refer to section .
[b] If no, go to step 6.
6. Check the air vents at the top of the Water Separator/Coalescer and final filters for
blockage.
[a] If the Water Separator/Coalescer and final filters have blockage, replace the fuel filters
as needed. Fuel Prefilter refer to section , Water Separator/Coalescer refer to section
, Final Filter refer to section .
[b] If no blockage is found, go to step 7.

9.1 CHECK FOR ROUGH RUNNING OR STALLING
7. Compare the calibration code(s) shown on the DDDL 7.X display with the six digit
calibration code(s) on the fuel injector(s).
[a] If the calibration codes match, check compression pressure, perform the Relative
Cylinder Compression Test refer to section 4.14.
[b] If the calibration code on the display is different then the calibration code on the
suspect fuel injector for that cylinder, the fuel injector setting must be reset using
DDDL 7.X.

10 LOW WHEEL HORSEPOWER
Section Page
10.1 CHECKING FOR LOW WHEEL HORSEPOWER ................................... 10- 3

10.2 ENGINE DIAGNOSTIC QUESTIONNAIRE ............................................. 10-10
10.3 BAROMETRIC PRESSURE VS ALTITUDE CHART ............................... 10-11
10.1 CHECKING FOR LOW WHEEL HORSEPOWER
Check as follows:
NOTE:
Have operator fill out Engine Diagnostic Questionnaire, refer to section 10.2.
1. Check for active/historic codes. If any code(s) are present, troubleshoot those codes
first. Go to step 2.
2. Check the following; DDEC parameters, progressive shift settings, torque limiting values,
and fuel injector codes:
Are they correct?
Is proper rating applied?
If vehicle is new, is it specified correctly?
3. Check that the dyno-measured power is within Detroit Diesel specifications as for
minimum acceptable wheel HP data Refer to section 4.17. Does the vehicle make correct
horsepower for its specifications?
[a] Yes; no concern found, release vehicle.
4. Acquire a fuel sample from the vehicle fuel tank(s).
5. Submit fuel sample for an ASTM test analysis.
[a] If the fuel meets specifications, go to step 6.
[b] If the fuel did not meet specifications, drain the fuel oil tanks, refer to OEM
guidelines, and dispose of properly. Refill the fuel tanks with new ultra-low sulfur
diesel fuel.
6. Using DDDL 7.X, check barometric pressure sensor. Refer to section 10.3 for a barometric
pressure sensor table. Does the barometric pressure sensor report OK? For a EPA10
engine ONLY: compare the barometric pressure sensor to the diesel exhaust fuel pressure
and air pressure sensors outputs.
[a] The barometric pressure sensor reports OK, go to step 7.
[b] The barometric pressure sensor does not report OK, repair or replace as necessary.
7. Check the air filter.
[a] If the air filter is restricted, repair or replace air filter as necessary. Refer to
OEM procedures.
[b] If the air filter is not restricted, go to step 8.
8. Perform crankcase pressure test. Refer to section 4.16.
[a] If crankcase pressure shows OK, go to step 9.
[b] If crankcase pressure is not OK, repair or replace as necessary.
9. Attach air-to-air charge air cooler test kit, J-41473; refer to OEM guidelines.

10. Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing.
11. Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor
connector; refer to OEM guidelines.
12. Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the
air inlet system to a pressure of 205 kPa (30 psi).
13. Apply a water and soap solution to each hose connection, across the face of the charge
air cooler.
14. Apply a water and soap solution to the air intake manifold and cylinder head mating
surface area.
15. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for
stress cracks.
[a] If charge air cooler leaks are present around the joints, replace the charge air cooler.
Refer OEM guidelines.
[b] If the intake manifold leaks, repair intake manifold. Refer to section .
[c] If neither charge air cooler nor intake manifold leaked, check the exhaust system.
Go to step 16.
16. Check the following exhaust system components for leaks:
Exhaust manifold and bellows, repair leaks if found, if no leaks are found go to step 17.
Turbocharger, repair leaks if found, if no leaks are found go to step 17.
Interstage Duct, repair leaks if found, if no leaks are found go to step 17.
DD15 Only: Axial Power Turbine, repair leaks if found, if no leaks are found
go to step 17.
17. Using DDDL 7.X. check the exhaust pressure from the DPF inlet pressure sensor.
18. Start and run the engine at idle with no-load for approximately 5 minutes, allowing the
engine coolant to reach normal operating range.
19. On the chassis dynamometer, run the engine speed to full load.
[a] If the exhaust back pressure at full load is less than 10.1 kPa (3.0 in. Hg), check for
high inlet air temperature. Go to step 20.
[b] If the exhaust back pressure at full load is 10.1 kPa (3.0 in. Hg) or greater, go to step
21.
20. Visually examine the charge air cooler. Clean the exterior radiator of all clogging, debris,
or excessive dirt; refer to OEM guidelines. Remove winter front (if equipped).
[a] If the charge air cooler is absent of clogging, debris, and dirt, check the radiator
shrouding for damage or incorrect positioning. If there is no damage or clogging to
the charge air cooler or radiator shrouding. Go to step 21.
[b] If the radiator shrouding is damaged, incorrectly positioned, or inadequate, Repair or
replace damaged radiator shrouding; refer to OEM guidelines.
21. Remove the Aftertreatment Device (ATD). For the EPA07 refer to section For the
EPA10 1-Box refer to section .For the EPA10 2-Box refer to section .

22. Deactivate the pressure and temperature sensors using DDDL 7.X. Install the
aftertreatment test pipes (J-48388-1) for 5 inch exhaust, or aftertreatment test pipes
(J-48388-2) for 4 inch exhaust. When running the vehicle on the dynamometer with test
pipe installed, was the low power concern resolved?
[a] Yes, repair or replace Aftertreatment Device (ATD). For the EPA10 1-Box
refer to section .For the EPA10 2-Box refer to section .
[b] No, install Aftertreatment Device (ATD) and go to step 23.
24. Run the engine at idle with a no-load for approximately 5 minutes, allowing the engine
coolant to reach normal operating range, 88-96C (190-210F).
[a] If the return fuel temperature is less than or equal to 60C (140F), check for
improper injector calibration setting; go to step 25.
[b] If the return fuel temperature is greater than 60C (140F), remove and replace the
fuel filters. Fuel Prefilter refer to section , Water Separator/Coalescer refer to section
, Final Filter refer to section .
25. Compare the calibration code(s) shown on the DDDL 7.X display with the six digit
calibration code(s) on the fuel injector(s).
[a] If the calibration codes match, check compression pressure, perform the Relative
Cylinder Compression Test refer to section 4.14.
[b] If the calibration code on the display is different then the calibration code on the
suspect fuel injector for that cylinder, the fuel injector setting must be reset using
DDDL 7.X.

10.1.1 Factors that Affect Wheel Horsepower
The factors affecting wheel horsepower are listed in the following table.
Factors Considerations
Throttle Position Using DDDL 7.X, verify that you have 100% throttle position.
DDEC Power Rating Is the correct power rating programmed into the MCM-MCM2? Is the driver
aware of the effects that cruise power, or the lack of cruise power has
on perceived power?
Road Speed Setting Is the road speed setting causing a perceived lack of power?
Crank Case Overfilled If the crank case level is too high, there will be a loss of power due to
churning losses created by the crank shaft throws contacting the oil.
Fuel Temperature Make sure there is sufficient fuel supply (at least 1/3 of normal capacity)
in the fuel tanks. Check fuel temperature. For every 10F increase in fuel
inlet temperature above 100F, the engine will experience a power loss of
up to one percent and could have a possible Amber Warning Light and
derate situation.
Fuel Blend (specific gravity) Check the specific gravity in the fuel/vehicle system. A typical D2 ULSD
fuel has a specific gravity raging from 0.830 to 0.85 @ 60F. It should be
noted that No. 1 diesel fuel can reduce horsepower to 3.5 to 4 % HP less
than No. 2 fuel. Blends of No. 1 and No. 2 (common in winter) will produce
less horsepower, depending on the percent of the blend. This is a common
concern when dealing with low power complaints in cold climate locations.
Fuel Filter Restriction Check for fuel flow restrictions which can be caused by undersize or
improperly routed/damaged fuel lines, faulty check valves, or contaminated
fuel filters. Check the restriction gauge or fuel pressure to determine filter
condition.
Fuel Shut-Off Valve Position Make sure the fuel shut-off valve is fully open.
Fuel System Leak Fuel system leaks which result in aerated fuel are normally caused by a
leak at the connections and /or filters between the suction side of the fuel
pump to the supply tank and not between the pressure side of the pump
and engine.
Fuel Tank Vent Restriction A plugged fuel tank vent will create a vacuum in the tank and result in a
loss in fuel pressure at the fuel injectors. This will reduce fuel delivery rate.
Air in Fuel Aerated fuel, caused by a fuel system leak, will result in reduced fuel
delivery and late injection timing.
Plugged or Cracked Fuel Tank Stand If the fuel tank stand pipe is plugged by a shop rag or other debris, fuel
Pipe delivery will be restricted. A cracked stand pipe will allow air to enter the
fuel system and reduce fuel flow and cause late injection timing.
Faulty fuel injector A faulty fuel injector will limit fuel delivery and alter the combustion process
such that power is compromised.
Fuel injector Codes Incorrect fuel injector codes will limit fuel delivery.
Valve Lash Incorrect valve lash will alter the combustion process such that power is
compromised.
Camshaft Timing Incorrect cam timing will alter the combustion process such that power
is compromised.

Air Flow Restriction Air flow must not be inhibited by plugged filter, or inadequate inlet air
duct shrouding.
Faulty Turbocharger A turbocharger that has wheel rubbing, oil leaks, bent blades, etc. will not
provide adequate air supply.
Temperature Controlled Fan A faulty thermo control will cause the fan to be locked on and drain power
on a continuous basis.
Air System Leaks (gaskets and seals) Air system leaks will result in insufficient air for optimum combustion.
or/and Charge Air System Leak
Climate (fresh air temp) The maximum allowable temperature rise from ambient air to engine inlet
is 30F. Undersized or dirty air cleaner element, as well as damaged or
obstructed air inlet piping can cause low power. Make sure under-hood hot
air is not being taken in. Pressure drop across the air to air charge cooler
should be checked (3.0 in. Hg maximum from turbocharger discharge
to intake manifold). Check turbocharger boost pressure and compare to
specification.
Altitude Performance Site altitude has an effect on engine horsepower. Expect approximately 2%
loss in power when operating at an altitude of 5280 feet (1 mile), relative
to sea level.
DDEC Parameter Settings Make sure vehicle settings such as: axle ratio, tire size, top gear ratio, etc.
are set correctly to avoid a false sense of engine performance.
EGR Valve A misadjusted or malfunctioning EGR valve will alter the amount of oxygen
available for combustion as well as introduce inert gas that does not
promote combustion.
Exhaust Restriction A damaged, undersized, or otherwise restricted ATS or exhaust system
can result in high exhaust back pressure. Refer to the engine specification
sheets for maximum allowable pressure.
Delta P sensor The Delta P sensor, along with the exhaust temperature, determines
EGR flow rate. A faulty Delta P sensor will cause the EGR system to
malfunction and alter the amount of oxygen available for combustion as
well as introduce inert gas that will not promote combustion.
Barometric Pressure sensor The engine will reduce horsepower as a function of altitude to protect
critical engine components. Power reduction starts at approximately
8700 ft. on power ratings greater than 500 hp. Altitude is determined by
barometric pressure. A faulty Barometric Pressure sensor could start a
premature power reduction.
Air Compressor Leak An air compressor leak will cause the air compressor to work more and
increase the parasitic load on the engine.
Air Conditioner Leak An air conditioner leak will cause the air conditioner to work more and
increase the parasitic load on the engine.
Excessive Play in Power Steering Continuous movement of the steering wheel will call for continuous work by
System the power steering unit. This will increase the parasitic load on the engine.
Alternator Load Excessive use of vehicle electrical power will cause increased use of the
alternator. This will increase the parasitic load on the engine.
Tire Pressure Under inflated tires will significantly increase driveline resistance to rotation.

Trailer Aerodynamics/Alignment A trailer that has poor aerodynamics or has misaligned axles (causing dog
tailing) will significantly increase vehicle inertia and resistance to forward
motion.
Exhaust Leaks These leaks will cause low power and black smoke.
Vehicle Payload As vehicle loading increases, vehicle inertia and resistance to forward
motion increases.
Winter-front Installation Improper installation or usage of a winter-front will result in extremely high
intake air temperatures and reduced mass flow of air into the combustion
chamber.
Vehicle Application Unusual applications such as triple drive axles, PTO's, pumps, high air
compressor duty cycle, etc., will have higher parasitic loses resulting in less
horsepower at the wheels.
APT Failure Damage to turbine causing low power
Table 10-1 Factors Affecting Wheel Horsepower
NOTE:
Service information letter instructions published following the date of this document
take precedence.

Symptoms
Excessive
Possible Causes Loss of Poor Erratic Engine Black Oil
Misfires
Power Acceleration Idle Dies Smoke Consump-
tion
Fuel Filter Restriction X X X X X
Fuel Shut-Off Valve not
X X X X X
Open
Air in the Fuel X X X X X
Faulty fuel injector(s) X X X X X X
Faulty Turbocharger X X X X
EGR Valve* X X X X
Delta P sensor or
X X X X
Plugged Lines*
Charge Air Cooler
X X X
Leak
Intake or Exhaust
X X X
Manifold Leak
Quality/Grade of Fuel X X X X X
High Fuel Temperature
X X
- Above 130F
Restricted Air Intake X X X
Crankcase Overfilled X X X
Faulty Fan Operation,
X X
Always On
Debris in Fuel Tank -
X X X X X
Air Vent Plugged
Table 10-2 Low Power Troubleshooting Chart

10.2 ENGINE DIAGNOSTIC QUESTIONNAIRE
10.2 ENGINE DIAGNOSTIC QUESTIONNAIRE
Engine Diagnostic Questionnaire is seen below:

10.3 BAROMETRIC PRESSURE VS ALTITUDE CHART
The engine will reduce horsepower as a function of altitude to protect critical engine components.
Power reduction starts at approximately 8700 ft. on power ratings greater than 500 hp. Altitude is
determined by barometric pressure. A faulty barometric pressure sensor could start a premature
power reduction. Check the barometric pressure sensor.
Baro (kPa) Altitude (Ft) Altitude (M)

100.01 0 0
99.4 200 61
98.7 400 121
98.0 600 182
97.4 800 242
96.7 1000 303
96.1 1200 364
95.4 1400 424
94.8 1600 485
94.2 1800 545
93.5 2000 606
92.9 2200 667
92.3 2400 727
91.6 2600 788
91.0 2800 848
90.4 3000 909
89.8 3200 970
89.1 3400 1030
88.5 3600 1091
87.9 3800 1152
87.3 4000 1212
86.7 4200 1273
86.1 4400 1333
85.5 4600 1394
84.9 4800 1455
84.3 5000 1515
83.7 5200 1576
83.1 5400 1636
82.5 5600 1697
81.9 5800 1758
81.3 6000 1818


80.7 6200 1879
80.1 6400 1939
79.5 6600 2000
79.0 6800 2061
78.4 7000 2121
77.8 7200 2182
77.2 7400 2242
76.7 7600 2303
76.1 7800 2364
75.5 8000 2424
75.0 8200 2485
74.4 8400 2545
73.8 8600 2606
73.3 8800 2667
72.7 9000 2727
72.2 9200 2788
71.6 9400 2848
71.1 9600 2909
70.6 9800 2970
70.0 10000 3030
69.5 10200 3091
68.9 10400 3152
68.4 10600 3212
67.9 10800 3273
67.3 11000 3333
66.8 11200 3394
66.3 11400 3455
65.8 11600 3515
65.2 11800 3576
64.7 12000 3636
64.2 12200 3697
63.7 12400 3758
63.2 12600 3818
62.7 12800 3879
62.2 13000 3939
61.7 13200 4000
61.2 13400 4061

60.7 13600 4121
60.2 13800 4182

59.7 14000 4242
59.2 14200 4303
58.7 14400 4364
58.2 14600 4424
57.7 14800 4485
57.3 15000 4545
56.8 15200 4606
56.3 15400 4667
55.8 15600 4727
55.4 15800 4788
54.9 16000 4848
Table 10-3 Barometric Pressure
If your vehicle is operating above sea level, a loss of power will be encountered, no further
troubleshooting is required.
If your vehicle is operating at or below sea level and there is a lack of power, refer to section 10.1.


11 EXCESSIVE NOISE
Section Page
11.1 DIFFERENT ENGINE NOISE .................................................................. 11- 3

11.2 BELT NOISE ............................................................................................ 11- 4
11.1 DIFFERENT ENGINE NOISE
Different engine noises that are heard when a problem occurs are listed in the following table.
Type of Noise Check the Following:

Whining Noise Gear Train, Refer to section 11.1.1.
Air intake including the Charge Air Cooler and all hoses
Turbocharger clamps
Whistling Noise
Gaskets in exhaust system
Internal turbo damage
Rod bearings
Low Pitch Knock Pistons
Wrist pin
Valve train damage
Fuel system problems
Belt accessory drive
High Pitch Knock/Squeal Belt tensioner
Alternator
A/C compressor
Water pump
11.1.1 Check Gear Train
A whining noise indicates a problem with the gear train.

Check as follows:
1. Pull the engine
2. Drain the engine oil.
3. Pull the oil pan.
4. Move the doser feed line.
5. Remove the Crankcase Position (CKP) sensor.
6. Remove the fuel pump gear plate.
7. Remove the flywheel housing.
8. Inspect the gears for damage.
9. Inspect the thrust washers and gear bushings for damage.
10. Check the gear lash.

11.2 BELT NOISE
11.2 BELT NOISE
Excessive belt noise can mean changing the belt drive tensioner or idler pulley or the poly-V belts.
First inspect the belt drive tensioner system for wear and tear.

11.2.1 Inspection of the Belt Drive Tensioner System
Check as follows:
1. Inspect the belt contacts surface for chips, flaking, cracks and discoloration.
ABRASION CHUNK-OUT
IMPROPER INSTALL CRACKING

11.2 BELT NOISE
PILLING UNEVEN RIB WEAR
MISALIGNMENT GRAVEL PENETRATION

2. Inspect the bearings by rotating the pulleys to look for bearing slop or choppy feeling
bearings.
3. Inspect the springs on the tensioner. If the rubber is damaged or if the spring is damaged,
change the assembly.
4. Inspect the pulleys for damage and excessive wear. If pulleys or the belts are damaged,
change the damaged pulley and the belt.

11.2 BELT NOISE
5. Check the belt wear pattern on all idler pulleys.

[a] If the belt wear pattern is incorrect (A), change the pulley and bracket assembly.
[b] If the belt wear pattern is correct (B), the idler and bracket can be reused.

12 POOR ENGINE BRAKE PERFORMANCE
Section Page
12.1 CHECKING FOR POOR ENGINE BRAKE .............................................. 12- 3

12.1 CHECKING FOR POOR ENGINE BRAKE
Use this procedure to determine the cause of poor engine brake performance when no codes
are present.
Check as follows:
1. Check the oil pressure using DDDL 7.X or later.
[a] If the oil pressure is OK, go to step 6.
[b] If the oil pressure is low, go to step 2.
2. Start engine, using a mechanical gauge, check the oil pressure.
[a] If pressure is fluctuating, go to step 4.
[b] If pressure is low but stable, go to step 3.
3. Stop the engine and wait 5 minutes for the oil to drain into the oil pan. Check the oil level.
[a] If oil is above maximum level with no oil previously added, go to step 5.
[b] If oil is not above maximum level, go to step 4.
4. Stop the engine and wait 5 minutes for the oil to drain into the oil pan. Perform the
following steps:
[a] Check the oil level. Add recommended oil to bring it to the proper level, if required.
[b] Check for faulty oil gauge. Replace, if required. Refer to OEM guidelines.
[c] Check for loose or cracked oil pump suction pipe. Refer to section .
[d] Check for loose drive or driven oil pump gear. Refer to section .
[e] Check for faulty oil pressure relief valve. Refer to section .
5. Check for possible fuel in oil.
[a] If fuel is found, locate and repair source of fuel leak. Change the oil.
[b] If fuel is not found, contact Detroit Diesel Customer Support Center at 3135925800.

6. Inspect the exhaust rocker shaft to ensure it is installed with the groove toward the front of
the engine as shown in graphic.
NOTICE:
The cam journal area is lubricated by oil that has to travel through
the rocker shaft. If the shaft is installed incorrectly, oil passages
do not line up. This results in insufficient lubrication and damage
to the cam journals.
NOTE:
On EPA10 engines the intake and exhaust rocker shafts are marked "TOP FRONT" and
TOP REAR. Top front must face towards the front of the engine.

[a] If the exhaust rocker shaft is correctly installed, go to step 7.

[b] If the exhaust rocker shaft is incorrectly installed, check the cams and valve train
for damage. Refer to section .
7. Check the camshaft timing. Refer to section .
[a] If camshaft timing is OK, go to step 8.
[b] If camshaft is not OK, repair as necessary.
8. Check valve lash and engine brake adjustment. Refer to section .
[a] If valve lash is OK and the engine brake is in adjustment, contact Detroit Diesel
Customer Support Center at 3135925800.
[b] If either are out of adjustment, readjust them and retest. Refer to section .


13 SPN 51 (MCM2) (EPA10)
Section Page
13.1 SPN 51/FMI 2 ........................................................................................... 13- 3

13.2 SPN 51/FMI 3 ........................................................................................... 13- 4
13.3 SPN 51/FMI 4 ........................................................................................... 13- 5
13.1 SPN 51/FMI 2
This diagnostic is typically intake throttle position deviation error.

Check as follows:
1. Turn ignition ON (key ON, engine OFF). Clear all code(s) using DDDL 7.X.
2. Turn ignition key OFF.
3. Turn ignition ON (key ON, engine OFF) and listen for the intake throttle valve to sweep.
4. If an audible sweep was heard and no faults are active, repeat step 1 and step 3. If
an audible sweep was still heard and no faults are active after repeating steps, test is
complete. Verify Repairs 219.1.
5. If no audible sweep heard and faults are active, go to step 6.
6. Disconnect intake throttle valve connector and inspect for bent, damaged, or corroded pins.
[a] If pin damage is found, repair as necessary. Verify Repairs 219.1.
[b] If no pin damage is found, go to step 7.
7. Disconnect the charge air pipe from the intake throttle valve. Check intake throttle plate
for obstructions or damage.
[a] If obstructions are found, repair as necessary. Verify Repairs 219.1.
[b] If damage is found, replace the intake throttle valve. Refer to section .

13.2 SPN 51/FMI 3
13.2 SPN 51/FMI 3
This diagnostic is typically intake throttle valve circuit failed high.

Check as follows:
1. Check for multiple codes.
[a] If 3563/3, 411/3, and 51/3 are present, repair open circuit between pin 117 of the
ACM2 120-pin connector and the Intake Throttle, intake manifold, and EGR Delta P
sensors.
[b] If only 51/3 is present, go to step 2.
2. Disconnect intake throttle valve connector.
3. Turn the ignition ON (key ON, engine OFF).
4. Measure the voltage between pins 2 and 3 of the intake throttle valve harness connector.
[a] If the voltage is between 4.5 and 5.5 volts, go to step 6.
[b] If the voltage is less than 4.5 volts, go to step 5.
5. Measure the voltage between pin 3 of the intake throttle valve sensor harness connector
and ground (battery ground lug by starter).
[a] If the voltage is between 4.5 and 5.5 volts, repair the open between pin 2 of the
intake throttle valve sensor harness connector and and pin 103 of the ACM2 120-pin
connector. Verify Repairs 219.1.
[b] If the voltage is less than 4.5 volts, repair the open between pin 3 of the intake
throttle valve sensor harness connector and pin 117 of the ACM2 120-pin connector.
Verify Repairs 219.1.
6. Turn the ignition to the OFF position.
7. Disconnect the ACM2 120-pin connector.
8. Measure the resistance between pin 1 of the intake throttle valve harness connector and
pin 90 of the ACM2 connector.
[a] If the resistance is greater than 5 , repair the open between pin 1 of the intake
throttle valve harness connector and pin 90 of the ACM2 120-pin connector.
[b] If the resistance is less than 5 , replace the intake throttle valve. Refer to section .

13.3 SPN 51/FMI 4
This diagnostic is typically intake throttle valve circuit failed low.

Check as follows:
[a] If 3563/3, 411/3, and 51/4 are present, repair short to battery (12 volt) between pin 58
of the ACM2 120-pin connector and the Intake Throttle, intake manifold, and EGR
Delta P sensors.
[b] If 3563/4, 411/4, and 51/4 are present, repair a short to ground on pin 58 or 117 of
the ACM2 120-pin connector.
[c] If 411/4 and 51/4 are present, repair open circuit between pin 117 of the ACM2
120-pin connector and the EGR Delta P sensor and intake throttle valve.
[d] If 411/3 and 51/4 are present, repair open circuit between pin 103 of the ACM2
120-pin connector and the EGR Delta P sensor and intake throttle valve.
[e] If only 51/4 is present, go to step 2.
2. Disconnect the intake throttle valve.
ground (battery ground lug by starter).
[a] If the resistance is less than 5 , repair short to ground between pin 90 of the ACM2
120-pin connector and pin 1 of the intake throttle valve connector. Verify Repairs
219.1.
[b] If resistance is greater than 5 , go to step 5.
pin 90 of the of the ACM2 120-pin connector.
[a] If resistance is greater than 5 , repair open circuit between pin 90 of the ACM2
120-pin connector and pin 1 of the intake throttle valve connector. Verify Repairs
219.1.
[b] If resistance is less than 5 , replace the intake throttle valve. Refer to section .

13.3 SPN 51/FMI 4

14 SPN 70 (CPC)
Section Page
14.1 SPN 70/FMI 13 ......................................................................................... 14- 3

14.2 SPN 70/FMI 19 ......................................................................................... 14- 4
14.1 SPN 70/FMI 13
This diagnostic is typically the J1939 Park Brake Switch signal from Source #1, #2, or #3
is missing.
Check as follows:
1. Check for multiple codes:
[a] If CPC SPN 168/FMI 0/14/18 (Battery Voltage) are present troubleshoot these first.
[b] If MCM SPN 625/FMI 9 is present, repair the CAN line faults.
[c] If only a J1939 Error fault is present, go to the next step.
2. Has the CPC been recently reprogrammed?
[a] If yes, check the proper configuration of the CPC.
[b] If no, connect ServiceLink to determine which modules are configured for the vehicle
and their communication status. Once this is done, follow the appropriate module
communication troubleshooting procedures for the affected module.

14.2 SPN 70/FMI 19
14.2 SPN 70/FMI 19
This diagnostic is typically J1939 Park Brake Switch signal from Source #1, #2, or #3 is erratic.
Check as follows:
[a] If CPC SPN 168/FMI 0/14/18 (Battery Voltage) are present troubleshoot and repair
these first.
[b] If MCM SPN 625/FMI 9 is present, troubleshoot and repair the CAN line.

15 SPN 84
Section Page
15.1 SPN 84/FMI 0 ........................................................................................... 15- 3

15.2 SPN 84/FMI 2 ........................................................................................... 15- 4
15.3 SPN 84/FMI 3 ........................................................................................... 15- 5
15.4 SPN 84/FMI 4 ........................................................................................... 15- 6
15.5 SPN 84/FMI 6 ........................................................................................... 15- 7
15.6 SPN 84/FMI 8 ........................................................................................... 15- 8
15.7 SPN 84/FMI 9 ........................................................................................... 15- 9
15.8 SPN 84/FMI 10 ......................................................................................... 15-10
15.9 SPN 84/FMI 11 ......................................................................................... 15-11
15.10 SPN 84/FMI 13 ......................................................................................... 15-12
15.11 SPN 84/FMI 14 ......................................................................................... 15-13
15.12 SPN 84/FMI 19 ......................................................................................... 15-14
15.13 SPN 84/FMI 21 ......................................................................................... 15-15
15.1 SPN 84/FMI 0
This diagnostic is typically vehicle speed above programmable threshold 1 while driving.
NOTE:
This is an information only fault. It indicates the vehicle speed is above a programmable
threshold. It may be necessary to contact the truck owner or fleet manager to see if
they have this feature enabled.
1. Does the fleet operator have this feature enabled?

[a] Yes, note the fault code in the repair order and clear the code only if the fleet or
owner requests it. Release the vehicle.
2. Using DDDL/DDRS, change the CPC parameters highlighted below to 99 (actual value
which will be displayed in window is 98.92).

15.2 SPN 84/FMI 2
15.2 SPN 84/FMI 2
This diagnostic is typically J1939 wheel-based vehicle speed signal from Source #1 is erratic.
[a] If CPC2+ SPN 168/VMI 0/14/18 (Battery Voltage) are present, troubleshoot and
repair these first.
[b] If MCM2 SPN 625/FMI 9 is present, troubleshoot and repair the CAN line.
[c] If only a J1939 Error fault is present, go to step 2.
2. Has the CPC2+ been recently reprogrammed?
[a] If yes, Connect to DDDL 7.x and check the proper Vehicle Speed sensor (VSS)
configuration of the CPC2+ in the parameters list.
communication troubleshooting procedure for the affected module.

15.3 SPN 84/FMI 3
This diagnostic is typically VSS open circuit.

Check as follows:
1. Disconnect the Vehicle Speed sensor (VSS).
2. Measure the resistance between pin 13 of the CPC connector #3 (21pin) and pin 1 of
the VSS.
[a] If the resistance is greater than 3 , repair the open between pin 13 of the CPC
connector #3 (21pin) and pin 1 of the VSS. Verify Repairs 219.1.
[b] If the resistance is less than 3 , go to the next step.
the VSS sensor.
[a] If the resistance is greater than 3 , repair the open wire between pin 14 of the CPC
#3 connector (21pin) and pin 2 of the VSS. Verify Repairs 219.1.
4. Measure the resistance between pin 13 and 14 of the CPC connector #3 (21pin).
[a] If the resistance greater than 3 , replace the VSS. Verify Repairs 219.1.
[b] If the resistance is less than 3 , repair the short in the harness between pins 13 and
14 of the CPC connector #3 (21pin). Verify Repairs 219.1.

15.4 SPN 84/FMI 4
15.4 SPN 84/FMI 4
This diagnostic is typically VSS circuit failed low.

Check for a short as follows:
1. Disconnect the VSS connector.
2. Disconnect the CPC #3 connector (21pin).
3. Measure the resistance between pin 1 and pin 2 of the VSS harness connector.
[a] If the resistance measurement is less than 5 , repair the short pin 13 and pin 14 of
the CPC #3 connector (21pin). Verify Repairs 219.1.
[b] If the resistance measurement is greater than 5 , go to the next step.
4. Measure the resistance between pin 1 of the VSS harness connector and ground.
[a] If the resistance measurement is less than 5 , repair the short to ground between
pin 13 of the CPC #3 connector (21pin) and pin 1 of the VSS harness connector.
[b] If the resistance measurement is greater than 5 , replace the VSS. Verify Repairs
219.1.

15.5 SPN 84/FMI 6
Contact the Detroit Diesel Support Center at 3135925800.

15.6 SPN 84/FMI 8
15.6 SPN 84/FMI 8
Contact the Detroit Diesel Support Center at 3135925800.

15.7 SPN 84/FMI 9
This diagnostic is typically J1939 wheel-based vehicle speed signal from Source #2 is missing.
repair these first.

15.8 SPN 84/FMI 10
15.8 SPN 84/FMI 10
This diagnostic is typically J1939 wheel-based vehicle speed signal from Source #3 is erratic.
repair these first.
communication troubleshooting procedure for the affected module

15.9 SPN 84/FMI 11
This diagnostic is typically vehicle speed above programmable threshold 2 while driving.
NOTE:
This is an information only fault. It indicates the vehicle speed is above a programmable
threshold. It may be necessary to contact the truck owner or fleet operator to see if
they have this feature enabled.
1. Does the fleet operator have this feature enabled?

[a] Yes, note the fault code in the repair order and clear the code only if the fleet or
owner requests it. Release the vehicle.
2. Using DDDL/DDRS, change the CPC parameters highlighted below to 99 (actual value
which will be displayed in window is 98.92).

15.10 SPN 84/FMI 13
15.10 SPN 84/FMI 13
This diagnostic is typically the J1939 wheel-based vehicle speed signal from Source #1, #2,
or #3 is missing.
Check as follows:

15.11 SPN 84/FMI 14
This diagnostic is typically J1939 wheel-based vehicle speed signal from Source #3 is missing.
repair these first.

15.12 SPN 84/FMI 19
15.12 SPN 84/FMI 19
This diagnostic is typically J1939 wheel-based vehicle speed signal from Source #1, #2, or #3
is erratic.
Check as follows:
these first.

15.13 SPN 84/FMI 21
This diagnostic is typically Vehicle Speed sensor Erratic.

1. Are there any battery (SPN 168 FMI any) or CAN (625 FMI any) faults present?
[a] Yes, repair those faults first.
[a] Yes, ensure the VSS parameters are configured correctly for the vehicle application,
if OK go to step 3.
3. Is the VSS hardwired or transmitted via J1939?
[a] Hardwired, go to step 4.
[b] J1939, refer to the Application and Installation Manual for the correct parameter
configuration, if configuration is correct refer to OEM material for J1939 VSS
troubleshooting.
4. Disconnect the Vehicle Speed sensor (VSS) harness connector, refer to OEM literature for
location.
5. Inspect the VSS harness connector for bent spread or corroded pins.
[a] If pin damage is found repair as necessary.
6. Disconnect CPC connector 3.
7. Measure the resistance between CPC connector 3 pins 13 and 14.
[a] If resistance is less than 1K ohms, repair short between CPC connector 3 pins 13
and 14 and the VSS connector.
[b] If the resistance is greater than 1K ohms, go to step 8.
8. Measure the resistance between CPC connector 3 pin 13 and the VSS+ harness connection.
[a] If resistance is greater than 10 ohms, repair wire between CPC connector 3 pin 13
and the VSS+ harness connection.
9. Measure the resistance between CPC connector 3 pin 14 and the VSS- harness connection.
[a] If resistance is greater than 10 ohms, repair wire between CPC connector 3 pin 14
and the VSS- harness connection.
[b] If the resistance is greater than 1K ohms, refer to OEM literature for VSS sensor
diagnostics.

15.13 SPN 84/FMI 21

16 SPN 84 (MCM) (EPA10)
Section Page
16.1 SPN 84/FMI 3 ........................................................................................... 16- 3

16.2 SPN 84/FMI 4 ........................................................................................... 16- 4
16.1 SPN 84/FMI 3
This SPN is broadcast to the MCM via the CPC.

This diagnostic is typically VSS open circuit.
Check as follows:
1. Disconnect the Vehicle Speed sensor (VSS).
the VSS.
[a] If the resistance is greater than 3 , repair the open between pin 13 of the CPC
connector #3 (21pin) and pin 1 of the VSS. Verify Repairs 219.1.
the VSS sensor.
[a] If the resistance is greater than 3 , repair the open wire between pin 14 of the CPC
#3 connector (21pin) and pin 2 of the VSS. Verify Repairs 219.1.
4. Measure the resistance between pin 13 and 14 of the CPC connector #3 (21pin).
[a] If the resistance greater than 3 , replace the VSS. Verify Repairs 219.1.
[b] If the resistance is less than 3 , repair the short in the harness between pins 13 and
14 of the CPC connector #3 (21pin). Verify Repairs 219.1.

16.2 SPN 84/FMI 4
16.2 SPN 84/FMI 4
This SPN is broadcast to the MCM via the CPC.

This diagnostic is typically VSS circuit failed low.
Check for a short as follows:
1. Disconnect the VSS connector.
2. Disconnect the CPC #3 connector (21pin).
3. Measure the resistance between pin 1 and pin 2 of the VSS harness connector.
[a] If the resistance measurement is less than 5 , repair the short pin 13 and pin 14 of
the CPC #3 connector (21pin). Verify Repairs 219.1.
[b] If the resistance measurement is greater than 5 , replace the VSS. Verify Repairs
219.1.

17 SPN 91 (CPC)
Section Page
17.1 SPN 91/FMI 2 ........................................................................................... 17- 3

17.2 SPN 91/FMI 3 ........................................................................................... 17- 5
17.3 SPN 91/FMI 4 ........................................................................................... 17- 6
17.1 SPN 91/FMI 2
This diagnostic is typically for the fault is erratic data.

Check as follows:
1. Disconnect the Accelerator Pedal (AP).
2. Turn ON the ignition (key ON, engine OFF).
3. Measure the voltage between pins B and C of the AP harness connector.

[b] If the voltage is less than 4.5, go to the next step.
4. Measure the voltage between pin C of the AP harness connector and ground.
[a] If the voltage is between 4.5 and 5.5 volts, repair the open circuit between pin B of
the AP harness connector and pin 4 of the CPC #1 connector. Verify Repairs 219.1.
[b] If the voltage is less than 4.5, repair the open circuit between pin C of the AP harness
connector and pin 8 of the CPC #1 connector. Verify Repairs 219.1.
5. Turn OFF the ignition.
6. Disconnect the CPC #1 connector.

17.1 SPN 91/FMI 2
7. Measure the resistance between pin A of the AP harness connector and pin 7 of the CPC
#1 connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin A of the AP
harness connector and pin 7 of the CPC #1 connector. Verify Repairs 219.1.
[b] If the resistance is less than 3 , replace the Accelerator Pedal. Verify Repairs 219.1.

17.2 SPN 91/FMI 3
This diagnostic is typically circuit failed high.

Check as follows:
4. Measure the voltage between pins C of the AP harness connector and ground.
7. Measure the resistance between pin A of the AP harness connector and pin 7 of the CPC
#1 connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin A of the AP
harness connector and pin 7 of the CPC #1 connector. Verify Repairs 219.1.

17.3 SPN 91/FMI 4
17.3 SPN 91/FMI 4
This diagnostic is typically is circuit failed low.

Check as follows:
4. Measure the voltage between pin C of the AP harness connector and ground.
7. Measure the resistance between pin B and pin C of the AP connector.
[a] If the resistance is less than 5 , repair the short between wires 8 and 4 of the CPC
#1 connector. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , go to the next step.
8. Measure the resistance between pin A and B of the AP connector.
9. Measure the resistance between pin C of the AP connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin C of the AP
connector and ground. Verify Repairs 219.1.
10. Measure the resistance between pin A of the AP connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin A of the AP
[b] If the resistance is greater than 5 , replace the Accelerator Pedal. Verify Repairs
219.1.

18 SPN 94 (MCM) (EPA07)
Section Page
18.1 SPN 94/FMI 3 ........................................................................................... 18- 3

18.2 SPN 94/FMI 4 ........................................................................................... 18- 4
18.1 SPN 94/FMI 3
This diagnostic is typically Fuel Compensation Pressure (FCP) sensor circuit failed high.
Check as follows:
[a] If 100/3, 4077/3, and 94/3 are present, repair short to power between pin 82 of
the MCM 120-pin connector and the engine oil pressure, Fuel Line, and Fuel
Compensation Pressure sensors.
[b] If 4407/3 and 94/3 are present, repair short to power between pin 104 of the MCM
120-pin connector and the Fuel Line and Fuel Compensation Pressure sensors.
[c] If only 94/3 is present, go to step 2.
2. Disconnect FCP sensor connector.
3. Disconnect the MCM 120-pin connector.
4. Measure the resistance across pins 1 and 2 of the Fuel Line Pressure sensor connector.
[a] If the resistance is less than 5 , repair the short between the MCM 120-pin connector
wires 82 and 84. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , repair the short to power on circuit between the
MCM 120-pin connector pin 84 and the FCP sensor connector pin 4. Verify Repairs
219.1.

18.2 SPN 94/FMI 4
18.2 SPN 94/FMI 4
This diagnostic is typically Fuel Compensation Pressure (FCP) sensor circuit failed low.
Check as follows:
[a] If 100/4, 4077/4, and 94/4 are present, go to step 2.
[b] If 4407/4 and 94/4 are present, repair short to power between pin 104 of the MCM
120-pin connector and the Fuel Line and Fuel Compensation Pressure sensors.
2. Disconnect the Fuel Compensation Pressure sensor.
4. Measure the resistance between the Fuel Compensation Pressure sensor harness connector
pin 1 and ground (battery ground lug by starter).
[a] If resistance is less than 5 , repair short to ground between pin 82 of the MCM
120-pin connector and the Engine Oil, Fuel Line, and Fuel Compensation Pressure
sensors. Verify Repairs 219.1.
[b] If resistance is greater than 5 , repair open circuit between pin 82 of the MCM
120-pin connector and the Engine Oil, Fuel Line, and Fuel Compensation Pressure
5. Disconnect the Fuel Compensation Pressure sensor.
7. Measure the resistance between the Fuel Compensation Pressure sensor harness connector
pin 1 and ground (battery ground lug by starter).
[a] If the resistance is less than 5 , repair short to ground between pin 84 of the MCM
120-pin connector and the Fuel Compensation Pressure sensor pin 1. Verify Repairs
219.1.
[b] If the resistance is greater than 5 , repair open circuit between pin 84 of the MCM
120-pin connector and the Fuel Compensation Pressure sensor pin 1. Verify Repairs
219.1.

19 SPN 97
Section Page
19.1 SPN 97/FMI 3 ........................................................................................... 19- 3

19.2 SPN 97/FMI 4 ........................................................................................... 19- 5
19.3 SPN 97/FMI 15 ......................................................................................... 19- 7
19.1 SPN 97/FMI 3
This diagnostic is typically a Water-in-Fuel sensor open circuit.
Check as follows:
[a] If any EGR faults are active at the same time, repair the open circuit between pin 67
of the MCM 120-pin connector and pin 3 of the Water-in-Fuel sensor. Verify Repairs
219.1.
[b] If only fault 97/3 is active, go to the next step.
2. Disconnect the Water-in-Fuel sensor.
4. Measure the voltage between pins 1 and 3 of the Water-in-Fuel sensor harness connector.
[b] If the voltage is less than 2.75 volts, go to the next step.

19.1 SPN 97/FMI 3
5. Measure the voltage between pin 1 of the Water-in-Fuel sensor harness connector and
ground.
[a] If the voltage is between 2.75 and 3.25 volts, repair the open circuit between pin
3 of the Water-in-Fuel sensor harness connector and pin 55 of the MCM 120-pin
[b] If the voltage is less than 2.75 volts, repair the open circuit between pin 1 of the
Water-in-Fuel sensor harness connector and pin 71 of the MCM 120-pin connector.
6. Disconnect the MCM 120-pin connector and measure the resistance between pin 57 and
pin 2 of the Water-in-Fuel sensor harness connector.
[a] If the resistance is less than 5 , repair the short between pin 2 and 57 of the MCM
120-pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , replace the Water-in-Fuel sensor. Refer to section
3.12.1.

19.2 SPN 97/FMI 4
This diagnostic is typically a Water-in-Fuel circuit short to ground.
Check as follows:
[a] If any EGR faults are active at the same time, repair the open circuit between pin 67
of the MCM 120-pin connector and pin 3 of the Water-in-Fuel sensor. Verify Repairs
219.1.
2. Disconnect the Water-in-Fuel sensor.
4. Measure the resistance between pin 1 of the Water-in-Fuel sensor connector and ground.
[a] If resistance is less than 5 , repair short between pin 1 and ground. Verify Repairs
219.1.
[b] If resistance is greater than 5 , go to the next step.
5. Measure the resistance between pin 2 of the Water-in-Fuel sensor harness connector
and ground.
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the
Water-in-Fuel sensor harness connector and ground. Verify Repairs 219.1.

19.2 SPN 97/FMI 4
6. Measure the resistance between pin 3 of the Water-in-Fuel sensor harness connector
and ground.
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the
Water-in-Fuel sensor harness connector and ground. Verify Repairs 219.1.
[b] If resistance is greater than 5 , review the previous steps. If the results are the same,
contact Detroit Diesel Customer Support Center (313-592-5800).

19.3 SPN 97/FMI 15
This diagnostic is typically Water In Fuel

1. Open the mechanical drain valve on the fuel filter module to drain the water.
2. After the water has been drained, hand tighten the drain plug and prime the fuel filter
module via hand pump (approximately 50 times).
3. Clear the fault code, Start the engine and let the engine run for 3 minutes. Does the fault
become active?
[a] Yes; repeat steps 1 through step 3. If the fault code is still active, go to step 4.
[b] No; repair is complete. Verify repairs.
4. Disconnect the Water-In-Fuel sensor connector.

19.3 SPN 97/FMI 15
6. Inspect the sensor harness for bent, spread, or corroded pins.

[a] If the pins are bent, spread, or corroded, repair as necessary.
[b] If connector shows no signs of damage, go to step 7.
7. Measure the voltage between pin 1 and 3 on the harness side of the Water-In-Fuel sensor.
[a] If the voltage is greater than 11.5 volts, go to step 8.

8. Measure the voltage between pin 2 and 3 on the harness side of the Water-In-Fuel sensor.
[a] If the voltage is between 4.5 and 5 volts, replace the Water-In-Fuel sensor.
Refer to section 3.12.1.
[b] If the voltage is not between 4.5 volts and 5 volts, repair the wire between pin 2 of the
harness side of the Water-In-Fuel sensor and pin 57 of the MCM 120-pin connector.
9. Measure the voltage between pin 1 on the harness side of the Water-In-Fuel sensor and
engine ground.
[a] If the voltage is less than 11.5 volts, repair the wire between pin 1 of the harness side
of the Water-In-Fuel sensor and pin 71 of the MCM 120-pin connector
[b] If the voltage is greater than 11.5 volts, repair the wire between pin 3 of the harness
side of the Water-In-Fuel sensor and pin 67 of the MCM 120-pin connector.

19.3 SPN 97/FMI 15

20 SPN 100
Section Page
20.1 SPN 100/FMI 1 ......................................................................................... 20- 3

20.2 SPN 100/FMI 3 ......................................................................................... 20- 5
20.3 SPN 100/FMI 4 ......................................................................................... 20- 7
20.4 SPN 100/FMI 18 ....................................................................................... 20- 9
20.1 SPN 100/FMI 1
This diagnostic is typically low engine oil pressure.
Check as follows:
[a] If fault codes 100/1 and 100/3 are both active, Refer to section 20.2.
[b] If fault codes 100/1 and 100/4 are both active, Refer to section 20.3.
[c] If only fault code 100/1 is active, go to the next step.
2. Observe the stability of the oil pressure.
[a] If the oil pressure is in normal operating range and stable, go to the next step.
[b] If the oil pressure is fluctuating, go to step 4.
3. Check the oil level.
NOTE:
An increase in the engine oil level indicates fuel may be leaking into the engine oil.
[a] If the oil level is high, check for fuel entering into the engine oil system and repair as
required. Change the engine oil. Verify Repairs 219.1.
[b] If the engine oil level is low, fill oil to proper level. Verify Repairs 219.1.

20.1 SPN 100/FMI 1
4. Check the operation of the oil gage.

[a] If the oil gage readings are erratic, repair or replace the oil gage as
required.Verify Repairs 219.1.
[b] If the oil gage readings are fine, go to the next step.
5. Check the condition of the oil pump suction pipe.
[a] If the pipe is loose or cracked, replace a cracked pipe and reinstall a loose pipe.
Refer to section .
[b] If there is no problem with the oil pump suction pipe, go to the next step.
6. Check the condition of the oil pump drive and driven gears.
[a] If either gear is loose, repair or replace loose gears as required. Refer to section .
[b] If neither gear is loose, go to the next step.
7. Check for a faulty oil pressure relief valve.
[a] If the relief valve does not open at the set pressure or sticks open, repair or replace a
faulty oil pressure relief valve as required. Refer to section .
[b] If the oil pressure relief valve is fine, Verify Repairs 219.1.

20.2 SPN 100/FMI 3
This diagnostic is typically is an Engine Oil Pressure sensor circuit failed high.
Check as follows:
1. Turn the ignition ON (key On, engine OFF).
[a] If 100/3, 94/3 and 4407/3 are present repair the short to power between pin 82 of
the 120pin MCM connector and the Engine Oil, Doser Fuel Line and Doser Fuel
Compensation sensors. Verify Repairs 219.1.
[b] If only 100/3 is present, go to the next step.
3. Disconnect the Engine Oil Pressure sensor.
4. Measure the voltage between pin 3 of the EOP sensor harness connector and ground.
[a] If voltage is greater than 5 volts, repair the short to power between pin 82 of the
120pin MCM connector and pin 2 of the EOP sensor connector. Verify Repairs
219.1.
[b] If no voltage is present, go to the next step.

20.2 SPN 100/FMI 3
5. Measure the voltage between pin 2 of the EOP sensor harness connector and ground.
[a] If voltage is greater than 5 volts, repair the short to power between pin 105 of the
219.1.
[b] If no voltage is present, go to the next step.
6. Measure the voltage between pins 1 and 3 of the EOP sensor.
[a] If voltage is less than 5 volts, repair the open between pin 105 of the 120pin MCM
connector and pin 1 of the EOP sensor connector. Verify Repairs 219.1.
[b] If the voltage is between 4.5 and 5 volts, repair the open between pin 54 of the
219.1.

20.3 SPN 100/FMI 4
This diagnosis is typically an Engine Oil Pressure sensor circuit failed low.
Check as follows:
[a] If 100/4, 94/4, 4407/4, 3609/4 and 3610/4 are present, repair the short to ground
between pin 82 of the 120pin MCM and the Engine Oil, Doser Fuel Line, Doser Fuel
Compensation, DPF Inlet and DPF Outlet Pressure sensors. Verify Repairs 219.1.
[b] If 100/4, 94/4 and 4407/4 are present, repair the open between pin 82 of the 120pin
MCM connector and the Engine Oil, Doser Fuel Line and Doser Fuel Compensation
[c] If only 100/4 is present, go to the next step.
3. Disconnect the Engine Oil Pressure sensor.
4. Measure the voltage between pins 1 and 3 of the EOP sensor harness connector.
[a] If the voltage is less than 4.5 volts, repair the open between pin 82 of the 120pin
MCM connector and pin 3 of the EOP sensor harness connector. Verify Repairs 219.1.
[b] If the voltage is greater than 4.5 volts, go to the next step.
5. Turn the ignition OFF.

20.3 SPN 100/FMI 4
6. Measure the resistance between pin 2 of the EOP sensor harness connector and pin 54
of the 120pin MCM connector.
[a] If the resistance is less than 5 , repair the open between pin 2 of the EOP sensor
harness connector and pin 54 of the 120pin MCM connector. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , repair the short to ground between pin 2 of
the EOP sensor harness connector and pin 54 of the 120pin MCM connector.

20.4 SPN 100/FMI 18
This diagnosis is typically very low oil pressure.

Check as follows:
1. Check for additional active fault codes.
[a] If fault code 100/3 is active in addition to code 100/18, Refer to section 20.2.
[b] If fault code 100/4 is active in addition to code 100/18, Refer to section 20.3.
[c] If only fault code 100/18 is active, go to the next step.
2. Start engine and check oil pressure.
[a] If pressure is fluctuating, go to the next step.
[b] If pressure is low but stable, go to step 4.
3. Stop the engine and allow sufficient time for the oil to drain into the oil pan. Perform
the following steps:
[a] Check the oil level. Add recommended oil to bring it to the proper level, if required.
[b] Check for faulty oil gage. Replace, if required. Refer to OEM guidelines.
[c] Check for loose or cracked oil pump suction pipe. Repair or replace, as required.
Refer to section .
[d] Check for loose drive or driven oil pump gear. Repair or replace, as required.
Refer to section .
[e] Check for faulty oil pressure relief valve. Repair or replace, as required.
Refer to section .
[f] Verify Repairs 219.1.
4. Stop the engine and allow sufficient time for the oil to drain into the oil pan. Check the
oil level.
[a] If oil is above maximum level with no oil previously added, go to the next step.
[b] If oil is not above maximum level, contact Detroit Diesel Customer Support Center
(3135925800).
5. Check for possible fuel in oil.
[a] If fuel is found, locate and repair source of fuel leak. Change the Oil. Verify Repairs
219.1.
[b] If fuel is not found, contact Detroit Diesel Customer Support Center at 3135925800.

20.4 SPN 100/FMI 18

21 SPN 103
Section Page
21.1 SPN 103/FMI 0 ........................................................................................ 21- 3

21.2 SPN 103/FMI 1 ........................................................................................ 21- 4
21.3 SPN 103/FMI 4 ......................................................................................... 21- 5
21.1 SPN 103/FMI 0
This diagnosis is typically turbocharger speed below threshold (Low Box).
Check as follows:
1. Inspect the entire air intake system for leaks and/or restrictions.
[a] If leaks or restrictions are found, repair as necessary. Verify Repairs 219.1.
[b] If no air intake system leaks or restrictions are found, go to the next step.
2. Connect to DDDL 7.X
4. Perform the DDDL Turbocharger Hysteresis Test.
[a] If the test passed, replace the Turbocharger Speed sensor (TSS). Refer to section
3.10.1
[b] If the test failed, refer to the appropriate workshop manual for repairs.

21.2 SPN 103/FMI 1
21.2 SPN 103/FMI 1
This diagnosis is typically turbocharger speed below threshold (High Box).
Check as follows:
1. Inspect the entire air intake system for leaks and/or restrictions.
[a] If leaks or restrictions are found, repair as necessary. Verify Repairs 219.1.
[b] If no air intake system leaks or restrictions are found, go to the next step.
2. Connect to DDDL 7.X
4. Perform the DDDL Turbocharger Hysteresis Test.
[a] If the test passed, replace the Turbocharger Speed sensor (TSS). Refer to section
3.10.1
[b] If the test failed, refer to the appropriate workshop manual for repairs.

21.3 SPN 103/FMI 4
This diagnosis is typically circuit failed low.
Check follows:
1. Disconnect the Turbocharger Speed sensor (TSS).
2. Disconnect the 120pin MCM connector.
3. Measure the resistance across pins 1 and 2 of the TSS connector.
[a] If the resistance is less than 5 , repair the short between the 120pin MCM
connector wires 50 and 51. Verify Repairs 219.1.
4. Measure the resistance between pin 1 of the TSS harness connector and ground.
[a] If the resistance is less than 5 , repair the short between pin 1 of the TSS harness
5. Measure the resistance between pin 2 of the TSS harness connector and ground.
[a] If the resistance is less than 5 , repair the short between pin 2 of the TSS harness
[b] If the resistance is greater than 5 , verify repairs 219.1.

21.3 SPN 103/FMI 4

22 SPN 108 (MCM)
Section Page
22.1 SPN 108/FMI 3 ......................................................................................... 22- 3

22.2 SPN 108/FMI 4 ......................................................................................... 22- 4
22.3 SPN 108/FMI 13 ....................................................................................... 22- 5
22.1 SPN 108/FMI 3
This diagnosis is typically the Barometric Pressure sensor circuit failed low.
If SPN 108/FMI 3 is present contact the Detroit Diesel Customer Support Center at 3135925800.

22.2 SPN 108/FMI 4
22.2 SPN 108/FMI 4
This diagnosis is typically the Barometric Pressure sensor circuit failed high.
If SPN 108/FMI 4 is present contact the Detroit Diesel Customer Support Center at 3135925800.

22.3 SPN 108/FMI 13
This diagnostic is typically Ambient Air Pressure Signal Not Available via CAN.
1. Has the ACM/MCM/CPC been recently reprogrammed?
[a] Yes, clear faults codes if they do not become active release vehicle.
2. Turn the ignition OFF (key OFF, engine OFF) and disconnect DDDL/DDRS, Wait 5
minutes for all modules to power down.
3. Turn ignition ON (key ON, engine OFF).
4. Reconnect DDDL/DDRS, are fault codes active?
[a] Yes, follow entire 2010 CPC SPN 625 FMI 9 procedure for further PT CAN
troubleshooting. Refer to section 57.1.
[b] No, clear faults codes and release vehicle.

22.3 SPN 108/FMI 13

23 SPN 110 (EPA10)
Section Page
23.1 SPN 110/FMI 0 ......................................................................................... 23- 3

23.2 SPN 110/FMI 2 ......................................................................................... 23- 4
23.3 SPN 110/FMI 3 ......................................................................................... 23- 5
23.4 SPN 110/FMI 4 ......................................................................................... 23- 7
23.5 SPN 110/FMI 9 ......................................................................................... 23- 8
23.6 SPN 110/FMI 14 ....................................................................................... 23- 9
23.1 SPN 110/FMI 0
This diagnostic is typically coolant temperature high.

Check as follows:
[a] If any other fault codes are active in addition to 110/0, service those first.
[b] If only fault code 110/0 is active, go to next step.
2. Check for coolant loss.
3. Check for blockage in radiator and charge air cooler.
4. Check fan belt condition (slippage).
5. Check for proper location of fan shroud.
6. Check for proper radiator hose condition (no collapsed hoses).
7. Check for proper viscous fan operation.

23.2 SPN 110/FMI 2
23.2 SPN 110/FMI 2
This diagnostic is typically coolant outlet temperature not plausible.

1. Are any cooling system issues present?
[a] Yes, repair cooling system issues first.
2. Start engine and bring to operating temperature 185F (85C).
3. Does engine reach operating temperature 85F (85C)?
[b] No, service cooling system thermostat
4. Shut engine OFF (key OFF, engine OFF).
5. Disconnect inlet and outlet coolant sensors.
6. Inspect inlet and outlet coolant sensors harness connectors for bent, spread or corroded
pins.
[a] If pin damage is found, repair as necessary.
[b] If no pin damage is found go to step 7.
7. Check coolant sensor resistance, refer to chart for specifications, replace sensor which
is out of range.
Resistance
Resistance Resistance Nominal Voltage Voltage
Temp (C) Temp (F) ()
Low () High () Voltage (V) Low (V) High (V)
Nominal
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95
Table 23-1 Coolant Sensor Resistance Chart

23.3 SPN 110/FMI 3
This diagnostic is typically the engine coolant outlet temperature circuit has failed high.
Check as follows:
[a] If 110/3, 174/3, 175/3 and 4076/3 are present, go to step 6.
2. Disconnect the Engine Coolant Outlet Temperature sensor.
3. Turn the ignition On (key ON, engine OFF).
4. Measure the voltage between pins 1 and 2 of the Engine Coolant Outlet Temperature
sensor harness connector.
[a] If the voltage is between 2.8 and 3 volts, replace the Engine Coolant Outlet
Temperature sensor. Refer to section 3.17.1.

23.3 SPN 110/FMI 3
5. Measure voltage between pin 2 of the Engine Coolant Outlet Temperature sensor and
ground.
[a] If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the Engine
Coolant Outlet Temperature sensor connector and pin 55 of the MCM 120pin
[b] If the voltage is less than 2.8 volts, repair the wire between pin 2 of the Engine
Coolant Outlet Temperature sensor connector and pin 110 of the MCM 120pin
6. Measure the voltage between pins 1 and 2 of the Engine Coolant Outlet Temperature
sensor harness connector.
[a] If the voltage is greater than 3 volts, repair the short to power on one of the following
MCM pins: 77, 80, 108 or 110. Verify Repairs 219.1.
[b] If no voltage is present, repair the open between pin 55 of the MCM 120pin
connector and the Coolant Out, Coolant In, Engine Oil and supply fuel temperature

23.4 SPN 110/FMI 4
The code is typically the engine coolant outlet temperature circuit failed low.
Repair the short to ground between pin 2 of the Engine Coolant Outlet sensor harness connector
and pin 110 of the MCM 120pin connector. Verify Repairs 219.1.

23.5 SPN 110/FMI 9
23.5 SPN 110/FMI 9
This diagnostic is typically coolant temperature signal not available via CAN.

23.6 SPN 110/FMI 14
This diagnostic is typically Coolant Temperature / Engine Oil Temperature Plausibility Fault.
2. Check engine oil level, if low fill as necessary.
3. Start engine and bring to operating temperature to 185F (85C).
[b] No, service cooling system thermostat.
6. Disconnect coolant outlet and oil temperature sensors.
7. Inspect the coolant outlet and oil temperature sensor harness connectors for bent, spread or
corroded pins.
8. Check coolant outlet and oil temperature sensor resistances, refer to chart for
specifications, replace sensor which is out of range.
Resistance
Nominal
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95

23.6 SPN 110/FMI 14

24 SPN 111 (CPC)
Section Page
24.1 SPN 111/FMI 1 ......................................................................................... 24- 3

24.2 SPN 111/FMI 3 ......................................................................................... 24- 5
24.3 SPN 111/FMI 4 ......................................................................................... 24- 7
24.1 SPN 111/FMI 1
This diagnosis typically coolant level low.
Check as follows:
1. Turn the vehicle ignition switch ON (key On, engine OFF).
[a] If other faults are active in addition to fault 111/1, troubleshoot the other faults first.

24.1 SPN 111/FMI 1
3. Check the coolant level in the reservoir.

[a] If the coolant level in the reservoir is not within limit, go to the next step.
[b] If the coolant level in the reservoir is within limit, replace the sensor. Refer to section
3.19.
4. Check for coolant leak at cylinder head gasket.

5. Check for coolant leak at air compressor head gasket.
6. Check for external coolant leak at hose connections.
7. Check for coolant in oil.
8. Check for loose or faulty radiator cap.
9. When these checks and subsequent repairs are finished. Verify Repairs 219.1.

24.2 SPN 111/FMI 3
This diagnostic is typically a circuit failed high.
Check as follows:
2. Disconnect the Engine Coolant Level (ECL) sensor.
3. Measure the resistance between pin 1 and 2 of the ECL sensor.
[a] If the resistance is greater than 600 k (submerged) or open, replace ECL sensor.
Refer to section 3.19
[b] If the resistance is less than 600 k, go to the next step.

24.2 SPN 111/FMI 3

5. Measure the voltage between pins 1 and 2 of the ECL sensor harness connector.
6. Measure the voltage between pin 1 of the ECL sensor harness connector and ground.
[a] If the voltage is greater than 2.75 volts, repair the open between pin 2 of the CPC #3
connector and the ECL sensor harness. Verify Repairs 219.1.
[b] If the voltage is less than 2.75 volts, repair the open between pin 11 of the CPC #3
connector and the ECL sensor harness. Verify Repairs 219.1.
8. Measure the resistance between pins 1 and 2 of the ECL sensor harness connector.
[a] If the resistance is less than 5 , repair the short between the ECL sensor harness
connector pins 1 and 2 and pins 2 and 11 of the CPC #3 connector. Verify Repairs
219.1.
[b] If the resistance is greater than 5 , review the steps already taken. If the results are
the same, call the Detroit Diesel Customer Support Center (3135925800).

24.3 SPN 111/FMI 4
This diagnostic is typically a circuit failed low.
Check as follows:
2. Read the diagnostic codes displayed.
3. Disconnect the ECL sensor.
4. Disconnect the CPC #3 connector (21-pin).

24.3 SPN 111/FMI 4
5. Measure the resistance across pins 1 and 2 of the ECL sensor connector.
[a] If the resistance is less than 5 , repair the short between the wires 2 and 11 of the
CPC #3 connector. Verify Repairs 219.1.
6. Measure the resistance between pin 1 of the ECL sensor harness connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin 1 of the ECL
sensor harness connector and ground. Verify Repairs 219.1.
7. Measure the resistance between pin 2 of the ECL sensor harness connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin 2 of the ECL
sensor harness connector and ground. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , review the steps already taken.. If the results are
the same, call the Detroit Diesel Customer Support Center (3135925800).

25 SPN 132
Section Page
25.1 SPN 132/FMI 1 ......................................................................................... 25- 3

25.1 SPN 132/FMI 1
This diagnostic is typically means the air mass flow is too low.
Check as follows:
[a] If any other fault codes are present, repair them first.
2. Perform pressure check/visual inspection of the following and repair as necessary.
Plugged inlet air filters
Charge air cooler leaks
Leaking intake manifold
Exhaust leaks/plugging

25.1 SPN 132/FMI 1

26 SPN 157
Section Page
26.1 SPN 157/FMI 2 ......................................................................................... 26- 3

26.1 SPN 157/FMI 2
This diagnostic is typically an erratic fuel rail pressure sensor signal.
Check as follows:
NOTE:
Step 7 of this procedure (PLV counter) must be verified.
1. Disconnect the fuel rail pressure sensor.

2. Inspect the fuel rail pressure sensor harness connector for loose, bent, spread or corroded
pins.
[b] If no connector damage is found, go to the next step.
3. Disconnect the MCM 120pin connector.
4. Inspect pins 58, 78, and 102 for bent, spread or corroded pins.
[b] If no connector damage is found, go to the next step.
5. Connect DDDL 7.X.

26.1 SPN 157/FMI 2
7. Under the Actions drop down menu, select PLV Change. On the PLV Change screen
select Read Accumulator.
[a] If the PLV counter is greater than 50, the PLV must be replaced. Refer to section
. After PLV replacement, reset the PLV accumulator value via the Reset
Accumulator button. Refer to section
[b] If the PLV counter is less than 50, troubleshooting is complete.

27 SPN 157 (MCM) (EPA10)
Section Page
27.1 SPN 157/FMI 16 ....................................................................................... 27- 3

27.1 SPN 157/FMI 16
This diagnostic is typically fuel rail pressure low.

External fuel leakage between the high pressure pump and fuel injectors
Fuel injector (amplifier or needle) leakage
Pressure limiting valve leakage (internal)
Fuel filter integrity (loose caps, plugged filters)
Fuel supply issues (fuel level, fuel aeration)
Intermittent loss of engine speed signal
Check as follows:
1. Did 157/16 code appear after the fuel system was repaired or filter maintenance was
performed?
[a] If YES, the code may be set due to air in the fuel system clear codes.
[b] If NO, go to next step.
3. Check fuel level.
[a] If fuel level is low, correct and road test vehicle.
[b] If no leakage was found, go to next step.
4. Using DDDL 7.X, check for multiple codes.
[a] If additional fault codes (with the exception of DPF codes) are present along with
157/16, service the additional fault codes first.
[b] If only 157/16 is present, go to next step.
5. Using DDDL 7.X check the value of Pressure Limiting Valve (PLV) openings
(E2P_RPG_CTR_PLV_OPEN) under Extended Data Record Number 5th list.
[a] If counter is greater than 50, replace PLV and road test vehicle. Refer to section .
[b] If counter is less than 50, go to next step.
6. Using DDDL 7.X monitor engine speed and KW/NW validity signal in chart form ranging
from idle to 1800 RPM.
[a] If engine speed and signal are stable and accurate, go to step 8.
[b] If engine speed and signal are unstable or erratic, go to the next step.

27.1 SPN 157/FMI 16
7. Check the following conditions:

[a] Check for external damage to Crankshaft Position sensor. Repair if necessary.
[b] Check for bent or spread pins on the Crankshaft Position sensor. Repair if necessary.
[c] Remove Crankshaft Position sensor and inspect sensor for damage or rubbing.
Repair if necessary.
[d] Check flywheel teeth for debris or damage. Repair if necessary.
[e] Check the cam timing. Repair if necessary.
[f] If no repairs are necessary, go to the next step.
8. Perform Low Pressure Fuel System Pressure Test. Refer to4.3
9. Inspect fuel system for leaks. Refer to4.1
10. Perform diagnosis on pumping elements.
11. Perform Aeration Fuel Test. Refer to section 4.4.
12. Perform the Rail Pressure Bleed Off (RPBO) test using DDDL. Refer to section 4.7.2.
[a] If the RPBO Test failed; go to next step.
[b] If the RPBO Test passed, fault condition may be intermittent..
13. Perform PLV Leakage Test. Refer to section.
[a] If the PLV Leakage Test passed; go to next step.
[b] If the PLV Leakage Test failed; replace pressure limiting valve. Refer to section .
14. Perform Amplifier/Needle Return Flow Test and measurements. Refer to section 4.5.
[a] If the Amplifier/Needle Return Flow Test passes, clear the code and run the
engine. If the code reappears, call the Detroit Diesel Customer Support Center
at 3135925800.
[b] If the Amplifier/Needle Return Flow Test fails, fix as necessary. Go to Verify
Repairs.

28 SPN 158
Section Page
28.1 SPN 158/FMI 2 ......................................................................................... 28- 3

28.1 SPN 158/FMI 2
This diagnostic is typically Ignition Switch Not Plausible.

1. If SPN 158/FMI 2 is active, go to step 3.
2. If SPN 158/FMI 2 is inactive, clear the fault code, cycle ignition switch and start the
engine.
[a] If SPN 158/FMI 2 does not reactivate within 10 seconds, release the truck back
to service.
[b] If SPN 158/FMI 2 is active, go to step 3.
4. Turn the Ignition ON, (key ON, engine OFF).
5. Measure the voltage between the MCM 21-pin connector, pin-7 and ground.
[b] If the voltage is less than 11.5 volts, repair the cause of the low/no voltage to the pin 7.
6. Turn the Ignition OFF (key OFF, engine OFF).
7. Disconnect the CPC connector #2.
8. Turn the Ignition ON (key ON, engine OFF).
9. Measure the voltage between the CPC connector #2, pin-3 and ground.
[a] If the voltage is greater than 11.5 volts, and fault is still active, repeat the
entire procedure and note results, then contact the Customer Support Center at
313-592-5800 for further diagnostic assistance.
[b] If the voltage is less than 11.5 volts, repair the cause of the low/no voltage to the
CPC connector #2, pin 3.

28.1 SPN 158/FMI 2

29 SPN 158 (EPA10)
Section Page
29.1 SPN 158/FMI 7 ......................................................................................... 29- 3

29.1 SPN 158/FMI 7
Fault sets if battery power is disconnected before Aftertreatment Control Module (ACM) has
completed the Diesel Exhaust Fluid (DEF) key off purge cycle. This is a silent fault (no dash
lamps).
1. Connect DDDL/DDRS 7.05 or higher.
2. Start the engine and idle for 1 minute.
3. Turn the ignition OFF (key OFF, engine OFF) and wait 5 minutes for purge cycle to
complete.
4. Turn ignition back ON (key ON, engine OFF), clear fault and release vehicle.

29.1 SPN 158/FMI 7

30 SPN 164
Section Page
30.1 SPN 164/FMI 0 ......................................................................................... 30- 3

30.2 SPN 164/FMI 1 ......................................................................................... 30- 5
30.3 SPN 164/FMI 2 ......................................................................................... 30- 6
30.4 SPN 164/FMI 3 ......................................................................................... 30- 8
30.5 SPN 164/FMI 4 ......................................................................................... 30-10
30.6 SPN 164/FMI 5 ......................................................................................... 30-12
30.7 SPN 164/FMI 7 ......................................................................................... 30-13
30.8 SPN 164/FMI 20 ....................................................................................... 30-14
30.9 SPN 164/FMI 21 ....................................................................................... 30-16
30.1 SPN 164/FMI 0
This diagnostic is typically a Quantity Control Valve High Side driver error. This condition
can occur when:
MCM pin 1 circuit is shorted to ground
Internal short of the Quantity Control Valve
Check as follows:
1. Check for multiple codes
[a] If 164/1 is stored along with 164/0, service 164/1 first.
[b] If only 164/0 is active, go to the next step.
2. Disconnect the Quantity Control Valve harness connector.
3. Ensure the multi meter (DVOM) resistance is zero.
[a] If meter can auto zero, perform this function before making a resistance measurement.
[b] If meter can not auto zero, note the resistance of the leads and subtract it from the
measurement taken in step 4
4. Measure the resistance across pins 1 and 2 of the Quantity Control Valve.
[a] If the resistance is less than 1.3 , replace Quantity Control Valve. Refer to section .
[b] If the resistance is between 1.3 and 1.4 , go to next step.
5. Disconnect the 120-pin MCM connector and check for corroded, bent or broken pins.
Ensure both the MCM and harness connector pins are checked. Repair or replace if needed.

30.1 SPN 164/FMI 0
6. Measure the resistance between pin 1 of the Quantity Control Valve harness connector
and ground.
[a] If the resistance is greater than 5 , replace Quantity Control Valve. Refer to section .
[b] If the resistance is less than 5 , repair the short circuit between pin 1 of the Quantity
Control Valve and ground. Verify Repairs 219.1.

30.2 SPN 164/FMI 1
This diagnostic is typically a Quantity Control Valve Low Side driver error. This condition
can occur when:
MCM pin 2 circuit is shorted to power
Internal short of the Quantity Control Valve
Check as follows:
1. Disconnect the Quantity Control Valve harness connector.
2. Ensure the multi meter (DVOM) resistance is zero.
[a] If meter can auto zero, perform this function before making a resistance measurement
[b] If meter can not auto zero, note the resistance of the leads and subtract it from the
measurement taken in step 3
3. Measure the resistance across pins 1 and 2 of the Quantity Control Valve.
[a] If the resistance is less than 1.3 , replace Quantity Control Valve. Refer to section .
[b] If the resistance is between 1.3 and 1.4 , go to the next step.
4. Disconnect the 120-pin MCM connector and check for corroded, bent or broken pins.
Ensure both the MCM and harness connector pins are checked. Repair or replace if needed
5. Turn ignition ON.
6. Measure the voltage at pin 2 of the Quantity Control Valve harness connector.
[a] If the voltage is 0, replace the MCM. Refer to section 2.3.
[b] If the voltage is greater than 0, repair the short circuit between pin 2 of the Quantity
Control Valve harness connector and battery. Verify Repairs 219.1.

30.3 SPN 164/FMI 2
30.3 SPN 164/FMI 2
This diagnostic is typically related to a signal drift condition with the fuel rail pressure sensor.
Check as follows
[a] If additional fault codes are present with 164/2, service the additional fault codes first.
[b] If only 164/2 is present go to the next step.
2. Using the DDEC VI break out box, monitor fuel rail pressure sensor voltage.
4. Measure the voltage on pin 78 of the 120pin breakout box.
[a] If the voltage is greater than or equal to 0.580 volts, replace fuel rail pressure sensor.
[b] If the voltage is less than or equal to 0.420 volts; replace fuel rail pressure sensor.
[c] If the voltage is between .420 and .580 volts, go to next step.
5. Start the engine and bring it up to operating temperature (over 140F/60C).
6. Turn the engine OFF and allow engine to soak for 10 minutes.

7. Turn the ignition ON (key ON, engine OFF) and measure the voltage on pin 78 of the
120pin breakout box.
[c] If the voltage is between .420 and .580 volts, there is no problem.

30.4 SPN 164/FMI 3
30.4 SPN 164/FMI 3
This diagnostic is typically the fuel rail pressure sensor circuit failed high (open circuit).
Check as follows:
[a] If faults for the intake manifold pressure/Temperature sensor are active at the same
time, repair the circuit between pin 58 or pin 102 of the MCM 120-pin Connector and
pin 2 or pin 4 of the intake manifold pressure/Temperature sensor. Refer to section
3.5.1.
2. Disconnect the fuel rail pressure sensor connector.
3. Measure the resistance across pins 1 and 2 of the fuel rail pressure sensor.
[a] If the resistance is greater than 4.7 k , replace fuel rail pressure sensor.
Refer to section 3.8.1
[b] If the resistance is less than 4.7 k , go to the next step.
5. Measure the voltage between pins 1 and 3 of the fuel rail pressure sensor harness connector.

6. Measure the voltage between pin 3 of the fuel rail pressure sensor harness connector
and ground.
[a] If the voltage is between 2.75 and 3.25 volts, repair the open circuit between pin 1
of the fuel rail pressure sensor harness connector and pin 102 of the 120-pin MCM
[b] If the voltage is less than 2.75 volts, repair the open circuit between pin 3 of the fuel
rail pressure sensor harness connector and pin 58 of the MCM 120-pin connector.
7. Disconnect the 120-pin MCM connector and measure the resistance between pin 78 of the
MCM 120pin connector and pin 2 of the fuel rail pressure sensor harness connector.
[a] If the resistance is less than 5 , repair the short between pin 2 of the fuel rail
pressure sensor harness connector and pin 78 of the MCM 120-pin connector.
[b] If the resistance is greater than 5 , replace the intake manifold pressure/Temperature
sensor. Refer to section 3.5.1.

30.5 SPN 164/FMI 4
30.5 SPN 164/FMI 4
This diagnostic is typically a fuel rail pressure sensor Circuit Failed Low (short to ground).
Check as follows:
[a] If faults for the intake manifold pressure/Temperature sensor are active at the same
time, repair the circuits between pin 58 or pin 102 of the MCM 120-pin Connector
and pin 2 or pin 4 of the intake manifold pressure/Temperature sensor. Verify Repairs
219.1.
4. Measure the resistance of pin 1 of the fuel rail pressure sensor connector and ground.
[a] If resistance is less than 5 , repair short between pin 102 of the 120-pin MCM
5. Measure the resistance between pin 2 of the fuel rail pressure sensor harness connector
and ground.
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the fuel rail
pressure sensor harness connector and ground. Verify Repairs 219.1.

6. Measure the resistance between pin 3 of the fuel rail pressure sensor harness connector
and ground.
[a] If resistance is less than 5 , repair the short circuit between pin 3 of the fuel rail
pressure sensor harness connector and ground. Verify Repairs 219.1.
[b] If resistance is greater than 5 , review steps 4 through 6. If the results are the same,
contact Detroit Diesel Customer Support Center (313-592-5800).

30.6 SPN 164/FMI 5
30.6 SPN 164/FMI 5
This diagnostic is typically fuel rail pressure sensor circuit open or a stuck in range sensor.
Check as follows:
5. Check for 5 volt supply at pin 3 of the fuel rail pressure sensor.
[a] If voltage is correct, replace the fuel rail pressure sensor. Refer to section 3.8.1.
[b] If no voltage was found, repair the circuit between pin 3 of the fuel rail pressure
sensor and pin 58 of the MCM 120pin connector. Verify Repairs 219.1.

30.7 SPN 164/FMI 7
This diagnostic is typically high pressure pump leakage or the TDC position is wrong (MU341).
This diagnostic is typically related to a pump that is out of time by +/- 6 degrees or high pressure
pump plunger failure. The MCM monitors rail pressure rise and timing then compares it to a
calibrated value.

30.8 SPN 164/FMI 20
30.8 SPN 164/FMI 20
This diagnostic is typically rail pressure sensor drift high
Check as follows
[a] If additional fault codes are present with 164/20, service the additional fault codes
first.


30.9 SPN 164/FMI 21
30.9 SPN 164/FMI 21
This diagnostic is typically related to a signal drift condition with the fuel rail pressure sensor.
Check as follows
first.


30.9 SPN 164/FMI 21

31 SPN 168 (EPA07)
Section Page
31.1 SPN 168/FMI 0 ......................................................................................... 31- 3

31.2 SPN 168/FMI 1 ......................................................................................... 31- 4
31.3 SPN 168/FMI 14 (CPC) ............................................................................ 31- 6
31.1 SPN 168/FMI 0
This diagnosis is typically battery voltage high.

Check as follows:
1. Measure battery voltage with the engine running at maximum rpm.
2. If greater than 16 volts, check for proper alternator operation and repair or replace, as
required. Verify Repairs 219.1.

31.2 SPN 168/FMI 1
31.2 SPN 168/FMI 1
This diagnosis is typically battery voltage low.
Check as follows:
1. Check the condition of the alternator drive belt and replace, if required.
[a] If fault is no longer active. Verify Repairs 219.1.
[b] If fault is still active, go to next step.
2. Check for loose alternator mounting and retighten or repair, as required.

3. Check for proper alternator operation and repair or replace, as required.

[a] If fault is no longer active, erase fault code memory.
4. Check the condition of the battery (does it hold the charge?) Replace if required.
5. Measure the resistance of the individual wires in the ground circuit (MCM 21/5, 21/6,
21/8, 21/9 and CPC 2/2).
[a] If resistance is greater than 0.5 in any wire, repair or replace the wire and
connector.Verify Repairs 219.1.
[b] If resistance is less than 0.5 in all wires, go to next step.
6. Measure the resistance of the individual wires in the power circuit (MCM 21/11, 21/12,
21/14, 21/15 and CPC 2/1) with the engine running and battery voltage greater than 12.5 V.
[a] If resistance is greater than 0.5 in any wire, repair or replace the power circuit
wires and connector. Verify Repairs 219.1.
[b] If resistance is less than 0.5 in any wire, go to next step.
7. Measure the current drop of the individual wires in the ground circuit (MCM 21/5, 21/6,
21/8, 21/9 and CPC 2/2).
[a] If the current drop is more than 0.2 volts in any wire, repair or replace the ground
circuit wires and connector. Verify Repairs 219.1.
[b] If the current drop is less than 0.2 volts in any wire, go to next step.
8. Measure the current drop of the individual wires in the power circuit (MCM 21/11, 21/12,
21/14, 21/15 and CPC 2/1).
[a] If the current drop is more than 0.2 volts in any wire, repair or replace the power
circuit wires and connector. Verify Repairs 219.1.
[b] If the current drop is more than 0.2 volts in any wire. Verify Repairs 219.1.

31.3 SPN 168/FMI 14 (CPC)
31.3 SPN 168/FMI 14 (CPC)
This diagnosis is typically ECU power down not completed (main battery terminal possibly
floating).
NOTE:
If vehicle is equipped with a battery disconnect switch, it must also be inspected for
proper connections.
This fault indicates the loss of battery voltage to pin 1 of the CPC #2 connector. To restore
battery voltage to pin 1 of the CPC #2 connector, refer to OEM literature for the vehicle power
distribution schematics.

32 SPN 168 (EPA10)
Section Page
32.1 SPN 168/FMI 1 ......................................................................................... 32- 3

32.1 SPN 168/FMI 1
This diagnosis is typically ACM battery voltage low.

1. Measure battery voltage with the engine running at maximum rpm.
[a] If less than 11.5 volts, check for proper alternator operation and repair or replace, as
required
[b] If voltage is between 13.5 and 16 volts, go to step 2.
2. Disconnect the ACM 21-pin connector.
4. Measure the voltage between ACM 21-pin connector pins 11, 12, 14, 15 and 18 (battery
voltage) and ground.
[a] If the voltage is less than 11.5 volts, restore voltage to ACM 21-pin connector pins
11, 12, 14, 15 and 18
[b] If voltage is greater than 11.5, restore ground connection to ACM 21-pin connector
pins 3, 5, 6 and 9

32.1 SPN 168/FMI 1

33 SPN 171 (CPC) (EPA07)
Section Page
33.1 SPN 171/FMI 3 ......................................................................................... 33- 3

33.2 SPN 171/FMI 4 ......................................................................................... 33- 4
33.3 SPN 171/FMI 9 ......................................................................................... 33- 5
33.4 SPN 171/FMI 14 ....................................................................................... 33- 6
33.1 SPN 171/FMI 3
This diagnostic is typically ambient air temperature circuit failed high. Call the Detroit Diesel

33.2 SPN 171/FMI 4
33.2 SPN 171/FMI 4
This diagnostic is typically ambient air temperature circuit failed low. Call the Detroit Diesel

33.3 SPN 171/FMI 9
This is typically J1587 Ambient Air Temperature sensor data stopped arriving. Call the Detroit
Diesel Customer Support Center at 3135925800.

33.4 SPN 171/FMI 14
33.4 SPN 171/FMI 14
This is typically J1587 Ambient Air Temperature sensor data not received this ignition cycle. Call
the Detroit Diesel Customer Support Center at 3135925800.

34 SPN 171 (ACM2) (EPA10)
Section Page
34.1 SPN 171/FMI 3 ......................................................................................... 34- 3

34.2 SPN 171/FMI 4 ......................................................................................... 34- 4
34.3 SPN 171/FMI 13 ....................................................................................... 34- 5
34.1 SPN 171/FMI 3
This diagnostic condition is typically ambient air temperature circuit failed high. Call the Detroit

34.2 SPN 171/FMI 4
34.2 SPN 171/FMI 4
This diagnostic condition is typically ambient air temperature circuit failed low. Call the Detroit

34.3 SPN 171/FMI 13
This diagnostic condition is typically Ambient Air Temperature Signal Not Available via CAN.
2. Turn the ignition OFF (key OFF, engine OFF) and disconnect DDDL/DDRS. Wait 5

34.3 SPN 171/FMI 13

35 SPN 174
Section Page
35.1 SPN 174/FMI 0 ......................................................................................... 35- 3

35.2 SPN 174/FMI 3 ......................................................................................... 35- 4
35.3 SPN 174/FMI 4 ......................................................................................... 35- 6
35.1 SPN 174/FMI 0
This diagnostic is typically the supply fuel temperature sensor (supply fuel temperature sensor)
high.
Check as follows:
2. Plug in the diagnostic tool and read the active codes.
[a] If fault 174/3 is active in addition to 174/0, Refer to section 35.2.
[b] If fault 174/4 is active in addition to 174/0, Refer to section 35.3.
[c] If fault 111/1 is active in addition to 174/0, Refer to section 24.1.
[d] If only fault code 174/0 is active, go to the next step and repair or replace, as required.
3. Check for coolant loss.
4. Check for blockage in radiator and charge air cooler.
5. Check fan belt condition (slippage).
6. Check for proper location of fan shroud.
7. Check for proper radiator hose condition (no collapsed hoses).
8. Check for proper viscous fan operation
9. Once checks and repairs are done. Verify Repairs 219.1.

35.2 SPN 174/FMI 3
35.2 SPN 174/FMI 3
This diagnostic is typically a indicates a supply fuel temperature sensor (supply fuel temperature
sensor) open circuit.
Check as follows:
[a] If faults 174/3, 175/3, and 4076/3 are active at the same time, repair the open
circuit between pin 55 of the MCM 120-pin connector and pin 1 of the supply fuel
temperature sensor, (or) pin 1 of the engine oil temperature sensor, (or) pin1 of
the engine coolant inlet temperature sensor, (or) pin 1 of the engine coolant outlet
temperature sensor. Verify Repairs 219.1.
2. Disconnect the supply fuel temperature sensor.
3. Measure the resistance across pins 1 and 2 of the supply fuel temperature sensor.
[a] If the resistance is greater than 2.2k , replace supply fuel temperature sensor.
[b] If the resistance is less than 2.2k , go to the next step.

5. Measure the voltage between pins 1 and 2 of the supply fuel temperature sensor harness
connector.
6. Measure the voltage between pin 2 of the supply fuel temperature sensor harness
connector and ground.
of the supply fuel temperature sensor harness connector and pin 55 of the MCM
[b] If the voltage is less than 2.75 volts, repair the open circuit between pin 2 of the
supply fuel temperature sensor harness connector and pin 77 of the 120-pin MCM
7. Disconnect the 120-pin MCM connector and measure the resistance between pins 1 and 2
of the supply fuel temperature sensor harness connector.
[a] If the resistance is less than 5 , repair the short between pins 55 and 77 of the MCM
[b] If the resistance is greater than 5 , replace supply fuel temperature sensor.

35.3 SPN 174/FMI 4
35.3 SPN 174/FMI 4
This diagnostic is typically a supply fuel temperature sensor short circuit to ground.
Check as follows:
1. Disconnect the supply fuel temperature sensor.
2. Disconnect the 120-pin MCM connector.
3. Measure the resistance across pins 1 and 2 of the supply fuel temperature sensor connector.
[a] If resistance is less than 5 , repair short between wires 55 and 77 of the 120-pin
MCM connector. Verify Repairs 219.1.
4. Measure the resistance between pin 1 of the supply fuel temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the supply fuel
temperature sensor harness connector and ground. Verify Repairs 219.1.
5. Measure the resistance between pin 2 of the supply fuel temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the supply fuel
[b] If resistance is greater than 5 , review steps 3 through step 5. If the results are the
same, contact Detroit Diesel Customer Support Center at 313-592-5800.

36 SPN 175
Section Page
36.1 SPN 175/FMI 3 ......................................................................................... 36- 3

36.2 SPN 175/FMI 4 ......................................................................................... 36- 5
36.3 SPN 175/FMI 14 ....................................................................................... 36- 6
36.1 SPN 175/FMI 3
This diagnosis is typically engine oil temperature circuit failed high.
Check as follows:
1. Turn the ignition the ON (key ON, engine OFF).
[a] If codes 110/3, 174/3, 175/3 and 3510/3 are active at the same time, go to the next
step.
[b] If only fault 175/3 is active, go to step 5.
3. Disconnect the fuel supply temperature sensor.
4. Measure the voltage between pin 1 of the supply fuel temperature sensor and ground.
[a] If the voltage is greater than 2.75 volts, repair the short to power between pin 55 of
the MCM 120pin connector and the engine coolant temperature sensor, the engine
oil temperature sensor and the supply fuel temperature sensor. Verify Repairs 219.1.
[b] If no voltage is present on pin 1 of the supply fuel temperature sensor, repair the open
between pin 55 of the MCM 120pin connector and the engine coolant temperature
sensor, the engine oil temperature sensor and the supply fuel temperature sensor.
5. Disconnect the engine oil temperature sensor.

36.1 SPN 175/FMI 3
6. Check the resistance across pins 1 and 2 of the engine oil temperature sensor.
[a] If the resistance is greater than 4 k, replace the engine oil temperature sensor.
[b] If he resistance is less than 4 k, go to the next step.
8. Measure the voltage between pins 1 and 2 of the engine oil temperature sensor harness
connector.
[a] If the voltage is between 2.75 and 3.24 volts. Verify Repairs 219.1.
9. Measure the voltage between pin 2 of the engine oil temperature sensor harness connector
and ground.
of the engine oil temperature sensor harness connector and pin 55 of the 120pin
MCM connector. Verify Repairs 219.1.
[b] If the voltage is less than 2.75 volts, repair the open circuit between pin 2of the
engine oil temperature sensor harness connector and pin 108 of the 120pin MCM

36.2 SPN 175/FMI 4
This diagnosis is typically oil temperature circuit failed low.
Check as follows:
2. Disconnect the 120pin connector at the MCM.
3. Measure the resistance across pins 1 and 2 of the engine oil temperature sensor harness
connector.
[a] If resistance is greater than 5 , go to the next step.
[b] If resistance is less than 5 , repair short to ground between pins 55 and 108 of the
120-pin MCM connector. Verify Repairs 219.1.
4. Measure the resistance between pin 2 of the engine oil temperature sensor harness
[a] If resistance is greater than 5 , repeat the previous steps. If the results are the same,
call the Detroit Diesel Customer Support Center (3135925800).
[b] If resistance is less than 5 , repair the short circuit between pin 2 of the engine oil

36.3 SPN 175/FMI 14
36.3 SPN 175/FMI 14
This diagnosis is typically engine oil temperature out of range (drifted low/high).
NOTE:
When diagnosing rationality erratic data faults (FMI 14) always refer to SILs or SIBs or
any known issues first.
Check as follows:
1. Check engine oil level. Add oil if needed and recheck for fault codes. If SPN 175/FMI 14
is still active, go to the next step.
3. Inspect the engine oil temperature sensor for bent, spread or corroded pins. If pin damage
is found, repair as necessary or replace the engine oil temperature. Refer to section 3.15.1.

37 SPN 175 (MCM) (EPA10)
Section Page
37.1 SPN 175/FMI 0 ......................................................................................... 37- 3

37.2 SPN 175/FMI 15 ....................................................................................... 37- 4
37.1 SPN 175/FMI 0
This diagnostic is typically Oil Temperature High - Warning

1. Check engine oil level.
[a] If low add appropriate oil to bring level to full mark.
[b] If oil level is within limits, go to step 2.
2. Inspect cooling system for leaks.
[a] If leaks are found, repair as necessary.
[b] If no leaks are found, go to step 3.
3. Check engine coolant fan operation.
[a] If fan does not function correctly, repair as necessary.
[b] If fan operation is OK, go to step 4.
4. Check coolant thermostat operation.
[a] If thermostat does not operate correctly, replace the engine coolant thermostat.
[b] If thermostat operates correctly, replace the oil temperature sensor

37.2 SPN 175/FMI 15
37.2 SPN 175/FMI 15
This diagnostic is typically Oil Temperature High Pre-Warning.

1. Check engine oil level.
[a] If low add appropriate oil to bring level to full mark.
[b] If oil level is within limits, go to step 2.
2. Inspect cooling system for leaks.
[a] If leaks are found, repair as necessary.
3. Check engine coolant fan operation.
[a] If fan does not function correctly, repair as necessary.
[b] If fan operation is OK, go to step 4.
4. Check coolant thermostat operation.
[a] If thermostat does not operate correctly, replace the engine coolant thermostat.
[b] If thermostat operates correctly, replace the oil temperature sensor.

38 SPN 188 (MCM) (EPA10)
Section Page
38.1 SPN 188/FMI 31 ....................................................................................... 38- 3

38.1 SPN 188/FMI 31
This diagnostic is typically idle speed is higher than targeted idle speed.
2. Are there any camshaft or crankshaft sensor faults present?
3. Are there any throttle pedal or idle validation switch faults present?
4. Perform idle speed balance test, Are any faulty fuel injectors identified?
[a] Yes, replace suspect fuel injector.
[b] No, obtain log file of engine at idle, extract all module parameters and contact the
Detroit Diesel Customer Support Center at 3135925800.

38.1 SPN 188/FMI 31

39 SPN 190 (EPA10)
Section Page
39.1 SPN 190/FMI 2 ......................................................................................... 39- 3

39.2 SPN 190/FMI 9 ......................................................................................... 39- 4
39.1 SPN 190/FMI 2
This diagnostic is typically an information code only. SPN 190/FMI 2 is active when the MCM
detects an engine speed greater than 2,500 rpm for a specific amount of time. The driver should
be questioned about vehicle driving conditions.

39.2 SPN 190/FMI 9
39.2 SPN 190/FMI 9
This diagnostic is typically Engine Speed Signal Not Available via CAN.

40 SPN 191 (CPC)
Section Page
40.1 SPN 191/FMI 9 ......................................................................................... 40- 3

40.2 SPN 191/FMI 13 ....................................................................................... 40- 4
40.3 SPN 191/FMI 19 ....................................................................................... 40- 5
40.1 SPN 191/FMI 9
This diagnostic is typically the J1939 ETC1 message is missing.

Check as follows:

40.2 SPN 191/FMI 13
40.2 SPN 191/FMI 13
This diagnostic is typically the transmission output speed shaft signal is missing.
Check as follows:

40.3 SPN 191/FMI 19
This diagnostic is typically the transmission output speed shaft signal is erratic.
Check as follows:

40.3 SPN 191/FMI 19

41 SPN 247 (CPC)
Section Page
41.1 SPN 247/FMI 0 ......................................................................................... 41- 3

41.2 SPN 247/FMI 1 ......................................................................................... 41- 4
41.3 SPN 247/FMI 9 ......................................................................................... 41- 5
41.1 SPN 247/FMI 0
This diagnostic is typically MCM engine hours data higher than expected This fault usually
occurs after reprogramming the CPC or MCM. The internal clocks of the CPC or MCM do not
match. After reprogramming either module, all fault codes must be cleared.
NOTE:
The CPC digital outputs have the same SPN as some MCM faults. DDDL 7.X makes the
distinction between the MCM and CPC when diagnosing a fault.

41.2 SPN 247/FMI 1
41.2 SPN 247/FMI 1
This diagnostic is typically MCM engine hours data lower than expected This fault usually
occurs after reprogramming the CPC or MCM. The internal clocks of the CPC or MCM do not
match. After reprogramming either module, all fault codes must be cleared.
NOTE:

41.3 SPN 247/FMI 9
This diagnostic is typically MCM engine hours data not received or stopped arriving This fault
usually occurs after reprogramming the CPC or MCM. The internal clocks of the CPC or MCM
do not match. After reprogramming either module, all fault codes must be cleared.
NOTE:

41.3 SPN 247/FMI 9

42 SPN 411 (EPA07)
Section Page
42.1 SPN 411/FMI 0 ......................................................................................... 42- 3

42.2 SPN 411/FMI 1 ......................................................................................... 42- 5
42.3 SPN 411/FMI 3 ......................................................................................... 42- 8
42.4 SPN 411/FMI 4 ......................................................................................... 42-11
42.5 SPN 411/FMI 13 ....................................................................................... 42-14
42.1 SPN 411/FMI 0
EGR differential pressure too high (Low Box)

This diagnostic is typically EGR delta P pressure is too high at low speeds and loads.
2. Using DDDL/DDRS monitor EGR Delta P voltage (pin 109).
3. Is the EGR Delta P voltage between 0.55 and 0.83 volts?
4. Remove the EGR Delta P sensor from the mounting pad, leave electrical harness
connected.
6. Inspect the EGR Delivery pipe Delta P pressure ports for blockage.
[a] If excessive build up or blockage is found, clean the venturi pipe and reinstall the
sensor, go to step 22.
7. Disconnect the EGR Delta P sensor harness connector.
8. Inspect the EGR Delta P sensor harness connector for loose, bent, spread or corroded pins.
[b] If no damage is found, go to step 9.
9. Inspect the EGR valve for physical damage (broken butterfly).
[a] If EGR valve is damaged, replace the EGR valve. For the DD15 ONLY:
Refer to section . For the DD13: Refer to section . Then Go to step 22.
11. Measure the resistance between pins 1 and 2 of the EGR Delta P sensor.
[a] If the resistance is greater than 5, go to next step 12.
[b] If the resistance is less than 5, repair the short between pins 103 and 117 of the
MCM 120pin connector. Go to step 22.
[a] If the resistance is greater than 5. Go to step 13.

42.1 SPN 411/FMI 0
13. Measure the resistance between pin 1 of the EGR Delta P sensor and ground.
[b] If the resistance is less than 3, repair the short circuit between pin 1 of the EGR
Delta P sensor harness connector and ground. Go to step 22.
[a] If the resistance is greater than 3, repeat the previous steps. If the results are the
same, call the Detroit Diesel Customer Support Center (3135925800).
[a] If the resistance is greater than 5, go to step 19.
same, replace the EGR Delta P sensor. Go to step 22.
22. What is the MCM software version?
[a] V11.4 or lower, reprogram the MCM to the latest software version.
[b] V13.2 or higher, repair is complete.

42.2 SPN 411/FMI 1
EGR differential pressure too low (high box)

This diagnostic is typically the EGR delta pressure is too low at high speeds and loads
connected.
6. Inspect the EGR delivery pipe delta P pressure ports for blockage.
sensor, go to step 24.
7. Remove EGR cooler hot pipe, EGR crossover pipe and delivery pipe and inspect for
excessive build up or blockage.
[a] If excessive build up or blockage is found, clean piping and replace EGR cooler. For
the DD13 only: refer to section For the DD15 only: refer to section . Go to step 24.
[b] If there is no excessive build up or blockage, go to step 8.
10. Visually inspect the EGR system for leaks, obstructions, loose clamps or damage.
[a] If damage is found, repair as necessary. Go to step 24.
Refer to section . For the DD13: Refer to section . Then go to step 24.

42.2 SPN 411/FMI 1

same, replace the EGR Delta P sensor refer to section 3.13.1. Go to step 24.
24. What is the MCM software version?
[a] V11.4 or lower, reprogram the MCM to the latest software version.
[b] V13.2 or higher, repair is complete.

42.3 SPN 411/FMI 3
42.3 SPN 411/FMI 3
This diagnosis is typically EGR Delta P sensor circuit failed high.

connected.
sensor.
[b] If no blockage is found, go to step 7..


MCM 120pin connector.
Delta P sensor harness connector and ground.

42.3 SPN 411/FMI 3
same, replace the EGR Delta P sensor. Refer to section 3.13.1.

42.4 SPN 411/FMI 4
This diagnosis is typically EGR Delta P sensor short to ground.

connected.
sensor.

42.4 SPN 411/FMI 4



42.5 SPN 411/FMI 13
42.5 SPN 411/FMI 13
This diagnosis is typically EGR Delta P sensor out of calibration.

connected.
sensor.



42.5 SPN 411/FMI 13

43 SPN 411 (MCM2) (EPA10)
Section Page
43.1 SPN 411/FMI 0 ......................................................................................... 43- 3

43.2 SPN 411/FMI 1 ......................................................................................... 43- 5
43.3 SPN 411/FMI 2 ......................................................................................... 43- 8
43.4 SPN 411/FMI 3 ......................................................................................... 43-11
43.5 SPN 411/FMI 4 ......................................................................................... 43-13
43.1 SPN 411/FMI 0
This diagnosis is typically the EGR delta pressure is too high at low speeds and loads.
connected.
[a] If excessive build up or blockage is found, clean the venture pipe and reinstall the
sensor.
10. Disconnect the MCM2 120pin connector.
MCM2 120pin connector.

43.1 SPN 411/FMI 0

43.2 SPN 411/FMI 1
This code is typically the EGR delta pressure is too low at high speeds and loads
connected.
6. Inspect the EGR delivery pipe delta P pressure ports for blockage.
sensor.
DD13 only: refer to section . For DD15 only: refer to section .
10. Visually inspect the EGR system for leaks, obstructions, loose clamps or damage.
[a] If damage is found, repair as necessary.

43.2 SPN 411/FMI 1


43.3 SPN 411/FMI 2
43.3 SPN 411/FMI 2
This diagnosis is typically a EPA10 EGR Delta P sensor is out of calibration.

connected.
sensor.



43.3 SPN 411/FMI 2

43.4 SPN 411/FMI 3
This diagnosis is typically EGR Delta P sensor circuit failed high.

connected.
[a] If excessive build up or blockage is found, clean the venture pipe and reinstall the
sensor.

43.4 SPN 411/FMI 3

43.5 SPN 411/FMI 4
This diagnosis is typically EGR Delta P sensor short to ground.

connected.
sensor

43.5 SPN 411/FMI 4

44 SPN 513 (ACM2) (EPA10)
Section Page
44.1 SPN 513/FMI 9 ......................................................................................... 44- 3

44.1 SPN 513/FMI 9
This diagnostic condition is typically Actual Torque Signal Not Available via CAN

44.1 SPN 513/FMI 9

45 SPN 523 (CPC)
Section Page
45.1 SPN 523/FMI 19 ....................................................................................... 45- 3

45.2 SPN 523/FMI 13 ....................................................................................... 45- 4
45.1 SPN 523/FMI 19
This diagnostic is typically the transmission current gear signal is erratic.

Check as follows:

45.2 SPN 523/FMI 13
45.2 SPN 523/FMI 13
This diagnostic is typically the transmission current gear signal is missing.

Check as follows:

46 SPN 524 (CPC)
Section Page
46.1 SPN 524/FMI 9 ......................................................................................... 46- 3

46.1 SPN 524/FMI 9

Check as follows:

46.1 SPN 524/FMI 9

47 SPN 527 (CPC)
Section Page
47.1 SPN 527/FMI 9 ......................................................................................... 47- 3

47.1 SPN 527/FMI 9
This diagnostic is typically the J1939 CCVS message from Source #1, #2, or #3 is missing.
Check as follows:

47.1 SPN 527/FMI 9

48 SPN 558 (CPC)
Section Page
48.1 SPN 558/FMI 1 ......................................................................................... 48- 3

48.2 SPN 558/FMI 3 ......................................................................................... 48- 4
48.3 SPN 558/FMI 4 ......................................................................................... 48- 5
48.1 SPN 558/FMI 1
This fault is a typically incorrect wiring of the Idle Validation Switch (IVS).
Check as follows:
1. Connect the diagnostic tool
3. Monitor IVS #1 and IVS #2 with the throttle pedal in the idle position.
4. If IVS #1 reads OFF and IVS #2 reads ON, verify the proper wire pin outs.
IVS #1 should be routed from Idle Validation Switch pin 5 to pin 6 of the CPC #1
connector.
IVS #2 should be routed from Validation Switch pin 6 to pin 3 of the CPC #1 connector.
5. If wiring checks OK, contact the Detroit Diesel Customer Support Center (3135925800).

48.2 SPN 558/FMI 3
48.2 SPN 558/FMI 3
This diagnostic is typically an open circuit.

Check as follows:
1. Disconnect the Idle Validation Switch.
3. Measure the voltage between the Idle Validation Switch pins 4 and 6.
4. Measure the voltage between the Idle Validation Switch pin 4 and ground.
[a] If the voltage is greater than 11.5 volts, go to the next step.
[b] If the voltage is less than 11.5 volts, repair the open wire between pin 6 of the CPC
#1 connector and pin 4 of the Idle Validation Switch. Verify Repairs 219.1.
6. Measure the resistance between pin 2 of the CPC #2 connector and pin 6 of the Idle
Validation Switch.
[a] If the resistance is greater than 5, repair the open the wire between pin 2 of the CPC
#2 connector and pin 6 of the Idle Validation Switch. Verify Repairs 219.1.
[b] If the resistance is less than 5, replace the Idle Validation Switch. Verify Repairs
219.1.
7. Measure the voltage between the Idle Validation Switch pins 5 and 6.
[a] If the voltage is greater than 11.5 volts, replace the Idle Validation Switch.
[b] If the voltage is less than 11.5 volts, repair the open the wire between pin 3 of the
CPC #1 connector and pin 5 of the Idle Validation Switch. Verify Repairs 219.1.

48.3 SPN 558/FMI 4
This diagnostic is typically either a short to ground or an open wire.

Check as follows:
1. Disconnect the Idle Validation Switch.

3. Measure the resistance between pin 4 of the Idle Validation Switch connector and ground.
[a] If the resistance is less than 5 , repair the short to ground between pin 6 of the CPC
#1 connector and pin 4 of the Idle Validation Switch connector. Verify Repairs 219.1.
4. Measure the resistance between pin 5 of the Idle Validation Switch connector and ground.
[a] If the resistance is less than 5 , repair the short to ground between pin 3 of the CPC
#1 connector and pin 5 of the Idle Validation Switch connector. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , replace the Idle Validation Switch. Verify Repairs
219.1.

48.3 SPN 558/FMI 4

49 SPN 596 (CPC)
Section Page
49.1 SPN 596/FMI 13 ....................................................................................... 49- 3

49.2 SPN 596/FMI 19 ....................................................................................... 49- 4
49.1 SPN 596/FMI 13
This diagnostic is typically the J1939 Cruise Control Enable Switch signal from Source #1,
#2, or #3 is missing.
Check as follows:

49.2 SPN 596/FMI 19
49.2 SPN 596/FMI 19
This diagnostic is typically J1939 Cruise Control Enable Switch signal from Source #1, #2,
or #3 is erratic.
Check as follows:
these first.

50 SPN 597 (CPC)
Section Page
50.1 SPN 597/FMI 13 ....................................................................................... 50- 3

50.2 SPN 597/FMI 19 ....................................................................................... 50- 4
50.1 SPN 597/FMI 13
This diagnostic is typically the J1939 Service Brake Switch signal from Source #1, #2, or #3
is missing.
Check as follows:

50.2 SPN 597/FMI 19
50.2 SPN 597/FMI 19
This diagnostic is typically J1939 Service Brake Switch signal from Source #1, #2, or #3 is erratic.
Check as follows:
these first.

51 SPN 599 (CPC)
Section Page
51.1 SPN 599/FMI 4 ......................................................................................... 51- 3

51.1 SPN 599/FMI 4
This diagnosis is typically both Cruise Control switches, SET and RES, are shorted to ground.
Check as follows:
1. Turn the ignition ON (key ON, engine OFF) and place the Cruise Control Switch in the
OFF position. DO NOT start the engine.
2. Check the driver console display.
[a] If Cruise Control switch status RES is displayed, go to step 3.
[b] If Cruise Control switch status SET is displayed, go to step 4.
3. Unplug the RES Cruise Control Switch.
[a] If RES status is no longer displayed, replace the Cruise Control RES Switch.
[b] If RES status is still displayed, repair the short to ground in the wire from the RES
switch to pin 16 of the CPC #1 connector. Verify Repairs 219.1.
4. Unplug the SET Cruise Control Switch.
[a] If SET status is no longer displayed, replace the Cruise Control SET Switch.
[b] If SET status is still displayed, repair the short to ground in the wire from the SET
switch to pin 12 of the CPC #1 connector. Verify Repairs 219.1.

51.1 SPN 599/FMI 4

52 SPN 600 (CPC)
Section Page
52.1 SPN 600/FMI 13 ....................................................................................... 52- 3

52.2 SPN 600/FMI 19 ....................................................................................... 52- 4
52.1 SPN 600/FMI 13
This diagnostic is typically the J1939 Cruise Control Coast Switch signal from Source #1, #2,
or #3 is missing.
Check as follows:

52.2 SPN 600/FMI 19
52.2 SPN 600/FMI 19
This diagnostic is typically J1939 Cruise Control Coast Switch signal from Source #1, #2, or #3
is erratic.
Check as follows:
these first.

53 SPN 602 (CPC)
Section Page
53.1 SPN 602/FMI 13 ....................................................................................... 53- 3

53.2 SPN 602/FMI 19 ....................................................................................... 53- 4
53.1 SPN 602/FMI 13
This diagnostic is typically the J1939 Cruise Control Accelerate Switch signal from Source #1,
#2, or #3 is missing.
Check as follows:

53.2 SPN 602/FMI 19
53.2 SPN 602/FMI 19
This diagnostic is typically J1939 Cruise Control Accelerate Switch signal from Source #1,
#2, or #3 is erratic.
Check as follows:
these first.

54 SPN 609
Section Page
54.1 SPN 609/FMI 12 ....................................................................................... 54- 3

54.2 SPN 609/FMI 14 ....................................................................................... 54- 4
54.1 SPN 609/FMI 12
This diagnostic is typically MCM failed or programmed incorrectly.

Check as follows:
1. Using your diagnostic tool, reset the parameters on the MCM.
[a] If fault code 233/12 is not active after resetting parameters, troubleshooting is
finished.
[b] If fault code 233/12 is still active after resetting parameters, go to the next step.
2. Check the MCM parameters to ensure they are correct for the vehicle configuration.
[a] If parameters are not correct, reset parameters on the MCM.
[b] If parameters are correct, replace the MCM. Refer to section 2.3. Set parameters
on the new MCM.

54.2 SPN 609/FMI 14
54.2 SPN 609/FMI 14
This diagnostic is typically MCM incorrect or not programmed correctly.

Check as follows:
1. Check to ensure the MCM is correct for the engine.
[a] If MCM is correct for the engine, go to the next step.
[b] If MCM is not correct for the engine, replace the MCM. Refer to section 2.3. Set
parameters on the new MCM.
2. Reset the MCM parameters.
[a] If fault code 233/14 is not active after the MCM parameters are reset, troubleshooting
is complete.
[b] If fault code 233/14 is still active after the MCM parameters are reset, go to the
next step.
3. Check the MCM parameters to ensure they are correct for the vehicle configuration.
[a] If the MCM parameters are not correct, reset the parameters.
[b] If the MCM parameters are correct, replace the MCM. Refer to section 2.3. Set the
parameters on the new MCM.

55 SPN 615 (CPC)
Section Page
55.1 SPN 615/FMI 3 ........................................................................................ 55- 3

55.2 SPN 615/FMI 4 ........................................................................................ 55- 4
55.3 SPN 615/FMI 5 ........................................................................................ 55- 5
55.4 SPN 615/FMI 9 ......................................................................................... 55- 6
55.5 SPN 615/FMI 14 ....................................................................................... 55- 7
55.1 SPN 615/FMI 3
This diagnostic is typically Axial Power Turbine (APT) Air Seal Pressure Regulator Valve
Circuit Failed Low.
Repair short to ground between turbocharger compound air seal pressure regulator valve harness
connector pin 1 and pin 70 of the MCM 120-pin connector.

55.2 SPN 615/FMI 4
55.2 SPN 615/FMI 4
Circuit Failed High.
Repair short to power between turbocharger compound air seal pressure regulator valve harness
connector pin 1 and pin 70 of the MCM 120-pin connector.

55.3 SPN 615/FMI 5
Circuit Failed Open.
1. Disconnect the turbocharger compound air seal pressure regulator valve.
2. Turn the ignition ON.
3. Measure the voltage between pins 1 and 2 of the turbocharger compound air seal pressure
regulator valve harness connector.
[a] If the voltage is greater than 11.5 volts, replace the turbocharger compound air seal
pressure regulator valve. For the DD13 only: refer to section For the DD15 only:
refer to section
[b] If the voltage is less than 11.5, go to next step.
4. Measure the voltage between pin 2 of the turbocharger compound air seal pressure
regulator valve harness connector and ground.
[a] If the voltage is less than 11.5, repair wire between pin 2 of the turbocharger
compound air seal pressure regulator valve connector and pin 93 of the MCM
120-pin connector.
[b] If the voltage is greater than 11.5, repair wire between pin 1 of the turbocharger
compound air seal pressure regulator valve connector and pin 70 of the MCM
120-pin connector.

55.4 SPN 615/FMI 9
55.4 SPN 615/FMI 9
This diagnostic is typically the J1939 DM1 message from the transmission is missing.
Check as follows:

55.5 SPN 615/FMI 14
This diagnostic is typically related to an internal or external leakage of the high pressure fuel
system. The MCM monitors the rail pressure and when a leakage rate is greater than 150 l/h, the
MCM sets the code. There is no fault reaction (limp home mode) associated to this code. This
fault can occur due to the following conditions:
This SPN indicates there is leakage in the high pressure fuel system (too high) (MU232).
Check as follows:
first.
3. Inspect the following fuel system components for external leakage: high pressure pump,
lines to fuel rail, fuel rail, pressure limiting valve (PLV), and fuel lines from rail to fuel
injector.
[a] If leakage was found, repair as necessary. Verify Repairs 219.1.
4. Perform the Rail Pressure Bleed Off (RPBO) Test using DDDL 7.X. Refer to section 4.7.
[a] If the RPBO test failed; go to next step.
[b] If the RPBO test passed, no problem found.
5. Perform pressure limiting valve (PLV) leakage test. Refer to section .
[a] If the pressure limiting valve (PLV) test passed; go to next step.
[b] If the pressure limiting valve (PLV) test failed; replace pressure limiting valve.
Refer to section .
6. Perform amplifier/needle return measurements. Refer to section 4.5.
[a] If the amplifier/needle return flow test passed; no problem found.
[b] If the amplifier/needle return flow test failed; fix as necessary. Verify Repairs 219.1.

55.5 SPN 615/FMI 14

56 SPN 625 (EPA07)
Section Page
56.1 SPN 625/FMI 2 ......................................................................................... 56- 3

56.2 SPN 625/FMI 4 ......................................................................................... 56- 5
56.3 SPN 625/FMI 9 ......................................................................................... 56- 7
56.1 SPN 625/FMI 2
This diagnostic is typically erratic data or the CAN propriety data link has failed between the
MCM and the CPC.
NOTE:
The following diagnostics pertain to faults received from the MCM and /or the CPC.
Check as follows:
1. Have the MCM and/or the CPC have recently been changed or reprogrammed?
[a] If yes, verify the that the correct MCM calibration and/or the correct CPC parameter
list has been installed. If the correct calibration and correct parameter list have been
installed, then go to the next step.
[b] If the MCM and/or the CPC have not recently been changed or reprogrammed, go to
the next step.
4. Measure the battery voltage at pin 7 on the MCM 21pin connector.
[a] If the battery voltage is less than 10.5 volts, restore the battery voltage at pins 7, 11,
12, 14, and 15 on the MCM 21pin connector.
NOTE:
Poor battery grounds can be a possible cause of low battery voltage.
[b] If the battery voltage is greater than 10.5 volts, go to the next step.
5. Turn ignition OFF, leave the 21pin MCM connector disconnected.
7. Measure the resistance between pins 1 and 3 of the CPC #4 connector.
[a] If the resistance is greater than 5 , go to the next step.
[b] If the resistance is less than 5 , repair the short circuit in the wires between pins 1
and 3 of the CPC #4 connector and pins 13 and 19 of the 21pin MCM connector.
8. Measure the resistance between pin 1 of the CPC #4 connector and ground.
[b] If the resistance is less than 5 , repair the short circuit to ground between pin 1 of
the CPC #4 connector and ground. Verify Repairs 219.1.

56.1 SPN 625/FMI 2
9. Check the resistance between pin 3 of the CPC #4 connector and ground.
10. Measure the resistance between pin 1 of the CPC #4 connector and pin 19 of the 21pin
MCM connector.
[a] If the resistance is greater than 5 , repair the open circuit between pin 1 of the CPC
#4 connector and pin 19 of the 21pin MCM connector. Verify Repairs 219.1.
MCM connector.
[b] If the resistance is less than 5 , call the DDC Customer Support Center
(3135925800).

56.2 SPN 625/FMI 4
MCM and the CPC.
NOTE:
Check as follows:
1. Have the MCM and/or the CPC have recently been changed or reprogrammed?
installed, then go to the next step.
[b] If the MCM and/or the CPC have not recently been changed or reprogrammed, go to
the next step.
NOTE:

56.2 SPN 625/FMI 4
MCM connector.
MCM connector.
(3135925800).

56.3 SPN 625/FMI 9
MCM and the CPC.
NOTE:
Check as follows:
1. Have the MCM and/or the CPC been recently changed or reprogrammed?
installed, go to the next step.
[b] If no, go to the next step.
NOTE:

56.3 SPN 625/FMI 9
MCM connector.
MCM connector.
(3135925800).

57 SPN 625 (CPC) (EPA10)
Section Page
57.1 SPN 625/FMI 9 ......................................................................................... 57- 3

57.1 SPN 625/FMI 9
This diagnostic is typically ACM PT-CAN DM1 Message Not Received or has Stopped Arriving.
1. Are there any battery voltage faults (SPN 168 FMI ANY)?
[a] Yes, troubleshoot battery voltage faults first.
2. Has the ACM2/MCM2/or CPC2+ been recently programmed?
[a] Yes, clear the fault codes, if faults do not become active, release the vehicle, if faults
become active, go to step 3.
[b] No, clear the fault codes, if faults do not become active, release the vehicle, if faults
become active, go to step 3.
3. Turn ignition OFF and wait 5 minutes before proceeding, main battery power must be
left ON (The 5 minute time frame allows the ACM to go completely offline).
5. Measure and record the resistance across pins 13 and 19 of the MCM 21-pin connector.
[a] If the resistance is greater than 80 ohms, go to step 6.
[b] If the resistance is between 60 +/- 20 ohms, reconnect the MCM 21-pin connector,
go to step 16.
[c] If the resistance is less than 5 ohms, replace the PTCAN harness.

57.1 SPN 625/FMI 9
7. Check ACM internal terminating resistor by measuring and recording the resistance across
pins 10 and 20 of the ACM 21-pin connector.
[a] If the resistance is 120 +/- 10 ohms, go to next step.
[b] If the resistance is not between 120 +/- 10 ohms, replace the ACM.
8. Disconnect the CPC Connector #3.

9. Check CPC internal terminating resistor by measuring and recording the resistance across
pins 19 and 21 of the CPC Connector Cavity #3.
[a] If the resistance is 120 +/- 10 ohms, go to step 10.

[b] If the resistance is not between 120 +/- 10 ohms, replace the CPC.
10. Check for continuity between CPC connector #3 pin 19 and ACM 21-pin connector pin 20.
[a] If there is continuity, go to step 11.
[b] If there is no continuity, repair the wire between CPC connector #3 pin 19 and the
ACM 21-pin connector pin 20.
11. Measure and record the resistance between CPC connector #3 pin 21 and ACM 21-pin
connector pin 10.
[b] If there is no continuity, repair the wire between CPC connector #3 pin 21 and ACM
21-pin connector pin 10.
12. Measure and record the resistance between CPC connector #3 pin 19 and MCM 21-pin
connector pin 19.
[b] If there is no continuity, repair the wire between CPC connector #3 pin 19 and MCM
13. Measure and record the resistance between CPC connector #3 pin 21 and MCM 21-pin
connector pin 13.
[b] If there is no continuity,, repair the wire between CPC connector #3 pin 21 and MCM
14. Measure and record the resistance between of the MCM 21-pin connector pin 19 and of
the ACM 21-pin connector pin 20.

57.1 SPN 625/FMI 9

[b] If there is no continuity, repair the wire between MCM 21-pin connector pin 19 and
of the ACM 21-pin connector pin 20.
15. Measure and record the resistance between the MCM 21-pin connector pin 13 and of the
ACM 21-pin connector pin 10.
[a] If there is continuity, contact the Customer Support Center.
[b] If there is no continuity, repair the wire between MCM 21-pin connector pin 13 and
of the ACM 21-pin connector pin 10.

18. Measure the voltage between ACM 21-pin connector pins 11, 12, 14, 15 and 18 (battery
voltage) and ground.
[a] If the voltage is less than 11.5 volts, restore voltage to ACM 21-pin connector pins
11, 12, 14, 15 and 18.
[b] If voltage is greater than 11.5, restore ground connection to ACM 21-pin connector
pins 3, 5, 6 and 9.

57.1 SPN 625/FMI 9

58 SPN 628 (CPC)
Section Page
58.1 SPN 628/FMI 13 (ALL FAULT DESCRIPTIONS) ..................................... 58- 3

58.2 SPN 628/FMI 14 ....................................................................................... 58- 4
58.1 SPN 628/FMI 13 (ALL FAULT DESCRIPTIONS)
This diagnostic is typically multiple fault descriptions for SPN 628/FMI 13. The troubleshooting
solution is the same for any and all fault descriptions: reprogram the CPC with the latest software
release.

58.2 SPN 628/FMI 14
58.2 SPN 628/FMI 14
This diagnostic is typically an XFLASH failure. Replace the CPC and reprogram with the latest
software release.

59 SPN 629 (CPC)
Section Page
59.1 SPN 629/FMI 2 ......................................................................................... 59- 3

59.2 SPN 629/FMI 12 ....................................................................................... 59- 4
59.1 SPN 629/FMI 2
solution is the same for any and all fault descriptions: Replace the CPC and reprogram with
the latest software release.

59.2 SPN 629/FMI 12
59.2 SPN 629/FMI 12
solution is the same for any and all fault descriptions: Replace the CPC and reprogram with
the latest software release.

60 SPN 630 (CPC)
Section Page
60.1 SPN 630/FMI 14 ....................................................................................... 60- 3

60.1 SPN 630/FMI 14
This diagnostic is typically a communication interruption between the CPC and MCM. It is
caused by either of the following:
DDDL connecting to the CPC/MCM at a specific time within the first few seconds of
Ignition ON, and remaining connected for over 10 minutes
Sending parameters to the CPC while connected to both the CPC and MCM, and DDDL
remaining connected for over 10 minutes
The only required action is to disconnect DDDL, cycle the Ignition switch then reconnect DDDL.

60.1 SPN 630/FMI 14

61 SPN 636
Section Page
61.1 SPN 636/FMI 1 ......................................................................................... 61- 3

61.2 SPN 636/FMI 2 ......................................................................................... 61- 5
61.3 SPN 636/FMI 3 ......................................................................................... 61- 6
61.4 SPN 636/FMI 4 ......................................................................................... 61- 8
61.5 SPN 636/FMI 8 ......................................................................................... 61-10
61.6 SPN 636/FMI 14 ....................................................................................... 61-11
61.1 SPN 636/FMI 1
This diagnostic is typically CKP sensor Signal Voltage Too Low.
NOTE:
If the sensor is removed, be sure to check the sensor tip for metal debris and clutch
material and clean it if necessary.
Check as follows:
1. If fault occurs only when cranking the engine (and engine will not start), check that the
CKP and Camshaft Position (CMP) sensors are correctly wired to the MCM.
[a] If wires are not correctly wired, repair or replace wires as required. Verify Repairs
219.1.
[b] If wires are correctly wired, go to the next step.
2. If fault occurs at other times then when cranking the engine, check that the CKP sensor
position is correct (the sensor is seated in all the way and the tip of the sensor is clean).
[a] If fault is not active after checking CKP sensor position, repair the CKP sensor
clamping sleeve. Verify Repairs 219.1.
[b] If fault is still active after checking the CKP sensor position, go to the next step.
3. Check the flywheel position through the inspection window of the timing case using
turning tool. Look for timing marks and damage.
[a] If the flywheel is out of position, repair or replace, as required. Verify Repairs 219.1.
[b] If the flywheel is not out of position, go to the next step.

61.1 SPN 636/FMI 1
4. Check crankshaft axial play.

[a] If axial play is not within specifications, repair or replace crankshaft thrust bearings,
as required. Verify Repairs 219.1.
[b] If axial play is within specifications, replace the MCM. Refer to section 2.3.

61.2 SPN 636/FMI 2
This diagnostic is typically no match of camshaft and crankshaft signals.

1. Are there any other camshaft (SPN 723/FMI 3 or 4) or crankshaft (SPN 636/FMI 3 or
4) circuit faults active?
[a] Yes, repair circuit failure first, if the problem is still present after circuit repair, go to
the next step.
[b] No, go to the next step.
2. Has the engine been recently overhauled or had valve train maintenance?
[a] Yes, verify proper camshaft timing and gear lash adjustment.
[b] No, go to the next step.
3. Remove the Camshaft Position sensor (CMP).
4. Inspect the camshaft position sensor for physical damage.
[a] If damaged, replace the camshaft position sensor. Refer to section 3.7.1.
[b] If no damage is found, verify proper camshaft timing and gear lash adjustment.

61.3 SPN 636/FMI 3
61.3 SPN 636/FMI 3
This diagnostic is typically Crankshaft Position (CKP) sensor has an open circuit.
NOTE:
Check as follows:
1. Disconnect the CKP sensor.
2. Measure the resistance across pins 1 and 2 of the CKP sensor.
[a] If the resistance is between 774 and 946 , go to step 3.
[b] If the resistance is not between 774 and 946 , replace the CKP sensor.
3. Disconnect the 120-pin MCM connector.
4. Measure the resistance across pins 1 and 2 of the CKP sensor harness connector.
[a] If the resistance is greater than 5 , go to step 5.
[b] If the resistance is less than 5 , repair the short between pins 1 and 2 of the CKP
sensor harness connector and pins 73 and 43 of the 120pin MCM connector.
5. Measure the resistance between pin 1 of the CKP sensor harness connector and pin 73
[a] If the resistance is greater than 5 , repair the open between pin 1 of the CKP sensor
harness connector and pin 73 of the 120pin MCM connector.
[b] If the resistance is less than 5 , go to step 6.

[a] If the resistance is greater than 5 , repair the open between pin 2 of the CKP sensor
harness connector and pin 43 of the 120pin MCM connector.
7. Remove the CKP sensor and ensure the sensor and tone wheel are clean and ensure the
sensor is not damaged.
[a] If the sensor and tone wheel are not clean, inspect debris and identify source (clutch
material, flywheel material, etc.), clean and repair as necessary.
[b] If sensor damage is found, replace the CKP sensor. Refer to section 3.6.1.
[c] If the sensor and tone wheel are clean and there is no damage found, call the Detroit
Diesel Customer Support Center (3135925800).

61.4 SPN 636/FMI 4
61.4 SPN 636/FMI 4
This diagnostic is typically the CKP sensor shorted to ground.
NOTE:
Check as follows:
1. Disconnect the CKP sensor and clean the sensor tip.
2. Measure the resistance between pin 1 of the CKP sensor and ground.
[b] If the resistance is less than 5 , replace the CKP sensor. Refer to section 3.6.1.
3. Measure the resistance between pin 2 of the CKP sensor and ground.
5. Measure the resistance across pins 1 and 2 of the CKP sensor harness connector.
[b] If the resistance is less than 5 , repair the short between the CKP sensor harness
connector pins 1 and 2 and pins 73 and 43 of the 120pin MCM connector.

6. Measure the resistance between pin 1 of the CKP sensor harness connector and ground.
[b] If the resistance is less than 5 , repair the short to ground between pin 1 of the CKP
sensor harness connector and pin 73 of the 120pin MCM connector. Verify Repairs
219.1.
[a] If the resistance is greater than 5 , reconnect the 120pin MCM connector and
review the previous steps. If the results are the same, call the Detroit Diesel Customer
Support Center (3135925800).
[b] If the resistance is less than 5 , repair the short to ground between pin 2 of the CKP
sensor harness connector and pin 43 of the 120pin MCM connector. Verify Repairs
219.1.

61.5 SPN 636/FMI 8
61.5 SPN 636/FMI 8
This diagnostic is typically CKP sensor Time Out.
NOTE:
Check as follows:
2. Measure the resistance between pins 73 and 43 of the MCM 120pin connector.
[a] If the resistance is less than 140 , go to step 3.
[b] If the resistance is greater than 140 , go to step 5.
3. Disconnect the CKP sensor and clean the sensor tip.
[a] If the resistance is less than 3 , repair the short between pins 73 and 43 of the MCM
120pin connector and the CKP sensor. Verify Repairs 219.1.
[b] If the resistance is greater than 3 , replace the CKP sensor. Refer to section 3.6.1.
5. Disconnect the CKP sensor.
6. Jumper pins 1 and 2 of the CKP sensor harness.
[a] If the resistance is greater than 3 , repair the open between pins 73 and 43 of the
MCM 120pin connector and the CKP sensor connector. Verify Repairs 219.1.

61.6 SPN 636/FMI 14
This diagnostic is typically is swapped pins.
NOTE:
If this SPN and FMI are active, verify that the wiring from CKP sensor pin 1 to pin 73 of the
MCM 120pin connector and that the wiring from CKP sensor pin 2 to pin 43 of the MCM
120pin connector is correct.

61.6 SPN 636/FMI 14

62 SPN 639
Section Page
62.1 SPN 639/FMI 14 ...................................................................................... 62- 3

62.1 SPN 639/FMI 14
This diagnostic is typically J1939 Data Link Failure.

[a] If other faults are present, troubleshoot those faults first. This could be an indication
to which communication line is broken.
[b] If only a J1939 Error fault is present, go to step 2.
2. Connect ServiceLink to determine which modules are configured for the vehicle and their
communication status. Once this is done, follow the appropriate module communication
troubleshooting procedure for the affected module.

62.1 SPN 639/FMI 14

63 SPN 647
Section Page
63.1 SPN 647/FMI 3 ......................................................................................... 63- 3

63.2 SPN 647/FMI 4 ......................................................................................... 63- 4
63.3 SPN 647/FMI 5 ......................................................................................... 63- 5
63.1 SPN 647/FMI 3
This diagnostic is typically there is a short to power.

Check as follows:

2. Disconnect the fan control solenoid connector.
4. Measure the voltage between pin 1 of the fan control solenoid connector and ground.
[a] If the voltage is greater than 11.5 volts, repair the short to power between pin 1
of the fan control solenoid connector and pin 98 of the 120pin MCM connector.
[b] If the voltage is less than 11.5 volts, replace the fan control solenoid. Verify Repairs
219.1.

63.2 SPN 647/FMI 4
63.2 SPN 647/FMI 4
This diagnostic is typically there is a short to ground.

Check as follows:

4. Measure the resistance between pin 1 of the fan control solenoid connector and ground.
[a] If the resistance is less than 5 , repair the short to ground between pin 1 of the fan
control solenoid connector and pin 98 of the 120pin MCM connector. Verify Repairs
219.1.
[b] If the resistance is greater than 5 , repair the short to ground between pin 2 of
the fan control solenoid connector and pin 91 of the 120pin MCM connector.

63.3 SPN 647/FMI 5
This diagnostic is typically there is an open circuit.

Check as follows:

[a] If SPN 1071/5, SPN 1672/5, and SPN 647/5 are active, repair the open in between
pin 91 of the 120pin MCM connector and the fan and the Jake Brake solenoids.
[b] If only SPN 647/5 is active, go to the next step.
4. Measure the voltage between pin 1 and 2 of the fan control solenoid connector.
[a] If the voltage is less than 11.5 volts, go to the next step.
[b] If the voltage is between 11.5 and 13.5 volts, replace the fan control solenoid.
5. Measure the voltage between pin 2 of the fan control solenoid connector and pin 91 of the
120pin MCM connector. Verify Repairs 219.1.
[a] If the voltage is less than 11.5 volts, repair the open between pin 2 of the fan control
solenoid connector and ground. Verify Repairs 219.1.
[b] If the voltage is greater than 11.5, repair the open between pin 1 of the fan control
solenoid connector and pin 98 of the 120pin MCM connector. Verify Repairs 219.1.

63.3 SPN 647/FMI 5

64 SPN 651
Section Page
64.1 SPN 651/FMI 14 ....................................................................................... 64- 3

64.1 SPN 651/FMI 14
This diagnostic is typically an open circuit, short to ground or short to power.
Check as follows:
[a] If fault 168/1 is present along with any other faults, service 168/1 first.
[b] If 652/14 and 653/14 are present along with 651/14, go to step 2.
3. Disconnect the front fuel injector harness 14pin connector.
4. Inspect the front fuel injector harness 14pin fuel injector connector for bent or spread
pins, inspect the connector seal for damage (signs of water or oil intrusion).
[a] If water or oil intrusion, bent or spread pins are found, repair as necessary.
[b] If the connector shows no signs of damage, go to the next step.

64.1 SPN 651/FMI 14
5. Measure the resistance between pin 1 and pin 2 on the valve cover side of the fuel injector
harness. If using J-4867110, measure between fuel injector #1 pins 3 and 4.
[a] If the resistance is greater than 3 , replace the under valve cover fuel injector
harness. Refer to section .

7. Measure the resistance between pin 25 of the MCM 120pin connector and pin 1 of the
front fuel injector harness 14pin connector.
[a] If the resistance is greater then 3 , repair the open between pin 25 of the MCM
120pin connector and pin 1 of the front fuel injector harness 14pin connector.
8. Disconnect the negative battery cable.
9. Measure the resistance between the positive battery post and pin 25 of the MCM 120pin
connector.
[a] If the resistance is less than 3 , repair short to power between battery positive and
pin 25 of the MCM 120pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 3 , replace the MCM. Refer to section 2.3.
13. Remove the upper valve cover.
14. Disconnect fuel injector #1.
15. Measure the resistance between pin 1 of the on the valve cover side of the fuel injector
harness and pin 3 of the fuel injector #1 harness connector.

64.1 SPN 651/FMI 14
[a] If the resistance is greater than 3 , replace under valve cover fuel injector harness.
Refer to section .

Refer to section .
harness and ground.
[a] If the resistance is less than 3 , replace under valve cover fuel injector harness.
Refer to section .
[b] If the resistance is greater than 3 , replace the fuel injector #1. Refer to section .
18. Measure the resistance between pin 2 on the valve cover side of the fuel injector harness
and ground. If using J-4867110, measure between fuel injector #1 pin 4 and ground.
20. Disconnect the fuel injector #1 connector.
and ground. If using J-4867110, measure between fuel injector #1 pin 4 and ground.
[a] If the resistance is greater than 3 , replace the fuel injector #1. Refer to section .
[b] If the resistance is less than 3 , replace the under valve cover fuel injector harness.
Refer to section .
23. Measure the resistance between pin 2 on the MCM side of the fuel injector harness
connector and pin 26 of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair open circuit between pin 2 of the fuel
injector harness connector and pin 26 of the MCM 120pin connector. Verify Repairs
219.1.
[b] If the resistance is less than 3 , repair short to ground between pin 2 of the fuel
219.1.

64.1 SPN 651/FMI 14

65 SPN 651 (EPA10)
Section Page
65.1 SPN 651/FMI 6 ......................................................................................... 65- 3

65.1 SPN 651/FMI 6
This diagnostic is typically fuel injector Cylinder #1 Needle Control Valve, Valve Shorted Circuit
Check as follows:
1. Disconnect the front rocker cover 14-pin fuel injector harness connector.
3. Measure the resistance between pins 1 and 2 on the engine harness side of the front rocker
cover fuel injector 14-pin connector.
[a] If the resistance is less than 1k ohms, repair short in the engine harness between pins
1 and 2 of the front rocker cover fuel injector harness 14-pin connector and pins 25
and 26 of the MCM 120-pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 1k ohms, go to step 4.
5. Completely remove the front fuel injector harness from the engine.
6. With harness removed from the engine, test the front fuel injector harness, measure the
resistance between pins 1 and 2 of the front rocker cover fuel injector harness 14-pin
connector.
[a] If the resistance is less than 1k ohms, replace the front fuel injector harness.
Refer to section .
[b] If the resistance is greater than 1k ohms, replace the #1 fuel injector. Refer to section .

65.1 SPN 651/FMI 6

66 SPN 652
Section Page
66.1 SPN 652/FMI 14 ....................................................................................... 66- 3

66.1 SPN 652/FMI 14
This diagnostic is typically the fuel injector #2 cylinder needle control valve has an open circuit,
short to ground or short to power.
Check as follows:
[b] If 651/14 and 653/14 are present along with 652/14, go to the next step.
2. Turn the ignition OFF

66.1 SPN 652/FMI 14
harness If using J-4867110, measure between fuel injector #1 pins 3 and 4.

connector.
[b] If the resistance is greater than 3 , replace the MCM. Refer to section 2.3

66.1 SPN 652/FMI 14
Refer to section .
Refer to section .

harness and ground.
Refer to section .
and ground (if using J-48671-10 measure between fuel injector #2 pin 4 and ground).
20. Disconnect fuel injector #2 connector.
and ground If using J-4867110, measure between fuel injector #2 pin 4 and ground).
Refer to section .
219.1.
219.1.

66.1 SPN 652/FMI 14

67 SPN 652 (EPA10)
Section Page
67.1 SPN 652/FMI 6 ......................................................................................... 67- 3

67.1 SPN 652/FMI 6
Check as follows:
connector.
Refer to section .

67.1 SPN 652/FMI 6

68 SPN 653
Section Page
68.1 SPN 653/FMI 14 ....................................................................................... 68- 3

68.1 SPN 653/FMI 14
Check as follows:

68.1 SPN 653/FMI 14
6. Disconnect the MCM 120-pin connector

connector.
14. Disconnect the #3 fuel injector.
harness and pin 3 of the #3 fuel injector harness connector.

68.1 SPN 653/FMI 14
Refer to section .
harness and pin 4 of the #3 fuel injector harness connector.
Refer to section .

harness and ground.
Refer to section .
[b] If the resistance is greater than 3 , replace the #3 fuel injector. Refer to section .
and ground If using J-4867110, measure between fuel injector #3 pin 4 and ground.
20. Disconnect #3 fuel injector connector.
[a] If the resistance is greater than 3 , replace the #3 fuel injector. Refer to section .
Refer to section .
219.1.
[b] If the resistance is less than 3 , repair short to ground between pin 4of the fuel
219.1.

68.1 SPN 653/FMI 14

69 SPN 653 (EPA10)
Section Page
69.1 SPN 653/FMI 6 ......................................................................................... 69- 3

69.1 SPN 653/FMI 6
Check as follows:
connector.
Refer to section .

69.1 SPN 653/FMI 6

70 SPN 654
Section Page
70.1 SPN 654/FMI 14 ....................................................................................... 70- 3

70.1 SPN 654/FMI 14
Check as follows:
3. Disconnect the rear fuel injector harness 14pin connector.
4. Inspect the rear fuel injector harness 14pin fuel injector connector for bent or spread pins,
inspect the connector seal for damage (signs of water or oil intrusion).

70.1 SPN 654/FMI 14
harness (if using J-48671-10 measure between fuel injector #4 pins 3 and 4).

rear fuel injector harness 14pin connector.
120pin connector and pin 1 of the rear fuel injector harness 14pin connector.
connector.

70.1 SPN 654/FMI 14
Refer to section .
Refer to section .

harness and ground.
Refer to section .
Refer to section .
219.1.
219.1.

70.1 SPN 654/FMI 14

71 SPN 654 (EPA10)
Section Page
71.1 SPN 654/FMI 6 ......................................................................................... 71- 3

71.1 SPN 654/FMI 6
Check as follows:
1. Disconnect the rear rocker cover 14-pin fuel injector harness connector.
3. Measure the resistance between pins 1 and 2 on the engine harness side of the rear rocker
1 and 2 of the rear rocker cover fuel injector harness 14-pin connector and pins 19
5. Completely remove the rear fuel injector harness from the engine. Refer to section .
6. With harness removed from the engine, test the rear fuel injector harness, measure the
resistance between pins 1 and 2 of the rear rocker cover fuel injector harness 14-pin
connector.
[a] If the resistance is less than 1k ohms, replace the rear fuel injector harness.
Refer to section .

71.1 SPN 654/FMI 6

72 SPN 655
Section Page
72.1 SPN 655/FMI 14 ....................................................................................... 72- 3

72.1 SPN 655/FMI 14
Check as follows:

72.1 SPN 655/FMI 14

connector.
harness (if using J-48671-10 measure between fuel injector #5 pins 3 and 4).

72.1 SPN 655/FMI 14
Refer to section .
Refer to section .

harness and ground.
Refer to section .
and ground (if using J-48671-10 measure between fuel injector #5 pin 4 and ground).
Refer to section .
219.1.
219.1.

72.1 SPN 655/FMI 14

73 SPN 655 (EPA10)
Section Page
73.1 SPN 655/FMI 6 ......................................................................................... 73- 3

73.1 SPN 655/FMI 6
Check as follows:
connector.
Refer to section .

73.1 SPN 655/FMI 6

74 SPN 656
Section Page
74.1 SPN 656/FMI 14 ....................................................................................... 74- 3

74.1 SPN 656/FMI 14
Check as follows:

74.1 SPN 656/FMI 14

connector.
pin 25 of the MCM 120pin connector.

74.1 SPN 656/FMI 14
Refer to section .
Refer to section .

harness and ground.
Refer to section .
Refer to section .
injector harness connector and pin 18 of the MCM 120pin connector.
injector harness connector and pin 18 of the MCM 120pin connector.

74.1 SPN 656/FMI 14

75 SPN 656 (EPA10)
Section Page
75.1 SPN 656/FMI 6 ......................................................................................... 75- 3

75.1 SPN 656/FMI 6
Check as follows:
connector.
Refer to section .

75.1 SPN 656/FMI 6

76 SPN 677
Section Page
76.1 SPN 677/FMI 2 ......................................................................................... 76- 3

76.2 SPN 677/FMI 3 ......................................................................................... 76- 4
76.3 SPN 677/FMI 4 ......................................................................................... 76- 5
76.4 SPN 677/FMI 5 ......................................................................................... 76- 6
76.5 SPN 677/FMI 7 ......................................................................................... 76- 7
76.6 SPN 677/FMI 14 ....................................................................................... 76- 8
76.7 SPN 677/FMI 18 ....................................................................................... 76- 9
76.8 SPN 677/FMI 31 ....................................................................................... 76-10
76.1 SPN 677/FMI 2
The diagnosis is typically a low or no voltage for the starter switch.

Check as follows:
1. Check codes.
[a] If 677/2 is inactive, clear the fault code and start the engine. If 677/2 stays inactive,
clear the fault and release the truck back to service.
[b] If 677/2 is active, go to the next step.
NOTE:
The key must be in the crank position before measuring the voltage.
3. Measure the voltage between pin 20 of the MCM 21-pin connector and ground.
[a] If the voltage is greater than 11.5 volts, go to next step.
[b] If the voltage is less than 11.5 volts, repair the cause of the low/no voltage to pin
20. Verify repairs.
4. Disconnect the CPC connector #1.
NOTE:
The key must be in the crank position before measuring the voltage.
5. Measure the voltage between pin 18 of the CPC connector #1 and ground.
[a] If the voltage is greater than 11.5 volts, contact the Customer Support Center at
313-592-5800 for further diagnostic assistance.
[b] If the voltage is less than 11.5 volts, repair the cause of the low/no voltage to pin 18
of the CPC connector #1. Verify repairs.

76.2 SPN 677/FMI 3
76.2 SPN 677/FMI 3
The diagnosis is typically engine starter relay shorted to high source.
NOTE:
Ignition must be off for at least 30 seconds before performing this test.
1. Turn ignition OFF for 30 seconds (key OFF, engine OFF).

3. Turn the ignition ON, (key ON, engine OFF).
[a] If voltage is present, repair short to power on pin 21 of the MCM 21-pin connector
(refer to OEM manual for wiring diagram).
[b] If no voltage is present, replace the starter relay.

76.3 SPN 677/FMI 4
The diagnosis is typically engine starter relay circuit failed low.

2. Remove the engine starter relay.
NOTE:
Refer to OEM wiring schematic for correct pin location for the engine starter relay.
3. Measure the resistance between pin 21 of the MCM 21pin connector and the engine
starter relay.
[a] If the resistance is greater than 3, repair open between pin 21 of the MCM 21pin
connector and the engine starter relay. Verify repairs.
[b] If the resistance is less than 3, replace the engine starter relay. Verify repairs.

76.4 SPN 677/FMI 5
76.4 SPN 677/FMI 5
The diagnosis is typically engine starter relay open circuit.

2. Remove the engine starter relay.
NOTE:
Refer to OEM wiring for correct pin location on the engine starter relay.
3. Measure the resistance between pin 21 of the MCM 21-pin connector and the engine
starter relay.
[a] If the resistance is greater than 1K ohms, repair wire between pin 21 of the MCM
21-pin connector and the engine starter relay.
[b] If the resistance is less than 3 ohms, replace the engine starter relay.

76.5 SPN 677/FMI 7
The diagnosis is typically engine starter relay jammed.
NOTE:


76.6 SPN 677/FMI 14
76.6 SPN 677/FMI 14
The diagnosis is typically an electronic starter fault or MCM internal failure.

1. Does the engine crank and start?
[a] Yes, go to next step.
[b] No, contact the Customer Support Center at 313-592-5800 for further diagnostic
assistance.
2. Clear the code(s) and start the engine. Repeat engine start three times. If engine
successfully starts and fault does not re-occur, release the vehicle.

76.7 SPN 677/FMI 18
The diagnosis is typically starter relay low resistance.
NOTE:


76.8 SPN 677/FMI 31
76.8 SPN 677/FMI 31
The diagnosis is typically a starter jammed (tooth to tooth jam).
NOTE:
This fault indicates the starter teeth have not engaged correctly into the flywheel
(jammed).
Attempt to start the engine. If the engine starts correctly, attempt to start the engine three times.
If fault does not re-occur, clear code and release vehicle. If starter does not properly engage
the flywheel some possible causes may be:
Starter motor alignment
Starter drive damage
Incorrect starter installed
Flywheel damage

77 SPN 679
Section Page
77.1 SPN 679/FMI 7 ......................................................................................... 77- 3

77.1 SPN 679/FMI 7
This diagnostic is typically related to a Pressure Limiting Valve (PLV) staying open. The pressure
limiting valve will open when rail pressure is above 1150 bar. The MCM will command a lower
rail pressure trying to force the pressure limiting valve closed. If the pressure limiting valve does
not close, a fault code is generated. The condition that caused the PLV to open must be addressed.
Check as follows:
2. Using DDDL, monitor rail pressure at idle.
[a] If rail pressure is above 900 bar, check for a damaged needle return line and a
damaged line (fuel rail to fuel injector). Repair as necessary. Verify Repairs 219.1.
[b] If rail pressure is below 900 bar, go to next step.
3. Increase engine speed to 1800 rpm and check the rail pressure.
[a] If rail pressure is above 900 bar, check for a damaged needle return line, a damaged
amplifier return line and a damaged line (fuel rail to fuel injector). Repair as
necessary. Verify Repairs 219.1.
[b] If rail pressure is below 900 bar, replace the PLV. Refer to section .

77.1 SPN 679/FMI 7

78 SPN 698
Section Page
78.1 SPN 698/FMI 5 ......................................................................................... 78- 3

78.1 SPN 698/FMI 5
This diagnosis is typically grid heater circuit failed open.

Check as follows:
1. Disconnect the grid heater harness connector.
3. Measure the voltage between pin 2 of the grid heater harness connector and ground.
NOTE:
Voltage measurement must be taken with the first minute of key ON. If this was not
done, cycle the key and recheck voltage.
[a] If the voltage is greater than 11 volts, go to step 6.

[b] If the voltage is less than 11 volts, go to the next step.
4. Cycle the ignition switch.
5. Recheck the voltage between pin 2 of the grid heater harness connector and ground.
[a] If the voltage is greater than 11 volts, go to the next step.
[b] If voltage is still less than 11 volts, go to step 11.
[b] If voltage is less than 11 volts, go to the next step.
7. Turn the Ignition OFF.
9. Measure the resistance between pin 3 of the grid heater harness connector and pin 92
of the MCM 120pin connector.
[a] If the resistance is greater than 3 ohms, repair open between pin 3 of the grid heater
harness connector and pin 92 of the MCM 120pin connector. Verify Repairs 219.1.
[b] If the resistance is less than 3 ohms, go to the next step.
10. Measure the resistance between pin 1 of the grid heater harness connector and ground.
[a] If the resistance is greater than 3 , replace the grid heater. Refer to section .
[b] If the resistance is less than 3 , repair short to ground between pin 3 of the grid heater
11. Measure the resistance between pin 2 of the grid heater harness connector and pin 41
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair open between pin 2 of the grid heater
[b] If the resistance is less than 3 , replace the grid heater. Refer to section .

78.1 SPN 698/FMI 5

79 SPN 704 (CPC)
Section Page
79.1 SPN 704/FMI 3 ......................................................................................... 79- 3

79.2 SPN 704/FMI 4 ......................................................................................... 79- 4
79.1 SPN 704/FMI 3
High Exhaust System Temperature Lamp - indicates a short to power/open circuit on pin 7 of the
CPC #4 connector. For wiring schematic information refer to OEM literature.
NOTE:

79.2 SPN 704/FMI 4
79.2 SPN 704/FMI 4
High Exhaust System Temperature Lamp - indicates a short to ground on the pin 7 circuit of the
CPC #4 connector. For wiring schematic information refer to OEM literature.
NOTE:

80 SPN 705 (CPC)
Section Page
80.1 SPN 705/FMI 3 ......................................................................................... 80- 3

80.2 SPN 705/FMI 4 ......................................................................................... 80- 4
80.1 SPN 705/FMI 3
Malfunction Indicator Lamp (MIL)- indicates a short to power/open circuit on pin 13of the CPC
#1 connector. For wiring schematic information refer to OEM literature.
NOTE:

80.2 SPN 705/FMI 4
80.2 SPN 705/FMI 4
Malfunction Indicator Lamp (MIL) - indicates a short to ground on the pin 13 circuit of the CPC
#1 connector. For wiring schematic information refer to OEM literature.
NOTE:

81 SPN 709 (CPC)
Section Page
81.1 SPN 709/FMI 3 ......................................................................................... 81- 3

81.2 SPN 709/FMI 4 ......................................................................................... 81- 4
81.1 SPN 709/FMI 3
Red Stop Lamp (RSL) - indicates a short to power/open circuit on pin 16 of the CPC #3 connector.
For wiring schematic information refer to OEM literature.
NOTE:

81.2 SPN 709/FMI 4
81.2 SPN 709/FMI 4
Red Stop Lamp (RSL) - indicates a short to ground on the pin 16 circuit of the CPC #3 connector.
NOTE:

82 SPN 710
Section Page
82.1 SPN 710/FMI 3 ......................................................................................... 82- 3

82.2 SPN 710/FMI 4 ......................................................................................... 82- 4
82.1 SPN 710/FMI 3
This diagnostic is typically Digital Output 4 06 Circuit Failed High.

Wait to Start Lamp (WTS) - indicates a short to power/open circuit on pin 6 of the CPC2+ #4
connector. For wiring schematic information refer to OEM literature.
NOTE:
The CPC2+ digital outputs have the same SPN as some MCM2 faults. DDDL 7.X makes
the distinction between the MCM2 and CPC2+ when diagnosing a fault.

82.2 SPN 710/FMI 4
82.2 SPN 710/FMI 4
This diagnostic is typically Digital Output 4 06 Circuit Failed Low.

Wait to Start Lamp (WTS) - indicates a short to ground on pin 6 of the CPC2+ #4 connector. For
wiring schematic information refer to OEM literature.
NOTE:
The CPC2+ digital outputs have the same SPN as some MCM2 faults. DDDL 7.X makes
the distinction between the MCM2 and CPC2+ when diagnosing a fault.

83 SPN 711 (CPC)
Section Page
83.1 SPN 711/FMI 3 ......................................................................................... 83- 3

83.2 SPN 711/FMI 4 ......................................................................................... 83- 4
83.1 SPN 711/FMI 3
DPF Regen Lamp - indicates a short to power/open circuit on pin 5 of the CPC #1 connector. For
NOTE:

83.2 SPN 711/FMI 4
83.2 SPN 711/FMI 4
DPF Regen Lamp - indicates a short to ground on the pin 5 circuit of the CPC #1 connector. For
NOTE:

84 SPN 713 (CPC)
Section Page
84.1 SPN 713/FMI 3 ......................................................................................... 84- 3

84.2 SPN 713/FMI 4 ......................................................................................... 84- 4
84.3 SPN 713/FMI 5 ......................................................................................... 84- 5
84.4 SPN 713/FMI 7 ......................................................................................... 84- 6
84.1 SPN 713/FMI 3
TOP2 Lockout Solenoid - indicates a short to power on the pin 7 circuit of the CPC #3 connector.
NOTE:

84.2 SPN 713/FMI 4
84.2 SPN 713/FMI 4
TOP2 Lockout Solenoid - indicates a short to ground circuit on pin 7 of the CPC #3 connector.
NOTE:

84.3 SPN 713/FMI 5
TOP2 Lockout Solenoid - indicates an open circuit on the pin 7 circuit of the CPC #3 connector.
NOTE:

84.4 SPN 713/FMI 7
84.4 SPN 713/FMI 7
TOP2 Shift Failure indicates an open, ground or shot to power on the pin 7 of the CPC #3
NOTE:

85 SPN 714 (CPC)
Section Page
85.1 SPN 714/FMI 3 ......................................................................................... 85- 3

85.2 SPN 714/FMI 4 ......................................................................................... 85- 4
85.3 SPN 714/FMI 5 ......................................................................................... 85- 5
85.1 SPN 714/FMI 3
TOP2 Shift Solenoid - indicates a short to power on the pin 8 circuit CPC #3 connector. For
NOTE:

85.2 SPN 714/FMI 4
85.2 SPN 714/FMI 4
TOP2 Shift Solenoid - indicates a short to ground circuit on pin 8 of the CPC #3 connector. For
NOTE:

85.3 SPN 714/FMI 5
TOP2 Shift Solenoid - indicates a open circuit on the pin 8 circuit of the CPC #3 connector. For
NOTE:

85.3 SPN 714/FMI 5

86 SPN 715 (CPC)
Section Page
86.1 SPN 715/FMI 3 ......................................................................................... 86- 3

86.2 SPN 715/FMI 4 ......................................................................................... 86- 4
86.3 SPN 715/FMI 5 ......................................................................................... 86- 5
86.1 SPN 715/FMI 3
Vehicle Power Shutdown - indicates a short to power on the pin 10 circuit of the CPC #4
NOTE:

86.2 SPN 715/FMI 4
86.2 SPN 715/FMI 4
Vehicle Power Shutdown - indicates a short to ground circuit on pin 10 of the CPC #4 connector.
NOTE:

86.3 SPN 715/FMI 5
Vehicle Power Shutdown - indicates a open circuit on the pin 10 circuit of the CPC #4 connector.
NOTE:

86.3 SPN 715/FMI 5

87 SPN 723
Section Page
87.1 SPN 723/FMI 3 ......................................................................................... 87- 3

87.2 SPN 723/FMI 4 ......................................................................................... 87- 4
87.3 SPN 723/FMI 8 ......................................................................................... 87- 5
87.4 SPN 723/FMI 10 ....................................................................................... 87- 7
87.5 SPN 723/FMI 11 ....................................................................................... 87- 8
87.6 SPN 723/FMI 14 ....................................................................................... 87-10
87.7 SPN 723/FMI 31 ....................................................................................... 87-11
87.1 SPN 723/FMI 3
Check as follows:
1. Disconnect the camshaft position sensor.
3. Measure the voltage between pins 1 and 3 of the camshaft position sensor harness.
4. Measure the voltage between pin 1 of the camshaft position sensor harness and ground.
[a] If the voltage is less than 4.5 volts, repair the wire between pin 1 of the camshaft
position sensor harness and pin 82 of the MCM 120-pin connector.
[b] If the voltage is greater than 4.5 volts, repair the wire between pin 3 of the camshaft
5. Measure the voltage between pins 2 and 3 of the camshaft position sensor harness.
[a] If the voltage is greater than 11.5 volts, replace the camshaft position sensor.
[b] If the voltage is less than 11.5 volts, repair the wire between pin 2 of the camshaft

87.2 SPN 723/FMI 4
87.2 SPN 723/FMI 4
This diagnostic is typically is a short to ground.
Check as follows:
1. Disconnect the cam position sensor.
3. Measure the resistance between pins 1 of the camshaft position sensor harness and ground.
[a] If the resistance is less than 1k ohms, repair the wire between pin 1 of the camshaft
position sensor harness and pin 82 of the MCM 120-pin connector
4. Measure the resistance between pin 2 of the camshaft position sensor harness and ground.
[a] If the resistance is less than 1k ohms, repair the wire between pin 2 of the camshaft
[b] If the resistance is greater than 1k ohms, replace the camshaft position sensor.

87.3 SPN 723/FMI 8
This diagnostic is typically camshaft position sensor time out.
Check as follows:
1. Use DDDL to insure that cranking speed is over 150 RPM. Is cranking speed over 150
RPM?
[b] No; refer to section to determine the cause of low crank speed.
2. Disconnect the camshaft position sensor electrical harness connector.
3. Turn on the ignition (key ON, engine OFF).
5. Measure the voltage between pin 1 and pin 3 on the harness side of the camshaft position
sensor.

87.3 SPN 723/FMI 8
sensor.
of the camshaft position sensor and pin 45 of the MCM 120-pin connector.
[b] If the voltage is greater than 11.5 volts, go to step 8.
7. Measure the voltage between pin 1 on the harness side of the camshaft position sensor
and engine ground.
side of the camshaft position sensor and pin 45 of the MCM 120-pin connector.
8. Has the engine had any gear train, camshaft, or flywheel repairs made?
[a] Yes; verify proper gear train timing and proper flywheel installation.
9. Remove the camshaft position sensor and inspect for damage. Is there damage to the
sensor?
[a] Yes; inspect the tone wheel on the intake cam for damage. Check gear train for
excessive lash or damage. If damage is found, repair as necessary, and replace the
camshaft position sensor. Refer to section 3.7.1.
[b] No; replace the camshaft position sensor. Refer to section 3.7.1.

87.4 SPN 723/FMI 10
This diagnostic is typically camshaft position sensor signal erratic.

RPM?
[b] No; to refer to section determine the cause of low crank speed.
2. Disconnect the camshaft position sensor harness connector.
sensor.
sensor.
and engine ground.
sensor?

87.5 SPN 723/FMI 11
87.5 SPN 723/FMI 11
This diagnostic is typically camshaft position sensor failure.
RPM?
[a] Yes; go to next step.
[b] No; refer to section to determine the cause of low crank speed.
sensor.

sensor.
and engine ground.
sensor?

87.6 SPN 723/FMI 14
87.6 SPN 723/FMI 14
This diagnostic is typically swapped pins.

If this SPN and FMI are active, verify that the wiring from camshaft position sensor pin 1 to pin
44 of the MCM 120pin connector and that the wiring from camshaft position sensor pin 2 to pin
45 of the MCM 120pin connector is correct.

87.7 SPN 723/FMI 31
This diagnostic is typically no match of camshaft and crankshaft signals.

RPM?
[a] Yes; go to next step.
[b] No; to determine the cause of low crank speed. Refer to section .
[b] If connector shows no signs of damage, go to next step.
sensor.
sensor.
and engine ground.
[b] No; go to next step.
sensor?

87.7 SPN 723/FMI 31

88 SPN 729
Section Page
88.1 SPN 729/FMI 0 ......................................................................................... 88- 3

88.2 SPN 729/FMI 4 ......................................................................................... 88- 4
88.3 SPN 729/FMI 7 ......................................................................................... 88- 5
88.1 SPN 729/FMI 0
This diagnostic is typically grid heater permanently on.
Check as follows:
3. Measure the resistance between pin 1 of the grid heater harness connector and ground
[a] If the resistance is less than 5 , repair short to ground between pin 1 of the grid heater
[b] If the resistance is greater than 5 , replace the grid heater. Refer to section .

88.2 SPN 729/FMI 4
88.2 SPN 729/FMI 4
This diagnostic is typically grid heater Circuit Failed Low.

1. Check battery power and ground cable connections to the grid heater.
[a] If cables are secure and clean on both ends, go to step 2.
[b] If cables are not secure and clean, repair as necessary.
4. Measure the resistance between pin 1 of the grid heater harness connector and ground.
[a] If the resistance is less than 1k ohms, repair short to ground between pin 1 of the grid
heater harness connector and pin 79 of the MCM.
[b] If the resistance is greater than 1k ohms, replace the grid heater. Refer to section .

88.3 SPN 729/FMI 7
This diagnostic is typically a problem with the grid heater.

1. Ensure the grid heater positive and negative battery cables are securely fastened at both
ends.
[a] If properly fastened, go to next step.
[b] If not properly fastened, repair as necessary.
3. Turn the Ignition ON.
4. Measure the voltage between the grid heater harness connector pin 1 and pin 4.
[a] If the voltage is between 4.25 and 4.75, go to step 6.
[b] If the voltage is less than 4.25, go to step 5.
5. Measure the voltage between the grid heater harness connector pin 1 and ground.
[a] If the voltage is less than 4.25, repair wire between pin 1 of the grid heater harness
connector and pin 79 of the MCM.
[b] If the voltage is between 4.25 and 4.75, repair wire between pin 4 of the grid heater
harness connector and pin 95 of the MCM.
6. Measure the voltage between grid heater harness connector pin 3 and ground.
[b] If the voltage is less than 2.25, repair wire between pin 3 of the grid heater harness
connector and pin 92 of the MCM.
7. Turn the ignition OFF for 15 seconds, then back ON.
NOTE:
This measurement must be done within 30 seconds of Key ON; after this time has
elapsed the voltage will drop to approximately 9 volts. This is a normal condition.
[a] If the voltage is greater than 11.5, replace the grid heater. Refer to section .
[b] If the voltage is less than 11.5 cycle the ignition and recheck voltage. If voltage is
still below 11.5, repair wire between pin 2 of the grid heater harness connector and
pin 41 of the MCM.

88.3 SPN 729/FMI 7

89 SPN 904 (CPC)
Section Page
89.1 SPN 904/FMI 9 ......................................................................................... 89- 3

89.2 SPN 904/FMI 13 ....................................................................................... 89- 4
89.3 SPN 904/FMI 19 ....................................................................................... 89- 5
89.1 SPN 904/FMI 9
This diagnostic is typically the J1939 EBC2 message from the ABS is missing.
Check as follows:

89.2 SPN 904/FMI 13
89.2 SPN 904/FMI 13
This diagnostic is typically the front axle speed signal is missing.

Check as follows:

89.3 SPN 904/FMI 19
This diagnostic is typically the front axle speed signal is erratic.

Check as follows:

89.3 SPN 904/FMI 19

90 SPN 973 (CPC)
Section Page
90.1 SPN 973/FMI 9 ......................................................................................... 90- 3

90.2 SPN 973/FMI 13 ....................................................................................... 90- 4
90.3 SPN 973/FMI 19 ....................................................................................... 90- 5
90.1 SPN 973/FMI 9
This diagnostic is typically the J1939 EBC1 (Engine Brake Switches) is missing.
Check as follows:
[c] If only SPN 973/FMI 9 is present, go to the next step.
[a] If yes, ensure the CPC Group PGR001 parameter EBC1 Source Address SAE
J1939 is confi8gured properly: 33 = non multiplex switches, 49 = multiple switches.

90.2 SPN 973/FMI 13
90.2 SPN 973/FMI 13
This diagnostic is typically the engine retarder selection signal is missing.

Check as follows:

90.3 SPN 973/FMI 19
This diagnostic is typically the engine retarder selection signal is erratic.

Check as follows:

90.3 SPN 973/FMI 19

91 SPN 986 (CPC)
Section Page
91.1 SPN 986/FMI 9 ......................................................................................... 91- 3

91.1 SPN 986/FMI 9
This diagnostic is typically the J1939 CM1 message is missing.

Check as follows:

91.1 SPN 986/FMI 9

92 SPN 986 (CPC) (EPA10)
Section Page
92.1 SPN 986/FMI 13 ....................................................................................... 92- 3

92.2 SPN 986/FMI 19 ....................................................................................... 92- 4
92.1 SPN 986/FMI 13
This diagnostic is typically J1939 CM1 SPN986 Signal from source #1 or #2 is missing
This fault indicates that the CPC has received a J1939 CM1 message; however the SPN 986
Requested Fan Percent Speed Data Signal is not available. Note: this fault does not indicate a
CPC issue, do not replace the CPC.
and their communication status. Once this is done, troubleshoot the forward HVAC
control module or the MSF (Modular Switch Field) modules.

92.2 SPN 986/FMI 19
92.2 SPN 986/FMI 19
This diagnostic is typically J1939 CM1 SPN986 Signal from source #1 or #2 is erratic.
This indicates the J1939 CM1 message is received by the CPC; however the SPN 986 Requested
Fan Percent Speed is in error. Note: this fault does not indicate a CPC issue, do not replace
the CPC.

93 SPN 1037 (ACM2) (EPA10)
Section Page
93.1 SPN 1037/FMI 0 ....................................................................................... 93- 3

93.2 SPN 1037/FMI 16 ..................................................................................... 93- 4
93.1 SPN 1037/FMI 0
This diagnostic is typically very high HC Absorption in the DPF.

Check as follows:
ENGINE EXHAUST
exhaust is toxic.
2. Start engine.
HOT EXHAUST
During parked regeneration the exhaust gases will be
extremely HOT and could cause a fire if directed at
combustible materials. The vehicle must be parked
outside.
3. Using DDDL 7.X, perform a parked regeneration.

4. When regeneration is complete, clear all fault codes. Verify Repairs 219.1.

93.2 SPN 1037/FMI 16
93.2 SPN 1037/FMI 16
This diagnostic is typically high HC absorption in the DPF.

Check for DPF HC absorption high as follows:
ENGINE EXHAUST
exhaust is toxic.
2. Start engine.
HOT EXHAUST
outside.
3. Using DDDL 7.X, perform a parked regeneration.


94 SPN 1071
Section Page
94.1 SPN 1071/FMI 3 ....................................................................................... 94- 3

94.2 SPN 1071/FMI 4 ....................................................................................... 94- 4
94.3 SPN 1071/FMI 5 ....................................................................................... 94- 5
94.1 SPN 1071/FMI 3
This diagnostic is typically a short to power.

Check as follows:

of the fan control solenoid connector and pin 33 of the 120pin MCM connector.
[b] If the voltage is less than 11.5 volts, replace the fan control solenoid. Verify Repairs
219.1.

94.2 SPN 1071/FMI 4
94.2 SPN 1071/FMI 4
This diagnostic is typically a short to ground.

Check as follows:

2. Disconnect the fan control solenoid.
4. Measure the resistance between pin 1 of the fan control solenoid and ground.
[a] If the resistance is less than 5 , repair the short to ground between pin 1 of the fan
control solenoid and pin 33 of the 120pin MCM connector. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , repair the short to ground between pin 2 of the fan
control solenoid and pin 91 of the 120pin MCM connector. Verify Repairs 219.1.

94.3 SPN 1071/FMI 5

Check as follows:

[a] If SPN 647/5, SPN 1072/5 and SPN 1071/5 are active repair the open in between
the pin 91 of the 120pin MCM connector and the fan and the Jake Brake solenoids.
[b] If only SPN 1071/5 is active, go to the next step.
4. Measure the voltage between pin 1 and 2 of the fan control solenoid connector.
[b] If the voltage is between 11.5 and 13.5 volts, replace the fan control solenoid.
[a] If the voltage is less than 11.5 volts, repair the open between pin 2 of the fan control
[b] If the voltage is greater than 11.5, repair the open between pin 1 of the fan control

94.3 SPN 1071/FMI 5

95 SPN 1072
Section Page
95.1 SPN 1072/FMI 3 ....................................................................................... 95- 3

95.2 SPN 1072/FMI 4 ....................................................................................... 95- 4
95.3 SPN 1072/FMI 5 ....................................................................................... 95- 6
95.1 SPN 1072/FMI 3
Repair the short to battery power between pin 1 on the jake solenoid and pin 66 on the MCM
120-pin connector.

95.2 SPN 1072/FMI 4
95.2 SPN 1072/FMI 4
This diagnostic is typically Jake Brake Stage 1 circuit failed low.
Check as follows:
1. Disconnect the front fuel injector valve cover harness.

2. Measure resistance between pins 13 and ground on the front fuel injector valve cover
harness connector. If you are using J-4867110, measure either Jake 1 pin and ground.
[a] If the resistance is greater than 15 , repair short to ground between pin 13 of the
front fuel injector valve cover harness connector and pin 66 of the 120pin MCM
4. Disconnect the front Jake Brake.
5. Measure resistance between either terminal on the Jake Brake solenoid and ground.
[a] If the resistance is less than 5 ohms, replace the Jake Brake solenoid. Verify Repairs
219.1.
[b] If the resistance is greater than 5 , repair the short to ground between pins 13
and 14 of the front fuel injector valve cover harness and the Jake Brake solenoid.

95.3 SPN 1072/FMI 5
95.3 SPN 1072/FMI 5
This diagnostic is typically Jake Brake Stage 1 circuit failed open.
Check as follows:
1. Disconnect the front fuel injector valve cover harness.
2. Measure the resistance between pin 13 and 14 on the valve cover side of the front fuel
injector harness. If you are using J-4867110, measure across Jake 1 pins.
[a] If the resistance is between 9 12 , go to step 3.
[b] If the resistance not between 9 12 , go to step 5.
4. Measure the voltage between pin 14 on the engine harness side of the valve cover harness
and ground.
[a] If the voltage is less than 11.5 volts, repair the cause of low voltage between pin 91
of the MCM 120pin connector and pin 14 of the valve cover harness connector.
[b] If the voltage is greater than 11.5 volts, repair the open between pin 13 of the valve
cover harness connector and pin 66 of the MCM 120pin connector. Verify Repairs
219.1.

5. Remove the valve cover.

6. Disconnect the front Jake Brake solenoid.
7. Measure the resistance across the Jake Brake solenoid.
[a] If the resistance is between 9 11 , replace the under valve cover harness.
Refer to section .
[b] If the resistance is NOT between 9 11 , replace the Jake Brake solenoid.

95.3 SPN 1072/FMI 5

96 SPN 1073
Section Page
96.1 SPN 1073/FMI 3 ....................................................................................... 96- 3

96.2 SPN 1073/FMI 4 ....................................................................................... 96- 4
96.3 SPN 1073/FMI 5 ....................................................................................... 96- 6
96.1 SPN 1073/FMI 3
This diagnostic is typically Jake Brake Stage 2 Circuit Failed High

Repair the short to battery power between pin 1 on the jake solenoid and pin 32 on the MCM
120-pin connector.

96.2 SPN 1073/FMI 4
96.2 SPN 1073/FMI 4
This diagnostic is typically Jake Brake Stage 2 circuit failed low.
Check as follows:
1. Disconnect the rear fuel injector valve cover harness.

2. Measure resistance between pins 13 and ground on the rear fuel injector valve cover
harness connector. If you are using J-4867110, measure across the Jake 2 pins.
[a] If the resistance is greater than 15 , repair short to ground between pin 13 of the
front fuel injector valve cover harness connector and pin 32 of the 120pin MCM
4. Disconnect the rear Jake Brake.
5. Measure resistance between either terminal on the Jake Brake solenoid and ground.
[a] If the resistance is less than 5 ohms, replace the Jake Brake solenoid. Verify Repairs
219.1.
[b] If the resistance is greater than 5 , repair the short to ground between pins 13 and 14
of the front fuel injector valve cover harness. Verify Repairs 219.1.

96.3 SPN 1073/FMI 5
96.3 SPN 1073/FMI 5
This diagnostic is typically Jake Brake Stage 2 circuit failed open.
Check as follows:
1. Disconnect the rear fuel injector valve cover harness.
2. Measure the resistance between pin 13 and 14 on the valve cover side of the rear fuel
injector harness. If you are using J-4867110, measure across Jake 2 pins.
[a] If the resistance is between 9 12 , go to step 3.
[b] If the resistance not between 9 12 , go to step 5.
4. Measure the voltage between pin 14 on the engine harness side of the valve cover harness
and ground.
[a] If the voltage is less than 11.5 volts, repair the cause of low voltage between pin 62
of the MCM 120pin connector and pin 14 of the valve cover harness connector.
[b] I the voltage is greater than 11.5 volts, repair the open between pin 13 of the valve
cover harness connector and pin 32 of the MCM 120pin connector. Verify Repairs
219.1.


6. Disconnect the rear Jake Brake solenoid.
7. Measure the resistance across the Jake Brake solenoid.
[a] If the resistance is between 911 , replace the under valve cover harness.
Refer to section .
[b] If the resistance is NOT between 911 , replace the Jake Brake solenoid.

96.3 SPN 1073/FMI 5

97 SPN 1077
Section Page
97.1 SPN 1077/FMI 5 ....................................................................................... 97- 3

97.2 SPN 1077/FMI 7 ....................................................................................... 97- 4
97.3 SPN 1077/FMI 14 ..................................................................................... 97- 6
97.4 SPN 1077/FMI 15 ..................................................................................... 97- 7
97.5 SPN 1077/FMI 31 ..................................................................................... 97- 8
97.1 SPN 1077/FMI 5
SPN 1077/FMI 5 indicates a quantity control valve current too low.
Check as follows:
1. Disconnect the quantity control valve.
2. Measure the resistance across pins 1 and 2 of the quantity control valve.
[a] If the resistance is greater than 2 , replace quantity control valve. Refer to section .
4. Measure the resistance between pin 1 of the MCM 120-pin connector and pin 1 of the
quantity control valve.
[a] If the resistance is less than 5 , go to next step.
[b] If the resistance is greater than 5 , repair the open circuit between pin 1 of the 120
MCM connector and pin 1 of the quantity control valve. Verify Repairs 219.1.
5. Measure the resistance between pin 2 of the MCM 120-pin connector and pin 2 of the
quantity control valve.
[a] If the resistance is less than 5 , call the Detroit Diesel Customer Support Center at
3135925800 for authorization to replace the MCM. Refer to section 2.3.
[b] If the resistance is greater than 5 , repair the open circuit between pin 2 of the MCM
120-pin connector and pin 2 of the quantity control valve. Verify Repairs 219.1.

97.2 SPN 1077/FMI 7
97.2 SPN 1077/FMI 7
system. The MCM monitors the rail pressure and when rail pressure deviation is greater than
200 bar for eight seconds, the MCM sets the code. This fault can occur due to the conditions
listed below:
Fuel supply issues (fuel level, fuel aeration)
Intermittent loss of engine speed signal
Check as follows:
performed?
[a] If YES, the code may be set due to air in the fuel system clear codes.
[b] If NO, go to next step.
[a] If additional fault codes (with the exception of DPF codes) are present along with
1077/7, service the additional fault codes first.
[a] If counter is greater than 50, replace PLV and road test vehicle. Refer to section .
[b] If counter is less than 50, go to next step.
[a] If engine speed and signal are stable and accurate, go to step 8.
[b] If engine speed and signal are unstable or erratic, go to the next step.


8. Perform Low Pressure Fuel System Pressure Test. Refer to4.3
9. Inspect fuel system for leaks. Refer to4.1
10. Perform diagnosis on pumping elements.
12. Perform the Rail Pressure Bleed Off (RPBO) test using DDDL. Refer to4.7.1.
[b] If the RPBO Test passed, fault condition may be intermittent..
13. Perform PLV Leakage Test. Refer to.
at 3135925800.
[b] If the Amplifier/Needle Return Flow Test fails, fix as necessary. Go to Verify
Repairs.

97.3 SPN 1077/FMI 14
97.3 SPN 1077/FMI 14
system (too high, Leak Down Test). The MCM monitors rail pressure during engine shut down
and compares it to a stored learned value. If the bleed down rate has changed due to leakage and it
is below the learned value, the code will set.
Check as follows:
first.
2. Start the engine. Perform a Rail Pressure Bleed Off test (RPBO) using DDDL.
[a] If the Rail Pressure Bleed Off test passes, clear code and road test vehicle.
[b] If the Rail Pressure Bleed Off test fails, go to next step.
3. Check for internal and external high pressure fuel system leakage. Refer to section 4.2.
[a] If leaks are found, repair leaks, prime the fuel system, refer to Fuel System
Priming. Start engine and verify repair.
[b] If no leaks are found, go to next step.
4. Check the ISB Values. Refer to section 4.9.
[a] If there are no cylinders above 70% or below -70%, go to next step.
[b] If there is a cylinder(s) above 70% or below -70%, remove that fuel injector line
and cap off the rail with J-48704. Run the Rail Pressure Bleed Off test again. If
the Rail Pressure Bleed Off passes, change the fuel injector that is capped off and
verify repairs.
5. Check for leakage from the Pressure Limiting Valve (PLV). Refer to section .
[a] If the PLV is leaking, replace the PLV and verify repairs. Refer to section .
[b] If the PLV is not leaking, go to next step.
6. Perform Amplifier/Needle Return measurements. Refer to section 4.5.
[a] If the Amplifier/Needle Return Flow test failed, repair as necessary and verify repairs.
[b] If the Amplifier/Needle Return Flow test passed, replace the high pressure fuel pump.
Refer to section .

97.4 SPN 1077/FMI 15
system. The MCM monitors the rail pressure and when a leakage rate is greater than 100 l/h, the
MCM sets the code. There is no fault reaction (limp home mode) associated to this code. This
fault can occur due to the conditions listed below:
Check as follows:
[a] If additional fault codes are present along with 1077/15, service the additional fault
codes first
3. Inspect the following fuel system components for external leakage: high pressure pump,
lines to fuel rail, fuel rail, pressure limiting valve (PLV), and fuel lines from rail to fuel
injector.
[a] If leakage was found, repair and Verify Repairs 219.1.
4. Perform rail pressure bleed off test. Refer to section 4.7.1.
[a] If the RPBO test failed; go to next step.
[b] If the RPBO test passed, no problem found.
5. Perform pressure limiting valve (PLV) leakage test. Refer to section 4.8.
[a] If the pressure limiting valve (PLV) test passed; go to next step.
[b] If the pressure limiting valve (PLV) test failed; replace pressure limiting
valve.Refer to section .
6. Perform amplifier/needle return measurements. Refer to section 4.5.
[a] If the amplifier/needle return flow test passed; no problem found.
[b] If the amplifier/needle return flow test failed; fix as necessary. Verify Repairs 219.1.

97.5 SPN 1077/FMI 31
97.5 SPN 1077/FMI 31
This diagnostic is typically related to a low fuel pressure condition. The MCM monitors the rail
pressure and when rail pressure is below 80 BAR for a determined time the MCM determines
that it has lost control of the rail pressure and is forced into open loop. This fault can occur
due to the conditions listed below:
High pressure pump (pumping element failures)
Fuel supply issues (low fuel level, fuel aeration)
Check as follows:
codes first.
performed?
[a] Yes, the code may be set due to air in the fuel system and clear codes.
[a] If the counter is greater than 50 opening events, replace PLV and road test vehicle.
Refer to section .
[b] If counter is less than 50 opening events, go to next step.
[a] If engine speed and signal are stable and accurate go to step 8.
[b] If engine speed and signal are instable or erratic, go to the next step.


8. Perform Low Pressure Fuel System Pressure Test. Refer to section 4.3.
9. Inspect fuel system for leaks. Refer to section 4.1.
[a] If test passes; go to next step.
[b] If test fails; look for cause of aerated fuel.
11. Perform the Rail Pressure Bleed Off (RPBO) test using DDDL. Refer to section 4.7.
[b] If the RPBO Test passed; fault condition may be intermittent. Verify Repairs 219.1.
12. Perform PLV Leakage Test. Refer to section .
at 3135925800.
[b] If the Amplifier/Needle Return Flow Test fails, fix as necessary. Verify Repairs 219.1.

97.5 SPN 1077/FMI 31

98 SPN 1172
Section Page
98.1 SPN 1172/FMI 2 ....................................................................................... 98- 3

98.2 SPN 1172/FMI 3 ....................................................................................... 98- 4
98.3 SPN 1172/FMI 4 ....................................................................................... 98- 5
98.1 SPN 1172/FMI 2
This code is typically a coolant temperature/compressor inlet temperature plausibility error.

Check as follows:
1. Disconnect the turbocharger compressor inlet temperature sensor.
2. Inspect the turbocharger compressor inlet temperature sensor connectors for bent,
damaged or corroded pins.
[a] If damaged pins are found, repair as necessary. Verify Repairs 219.1.
[b] If no damage is found, replace the turbocharger compressor inlet temperature sensor.

98.2 SPN 1172/FMI 3
98.2 SPN 1172/FMI 3
This code is typically sensor or circuit failed high.

Check as follows:
[a] If 1172/3, 3250/3, 3242/3 and 3246/3 are present, go to the next step.
[b] If only 1172/3 is present, go to step 5
3. Disconnect the turbocharger compressor inlet temperature sensor (TCI sensor).
4. Measure the voltage between pin 1 of the TCI sensor and ground.
[a] If the voltage is greater than 2.75 volts, repair the short to power between pin
88 of the 120pin MCM connector and the TCI sensor, DOC Inlet Temperature
sensor, DOC Outlet Temperature sensor and the DPF Outlet Temperature sensor.
[b] If no voltage is present on pin 1 of the Intake Air Temperature sensor, repair the
open between pin 88 of the 120pin MCM connector and the TCI sensor, DOC
Inlet Temperature sensor, DOC Outlet Temperature sensor and the DPF Outlet
Temperature sensor. Verify Repairs 219.1.
5. Disconnect the turbocharger compressor inlet temperature sensor.
6. Measure the voltage between pin 1 and pin 2 of the turbocharger compressor inlet
temperature sensor.
[b] If the voltage is greater than 2.75 volts, replace the turbocharger compressor inlet
temperature sensor. Refer to section 3.11.
7. Measure the voltage between pin 2 of the turbocharger compressor inlet temperature
sensor and ground.
[a] If the voltage is less than 2.75 volts, repair the open between pin 2 of the turbocharger
compressor inlet temperature sensor and pin 86 of the 120pin MCM connector.
[b] If the voltage is greater than 2.75 volts, repair the open between pin 1 of the
turbocharger compressor inlet temperature sensor and pin 86 of the 120pin MCM

98.3 SPN 1172/FMI 4
This code is typically sensor or circuit failed low.

Check as follows:
2. Disconnect the TCI sensor.
4. Measure resistance between pin 1 and pin 2 of the TCI sensor Harness connector.
[a] If the resistance is less than 3 , repair the short between pin 1 and pin 2 of the TCI
sensor Harness connector and pin86 and pin 88 of the 120pin MCM connector.
[b] If the resistance is greater than 3 , repair the short to ground between pin 2 of the
TCI sensor and pin 86 of the 120pin MCM connector. Verify Repairs 219.1.

98.3 SPN 1172/FMI 4

99 SPN 1323
Section Page
99.1 SPN 1323/31 ............................................................................................ 99- 3

99.1 SPN 1323/31
The fault condition is related to cylinder #1 exhibiting a misfire event. The entry conditions
for this code are:
Engine speed is above low idle
All cylinders are active, no fault reactions
Engine speed/torque is steady
This fault can occur due to the conditions listed below:
Cylinder kit failure
Valve train failure
Lash adjustments
Fuel injector
High pressure fuel line (rail to fuel injector)
Debris entering fuel injector (intermittent faults)
Check as follows:
codes first.
[b] If only 1323/31 is present go to next step.
2. Using DDDL 7.X perform Compression Test listed under Service Routines.
[a] If cylinder #1 shows low compression, the issue is related to a mechanical
failure/issue for that cylinder. Fix cylinder concern and return to step 1.
[b] If all cylinders are within 10%, go to next step.
3. Start and bring engine up to operating temperature (over 140F/60C).
4. Using DDDL 7.X read parameter Idle Speed Balance Values: Cylinder #1 under
Instrumentation section.
NOTE:
For the idle speed balance values to update, the engine speed must be at idle.
[a] If value for cylinder #1 is at its maximum limit of +100, go to the next step.
[b] If value for cylinder #1 is less than +100, fault may be intermittent. Obtain
information from customer on driving habits, recent repairs, number of occurrences
when fault code set, or situations when the code occurred. Try to retest engine within
these parameters.
5. Inspect fuel line from rail to fuel injector for damage
[a] If damage is found, replace if necessary. Refer to section .
[b] If no damage was found, replace fuel injector. Refer to section .

99.1 SPN 1323/31

100SPN 1324
Section Page
100.1 SPN 1324/FMI 31 ..................................................................................... 100- 3

100.1 SPN 1324/FMI 31
for this code are:
Valve train failure
Lash adjustments
Fuel injector
Check as follows:
codes first.
4. Using DDDL 7.X read parameter Idle Speed Balance Values: cylinder #2 under
NOTE:
these parameters.
5. Inspect fuel line from rail to fuel injector for damage.

100.1 SPN 1324/FMI 31

101SPN 1325
Section Page
101.1 SPN 1325/FMI 31 ..................................................................................... 101- 3

101.1 SPN 1325/FMI 31
for this code are:
Valve train failure
Lash adjustments
Fuel injector
Check as follows:
codes first.
NOTE:
these parameters.

101.1 SPN 1325/FMI 31

102SPN 1326
Section Page
102.1 SPN 1326/31 ............................................................................................ 102- 3

102.1 SPN 1326/31
for this code are:
Valve train failure
Lash adjustments
Fuel injector
Check as follows:
codes first.
NOTE:
these parameters.
5. Inspect fuel line from rail to fuel injector for damage

102.1 SPN 1326/31

103SPN 1327
Section Page
103.1 SPN 1327/31 ............................................................................................ 103- 3

103.1 SPN 1327/31
for this code are:
Valve train failure
Lash adjustments
Fuel injector
Check as follows:
codes first.
NOTE:
these parameters.

103.1 SPN 1327/31

104SPN 1328
Section Page
104.1 SPN 1328/31 ............................................................................................ 104- 3

104.1 SPN 1328/31
for this code are:
Valve train failure
Lash adjustments
Fuel injector
Check as follows:
codes first.
NOTE:
these parameters.

104.1 SPN 1328/31

105SPN 1590 (CPC)
Section Page
105.1 SPN 1590/FMI 9 ....................................................................................... 105- 3

105.1 SPN 1590/FMI 9
This diagnostic is typically the J1939 ACC1 messag2 from Adaptive Cruise control is missing.
Check as follows:
[c] If only a J1939 Error fault is present, go to step.

105.1 SPN 1590/FMI 9

106SPN 1624 (CPC)
Section Page
106.1 SPN 1624/FMI 9 ....................................................................................... 106- 3

106.2 SPN 1624/FMI 13 ..................................................................................... 106- 4
106.3 SPN 1624/FMI 19 ..................................................................................... 106- 5
106.1 SPN 1624/FMI 9
This diagnostic is typically the J1939 TCO1 message is missing.

Check as follows:

106.2 SPN 1624/FMI 13
106.2 SPN 1624/FMI 13
This diagnostic is typically the tachograph vehicle speed signal is missing.

Check as follows:

106.3 SPN 1624/FMI 19
This diagnostic is typically the tachograph vehicle speed signal is erratic.

Check as follows:

106.3 SPN 1624/FMI 19

107SPN 1636
Section Page
107.1 SPN 1636/FMI 2 ....................................................................................... 107- 3

107.2 SPN 1636/FMI 3 ....................................................................................... 107- 4
107.3 SPN 1636/FMI 4 ....................................................................................... 107- 6
107.4 SPN 1636/FMI 20 ..................................................................................... 107- 7
107.1 SPN 1636/FMI 2
This diagnostic is typically engine air temperature plausibility fault out of range (low box)

107.2 SPN 1636/FMI 3
107.2 SPN 1636/FMI 3
This diagnostic is typically intake manifold temperature circuit failed high.
Check as follows:
[a] If 1636/3 and 2630/3 are present, go to step 6.
2. Disconnect the intake manifold Temperature sensor.
4. Measure the voltage between pins 1 and 2 of the intake manifold Temperature sensor
harness connector.
[a] If the voltage is between 2.8 and 3 volts, replace the intake manifold Temperature

5. Measure the voltage between pin 2 of the intake manifold Temperature sensor and ground.
[a] If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the intake
manifold Temperature sensor connector and pin 52 of the MCM 120pin connector.
[b] If the voltage is less than 2.8 volts, repair the wire between pin 2 of the intake
manifold Temperature sensor connector and pin 106 of the MCM 120pin connector.
6. Measure the voltage between pins 1 and 2 of the intake manifold Temperature sensor
harness connector.
[a] If the voltage is greater than 3 volts, repair the short to power on either pin 106 or 119
of the MCM 120pin connector. Verify Repairs 219.1.
connector and the intake manifold Temperature sensor and the Intake Air Temperature
sensor. Verify Repairs 219.1.

107.3 SPN 1636/FMI 4
107.3 SPN 1636/FMI 4
This diagnostic is typically intake manifold temperature circuit failed low.
Repair the short to ground between pin 2 of the intake manifold Temperature sensor harness
connector and pin 106 of the MCM 120pin connector. Verify Repairs 219.1.

107.4 SPN 1636/FMI 20
This diagnostic is typically intake manifold temperature drift (low box).

2. Measure voltage between pins 1 and 2 of the intake manifold Temperature sensor harness
connector.
[a] If voltage is between 2.75 and 3.0, replace the intake manifold Temperature sensor.
[b] If voltage is less than 2.75, go to next step.
3. Measure voltage between pin 2 of the intake manifold Temperature sensor harness
[a] If voltage is less than 2.75, repair wire between pin 2 of the intake manifold
Temperature sensor harness connector and pin 106 of the MCM 120pin connector.
[b] If voltage is between 2.75 and 3.0, repair wire between pin 1 of the intake manifold
Temperature sensor harness connector and pin 52 of the MCM 120pin connector.

107.4 SPN 1636/FMI 20

108SPN 1636 (MCM) (EPA10)
Section Page
108.1 SPN 1636/FMI 0 ....................................................................................... 108- 3

108.1 SPN 1636/FMI 0
This diagnostic is typically Charge Air Cooler Low Efficiency.

This fault indicates that the MCM has detected very high Charge Air and Intake Manifold
temperatures.
Possible causes:
Low vehicle speed with high engine load (steep grade climb)
Fan operation
Winter front in high ambient temperatures
If the above conditions did not occur, refer to OEM literature for Charge Air Cooler, leak and
performance tests.

108.1 SPN 1636/FMI 0

109SPN 1659 (MCM) (EPA10)
Section Page
109.1 SPN 1659/FMI 18 .................................................................................... 109- 3

109.1 SPN 1659/FMI 18
This diagnostic is typically Thermostat Error Detected.

2. Start engine and bring to operating temperature to 185F (85C).
[b] No, service cooling system thermostat.
4. Shut engine OFF (key OFF engine OFF).
pins.
is out of range.
Resistance
Nominal
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95

109.1 SPN 1659/FMI 18

110SPN 1716 (CPC)
Section Page
110.1 SPN 1716/FMI 9 ....................................................................................... 110- 3

110.1 SPN 1716/FMI 9
This diagnostic is typically the J1939 ERC1 message is missing.

Check as follows:
[c] If only a J1939 Error fault is present, go to step.

110.1 SPN 1716/FMI 9

111 SPN 1761 (ACM2) (EPA10)
Section Page
111.1 SPN 1761/FMI 1 ....................................................................................... 111- 3

111.2 SPN 1761/FMI 3 ....................................................................................... 111- 4
111.3 SPN 1761/FMI 4 ....................................................................................... 111- 6
111.4 SPN 1761/FMI 17 ..................................................................................... 111- 7
111.5 SPN 1761/FMI 18 ..................................................................................... 111- 8
111.6 SPN 1761/FMI 31 ..................................................................................... 111- 9
111.1 SPN 1761/FMI 1
DEF Tank Level 0 Condition - Empty Tank Speed Limited

This fault indicates that the DEF Tank Level is between 0 and 2.5 % and the warning lamps have
been ignored. A 25% engine derate and 5 mph speed limit is in effect. DEF must be added to the
DEF Tank (minimum tank). After refill idle engine for 5 minutes if fault does not go inactive or
dash lamp stays ON, refer to OEM literature for DEF Level sensor diagnostics.

111.2 SPN 1761/FMI 3
111.2 SPN 1761/FMI 3
This diagnostic is typically DEF Tank Level sensor Circuit Failed High
Check as follows:
[a] If SPN 1761/3 and 3031/3 are present go to step 2.
[b] If SPN 1761/3 is present go to step 9.
2. Disconnect the DEF tank temp/level sender.
3. Inspect the DEF tank temp/level sender connector for bent, spread or corroded pins.
[a] If bent, spread or corroded pins are found, repair as necessary.
[b] If no connector issues are found go to step 4.
5. Measure the voltage between pin 2 on the harness side of the DEF tank temp/level sender
and ground.
[a] If voltage is present, repair short to power between pin 2 on the harness side of the
DEF tank temp/level sender and pin 102 of the ACM.
[b] If no voltage is present go to step 6.
6. Turn the ignition OFF (key OFF, engine OFF).
7. Disconnect the ACM 120 pin connector.
8. Measure the resistance between pin 2 on the harness side of the DEF tank temp/level
sender and pin 102 of the ACM.
[a] If the resistance is greater than 5 ohms repair wire between 2 on the harness side of
the DEF tank temp/level sender and pin 102 of the ACM.
[b] If the resistance is less than 5 ohms, refer to OEM literature for DEF Level sensor
replacement.
[b] If no connector issues are found go to step 11.


12. Measure the voltage between pin 1 on the harness side of the DEF tank temp/level sender
and ground.
[a] If voltage is greater than 3.00 volts, repair short to power between pin 1 on the
harness side of the DEF tank temp/level sender and pin 109 of the ACM.
[b] If voltage is between 2.0 and 2.95 refer to OEM literature for DEF Level sensor
replacement.
[c] If voltage is less than 2.5 volts repair wire between 1 on the harness side of the DEF
tank temp/level sender and pin 109 of the ACM.

111.3 SPN 1761/FMI 4
111.3 SPN 1761/FMI 4
This diagnostic is typically DEF Tank Level sensor Circuit Failed Low
Check as follows:
[b] If no connector issues are found, repair short to ground between pin 1 of the DEF
tank temp/level sender and pin 109 of the ACM.

111.4 SPN 1761/FMI 17
DEF Tank Level 2 Condition - Tank Level Very Low

This fault indicates that the DEF Tank Level is between 2.5 and 7.5 %. A 25% engine derate is
in effect. DEF must be added to the DEF Tank (minimum tank). After refill idle engine for
5 minutes if fault does not go inactive or dash lamp stays ON, refer to OEM literature for DEF
Level sensor diagnostics.

111.5 SPN 1761/FMI 18
111.5 SPN 1761/FMI 18
DEF Tank Level 1 Condition - Empty Tank

This fault indicates that the DEF Tank Level is between 0 and 2.5 %. A 25% engine derate and
55 mph speed limit is in effect. DEF must be added to the DEF Tank (minimum tank). After
refill idle engine for 5 minutes if fault does not go inactive or dash lamp stays ON, refer to OEM
literature for DEF Level sensor diagnostics.

111.6 SPN 1761/FMI 31
DEF Tank Level 3 Condition - Tank Level Low

This fault indicates that the DEF Tank Level is between 7.5 and 12.5 %. DEF must be added
to the DEF Tank (minimum tank). After refill idle engine for 5 minutes if fault does not go
inactive or dash lamp stays ON, refer to OEM literature for DEF Level sensor diagnostics.

111.6 SPN 1761/FMI 31

112SPN 1845 (CPC)
Section Page
112.1 SPN 1845/FMI 9 ....................................................................................... 112- 3

112.1 SPN 1845/FMI 9
This diagnostic is typically the J1939 TCFG2 message is missing.

Check as follows:

112.1 SPN 1845/FMI 9

113SPN 2623 (CPC)
Section Page
113.1 SPN 2623/FMI 4 ....................................................................................... 113- 3

113.2 SPN 2623/FMI 14 ..................................................................................... 113- 4
113.1 SPN 2623/FMI 4
This diagnostic is typically the PWM Accelerator Pedal J1939 GAS2 signal is missing.
Check as follows:

113.2 SPN 2623/FMI 14
113.2 SPN 2623/FMI 14
This diagnostic is typically the PWM Accelerator Pedal J1939 GAS1 and GAS2 signals are
missing..
Check as follows:

114SPN 2630
Section Page
114.1 SPN 2630/FMI 2 ....................................................................................... 114- 3

114.2 SPN 2630/FMI 3 ....................................................................................... 114- 4
114.3 SPN 2630/FMI 4 ...................................................................................... 114- 6
114.4 SPN 2630/FMI 20 .................................................................................... 114- 7
114.5 SPN 2630/FMI 16 ..................................................................................... 114- 8
114.6 SPN 2630/FMI 21 .................................................................................... 114- 9
114.1 SPN 2630/FMI 2
This diagnostic is typically engine air temperature plausibility fault out of range (high box)

114.2 SPN 2630/FMI 3
114.2 SPN 2630/FMI 3
This diagnostic is typically Intake Air Temperature circuit failed high.
Check as follows:
[a] If codes 1636/3 and 2630/3 are active at the same time, go to step 6.
2. Disconnect the Intake Air Temperature sensor.
4. Measure the voltage between pins 1 and 2 of the Intake Air Temperature sensor harness
connector.
[a] If the voltage is between 2.8 and 3 volts, replace the Intake Air Temperature sensor.
5. Measure the voltage between pin 2 of the Intake Air Temperature sensor harness and
ground.
[a] If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of
the Intake Air Temperature sensor corrector and pin 52 of the MCM 120pin
[b] If the voltage is less than 2.8 volts, repair the wire between pin 2 of the Intake
Air Temperature sensor corrector and pin 119 of the MCM 120pin connector.

6. Measure the voltage between pins 1 and 2 of the Intake Air Temperature sensor harness
connector.
[a] If voltage is greater than 3 volts, repair the short to power on one of the following
pins 106 or 119 of the MCM 120pin connector. Verify Repairs 219.1.
[b] If the no voltage is present, repair the open between pin 52 of the MCM 120pin
connector and the Intake Air Temperature sensor and intake manifold Temperature
sensor. Verify Repairs 219.1.

114.3 SPN 2630/FMI 4
114.3 SPN 2630/FMI 4
This diagnostic is typically intake air temperature circuit failed low.
Repair the short to ground between pin 2 of the Intake Air Temperature sensor harness connector

114.4 SPN 2630/FMI 20
This diagnostic is typically Charge Air Outlet Temperature Drift (low box).
1. Inspect the entire air intake system including the Charge Air Cooler for leaks, cracks, or
plugging.
[b] If no damage is found, go to next step.
2. Disconnect the Charge Air Outlet Temperature sensor.
3. Inspect the Charge Air Outlet Temperature sensor harness connector for bent, spread or
corroded pins.
[a] If harness connector damage is found, repair as necessary.
[b] If no harness damage is found, go to next step.
5. Measure the voltage between pins 1 and 2 on the harness side of the Charge Air Outlet
Temperature.
[a] If the voltage is greater than 2.75 volts, replace the Charge Air Outlet Temperature
[b] If the voltage is less than 2.75 volts, repair wires between the Charge Air Outlet
Temperature sensor harness connector and pins 52/119 of the MCM 120pin
connector.

114.5 SPN 2630/FMI 16
114.5 SPN 2630/FMI 16
This fault indicates that the MCM has detected very high Charge Air and intake manifold
temperatures.
Possible causes:
Low vehicle speed with high engine load (steep grade climb)
Fan operation
Winter front in high ambient temperatures
If the above conditions did not occur, refer to OEM literature for Charge Air Cooler, leak and
performance tests.

114.6 SPN 2630/FMI 21
This diagnostic is typically Charge Air Outlet Temperature Drift (high box).
1. Inspect the entire air intake system including the Charge Air Cooler for leaks, cracks or
plugging.
2. Disconnect the Charge Air Outlet Temperature sensor.
3. Inspect the Charge Air Outlet Temperature sensor harness connector for bent, spread, or
corroded pins.
[a] If harness connector damage is found, repair as necessary.
[b] If no harness damage is found, go to next step.
5. Measure the voltage between pins 1 and 2 on the harness side of the Charge Air Outlet
Temperature.
[a] If the voltage is greater than 2.75 volts, replace the Charge Air Outlet Temperature
[b] If the voltage is less than 2.75 volts, repair wires between the Charge Air Outlet
Temperature sensor harness connector and pins 52/119 of the MCM 120pin
connector.

114.6 SPN 2630/FMI 21

115SPN 2630 (EPA10)
Section Page
115.1 SPN 2630/FMI 2 ....................................................................................... 115- 3

115.1 SPN 2630/FMI 2
This diagnostic is typically Engine Air Temperature - Plausibility Fault Out of Range (High Box)
2. Are any other EGR system related faults also present?
3. Disconnect the Charge Air Outlet and Intake Manifold temperature sensors.
4. Inspect temperature harness connectors for bent, spread or corroded pins, repair pin
damage if found and replace both the Charge Air Outlet and Intake Manifold temperature
sensors.

115.1 SPN 2630/FMI 2

116SPN 2631
Section Page
116.1 SPN 2631/FMI 3 ....................................................................................... 116- 3

116.2 SPN 2631/FMI 4 ....................................................................................... 116- 4
116.1 SPN 2631/FMI 3
This diagnostic is typically intake manifold pressure sensor Circuit Failed High.
[a] If 164/5 is present with 2361/3, repair the open between pin 4 on the harness side of
the intake manifold pressure sensor and pin 102 of the MCM 120-pin connector.
2. Disconnect the intake manifold pressure sensor connector.
5. Measure the voltage between pin 2 and 4 on the harness side of the intake manifold
pressure sensor.
pressure sensor.
of the intake manifold pressure sensor and pin 87 of the MCM 120-pin connector.
[b] If the voltage is greater than 4.5 volts, replace the intake manifold pressure sensor.
7. Measure the voltage between pin 2 on the harness side of the intake manifold pressure
sensor and engine ground.
[b] If the voltage is greater than 4.5 volts, repair the wire between pin 4 of the harness side

116.2 SPN 2631/FMI 4
116.2 SPN 2631/FMI 4
This diagnostic is typically intake manifold pressure sensor Circuit Failed Low.
1. Disconnect the intake manifold pressure sensor connector.
pressure sensor.
[a] If the voltage is greater than 5.25 volts, repair the wire between pin 1 on the harness
side of the intake manifold pressure sensor and pin 87 of the MCM 120-pin connector.
[b] If the voltage is less than 5.25 volts, go to next step.
7. Measure the resistance between pin 1 on the harness side of the intake manifold pressure
sensor and engine ground.
[a] If the resistance is less than 3 ohms, repairs the wire between pin 1 on the harness side
[b] If the resistance is greater than 3 ohms, replace the intake manifold pressure sensor.

117SPN 2659
Section Page
117.1 SPN 2659/FMI 0 ....................................................................................... 117- 3

117.2 SPN 2659/FMI 1 ....................................................................................... 117- 4
117.1 SPN 2659/FMI 0
This code is typically an EGR flow target error (high flow).

connected.
[b] If no connector damage is found, replace EGR Delta P sensor, Refer to section 3.13.1
after sensor replacement perform EGR Delta P re-calibration service routine, release
vehicle.
8. Remove Delta P sensor and inspect the EGR delivery pipe Delta P pressure ports for
blockage.
[a] If blockage is found, repair (clean) as necessary.
[a] If the EGR valve is damaged, replace the EGR valve. For the DD15 ONLY:
[b] If no damage is found, obtain a log file of the fault going active and contact the

117.2 SPN 2659/FMI 1
117.2 SPN 2659/FMI 1
This code is typically an EGR flow target error (low flow).

[a] If SPN 2791 FMI (any) is also present, repair 2791 FMI (any) fault first.
[b] If SPN 2791 FMI (any) is NOT present, go to step 2.
2. Visually inspect the entire EGR system for evidence of external leakage (e.g. soot, coolant
deposits at joints).
[a] If external leakage is found, repair as necessary.
[b] If no external leakage is found, go to step 3.
connected.
vehicle.
[a] If excessive build up or blockage is found, clean piping and the EGR cooler. For the
DD13 only: refer to section For the DD15 only: refer to section .

11. Inspect the EGR delivery pipe Delta P pressure ports for blockage.
[a] If the EGR valve is damaged, the EGR valve. For the DD15 ONLY: Refer to section
. For the DD13: Refer to section .

117.2 SPN 2659/FMI 1

118SPN 2659 (EPA10)
Section Page
118.1 SPN 2659/FMI 18 ..................................................................................... 118- 3

118.1 SPN 2659/FMI 18
This code is typically an EGR flow target error (low flow).

[a] If SPN 2791 FMI (any) is also present, repair 2791 FMI (any) fault first.
[b] If SPN 2791 FMI (any) is NOT present, go to step 2.
[b] If no external leakage is found, go to step 3.
connected.
vehicle.
the DD13 only: refer to section For the DD15 only: refer to section .

118.1 SPN 2659/FMI 18
11. Inspect the EGR delivery pipe Delta P pressure ports for blockage.
[a] If the EGR valve is damaged, replace the EGR valve. For the DD15 ONLY:

119SPN 2791
Section Page
119.1 SPN 2791/FMI 3 ....................................................................................... 119- 3

119.2 SPN 2791/FMI 4 ....................................................................................... 119- 4
119.3 SPN 2791/FMI 5 ....................................................................................... 119- 5
119.4 SPN 2791/FMI 7 ....................................................................................... 119- 6
119.5 SPN 2791/FMI 8 ....................................................................................... 119-10
119.6 SPN 2791/FMI 9 ....................................................................................... 119-13
119.7 SPN 2791/FMI 11 ..................................................................................... 119-17
119.8 SPN 2791/FMI 14 ..................................................................................... 119-21
119.9 SPN 2791/FMI 15 ..................................................................................... 119-25
119.10SPN 2791/FMI 16 ..................................................................................... 119-26
119.11SPN 2791/FMI 31 ..................................................................................... 119-27
119.1 SPN 2791/FMI 3
This diagnostic is typically circuit failed high

Check as follows:
1. Disconnect the EGR valve connector.
3. Measure the voltage between pin 1 of the EGR valve connector and ground.
[a] If the voltage is greater than 11.5 volts, repair the short to power between pin 1 of the
EGR valve connector and pin 61 of the 120pin MCM connector. Verify Repairs
219.1.
[b] If the voltage is less than 11.5 volts, replace the EGR valve. For the DD15 ONLY:

119.2 SPN 2791/FMI 4
119.2 SPN 2791/FMI 4
This diagnostic is typically circuit failed low.

Check as follows:
[a] If 3598/4 is also present, troubleshoot 3598/4 first.
2. Disconnect EGR valve connector.
3. Disconnect 120pin MCM connector.
4. Measure the resistance between pin 1 of the EGR valve connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin 1 of the EGR
valve connector and ground. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , replace the EGR valve. For the DD15 ONLY:

119.3 SPN 2791/FMI 5
This diagnostic is typically open circuit.

Check as follows:
[a] If 2791/5, 27/4, and 1073/4 are present, repair the open between pin 62 of the 120pin
MCM connector and EGR valve and front Jake Brake solenoid. Verify Repairs 219.1.
2. Disconnect the EGR valve.
4. Measure the resistance between pin 1 of the EGR valve harness connector and pin 61
[a] If the resistance is greater than 3 , repair the open between pin 1 of the EGR valve
harness connector and pin 61 of the 120pin MCM connector. Verify Repairs 219.1.
[b] If the resistance is less than 3 , replace the EGR valve. For the DD15 ONLY:

119.4 SPN 2791/FMI 7
119.4 SPN 2791/FMI 7
The fault description is the EGR actuator, Failsafe Mode, Motor On
Check as follows:

1. Using DDDL 7.x, check SPN 2791/FMI 7 Extended Data Record #3 Physical Data;
refer to chart below for the Reserved for Extreme Parameter value.
Reserved Extreme Parameter Action to take
3,4,9,10,22,23,65535 Go to next step

15,255 Go to step 5
8,11 Go to step 9
Replace EGR actuator DD13 refer to section
5,7,20
DD15 refer to section

3. Disconnect EGR actuator rod arm. Inspect ball sockets on arm for free movement.
[a] If sockets do not rotate/move freely, replace EGR actuator rod arm. For the DD13
ONLY: refer to section .
[b] If sockets move freely, go to next step.
4. Physically move EGR butterfly from stop to stop to check for full travel (some drag is
normal).
[a] If EGR butterfly does not move stop to stop, replace the EGR valve. For the DD15
ONLY: Refer to section . For the DD13: Refer to section .
[b] If EGR butterfly moves stop to stop, replace the EGR actuator. For the DD13 ONLY:
refer to section . For the DD15 ONLY: refer to section .
5. Disconnect EGR actuator harness connector.

119.4 SPN 2791/FMI 7
7. Measure the voltage between pins 1 and 2 of the EGR actuator connector (engine harness
side).
[b] If the voltage is less than 11 volts, go to next step.
8. Measure the voltage between pin 1 of the EGR actuator connector and ground (engine
harness side).
[a] If the voltage is less than 11 volts, repair wire between pin 1 of the EGR actuator
connector harness and pin 62 of the MCM 120-pin connector.
[b] If the voltage is greater than 11 volts, repair wire between pin 2 of the EGR actuator
connector (engine harness side) and pin 67 of the MCM 120-pin connector.
10. Measure the resistance between pins 3 and 4 of the EGR actuator connector (engine
harness side).
[a] If the resistance is between 55 and 65 ohms, replace the EGR actuator. For the DD13
ONLY: refer to section . For the DD15 ONLY: refer to section .
[b] If the resistance is not between 55 and 65 ohms, go to next step.
harness side).
[a] If the resistance is less than 3 ohms, repair short between pins 3 and 4 of the EGR
actuator harness connector and MCM pins 74/75.
[b] If the resistance is greater than 3 ohms, go to next step.
13. Measure the resistance between pin 3 of the EGR actuator connector harness and pin 74
of the MCM 120-pin connector.
[a] If the resistance is greater than 3 ohms, repair wire between pin 3 of the EGR actuator
[b] If the resistance is less than 3 ohms, go to next step.
[b] If the resistance is less than 3 ohms, so to next step.
15. Install test MCM; clear codes; cycle ignition and repeat procedure.
[a] If fault is still active with the test MCM, obtain log file of active code, note
measurements in all steps and contact the Detroit Diesel Customer Support Center at
3135925800 for further instruction.
[b] If fault does not become active, reconnect the original MCM. Go to next step.

16. Is the fault active with the original MCM.

[a] Yes; replace the MCM. Refer to section 2.3.
[b] No; inspect connections at MCM and EGR actuator connector harness, repair as
necessary.

119.5 SPN 2791/FMI 8
119.5 SPN 2791/FMI 8
The fault description is the EGR actuator internal test running.
Check as follows:
1. Using DDDL 7.X, check SPN 2791/FMI 8 Extended Data Record #3 Physical Data for
the Reserved Extreme Parameter value as seen in the following DDDL screen.

2. The action to take is listed in the following table.
Reserved Extreme Parameter Action to Take

3, 4, 9, 10, 22, 23, 65535 Go to step 3.
15, 255 Go to step 7.
8, 11 Go to step 11.
5, 7, 20

4. Physically move EGR actuator rod from stop to stop to check for unrestricted movement.
[a] If unrestricted movement is felt, go to step 7.
[b] If actuator rod does not freely move from stop to stop, go to the next step.
5. Disconnect the EGR actuator rod arm. Inspect the ball sockets on arm for free movement.
[a] If the sockets do not rotate/move freely, replace the EGR actuator rod arm. For the
DD13 ONLY: refer to section .
[b] If the sockets move freely, go to the next step.
6. Physically move the EGR butterfly valve from stop to stop to check for unrestricted
movement.
[a] If the EGR butterfly valve does not move stop to stop, replace the EGR valve.
Refer to section .
[b] If EGR butterfly valve moves stop to stop, replace the EGR actuator. For the DD13
7. Disconnect EGR actuator harness connector.
9. Measure the voltage between pins 1 and 2 of the EGR actuator connector.
[b] If the voltage is less than 11 volts, go to the next step.
10. Measure the voltage between pin 1 of the EGR actuator connector and ground.
12. Disconnect the EGR actuator.

119.5 SPN 2791/FMI 8
13. Measure the resistance between pins 3 and 4 on the engine harness side of the EGR
actuator connector.
[a] If the resistance is between 55 and 65 , replace the EGR actuator. For the DD13
[b] If the resistance is not between 55 and 65 , go to the next step.
15. Measure the resistance between pins 3 and 4 of the EGR actuator connector.
[a] If the resistance is less than 3 , repair short between pins 3 and 4 of the EGR
actuator connector and MCM pins 74/75. Verify Repairs 219.1.
16. Measure the resistance between pin 3 of the EGR actuator connector and pin 74 of the
[a] If the resistance is greater than 3 , repair wire between pin 3 of the EGR actuator
17. Measure the resistance between pin 4 of the EGR actuator connector and pin 75 of the
MCM 120-pin connector.
[a] If the resistance is greater than 3 , repair wire between pin 4 of the EGR actuator
[b] If the resistance is less than 3 , replace the MCM. Refer to section 2.3.

119.6 SPN 2791/FMI 9
The fault description is the EGR actuator (Failsafe Mode, Motor Off).
Check as follows:

119.6 SPN 2791/FMI 9
1. 1. Using DDDL 7.x check SPN 2791/FMI 9 Extended Data Record #3 Physical Data,
refer to chart below for the Reserved Extreme Parameter value.
3,4,9,10,22,23,65535 Go to next step

15,255 Go to step 5
8,11 Go to step 9
5,7,20

normal).
5. Disconnect EGR actuator harness connector

side).
[a] If the voltage is greater than 11 volts go to step 9
[b] If the voltage is less than 11 volts go to next step.
harness side).
harness side).
harness side).
[a] If the resistance is less than 3 ohms repair short between pins 3 and 4 of the EGR
[b] If the resistance is greater than 3 ohms go to next step.
15. Install test MCM clear codes, cycle ignition and repeat procedure.
[a] If fault does not become active, reconnect the original MCM. Go to next step.
[b] If fault is still active with the test MCM, obtain log file of active code, note

119.6 SPN 2791/FMI 9

necessary.

119.7 SPN 2791/FMI 11
The fault description is the EGR actuator (Restricted Operability).
Check as follows:

119.7 SPN 2791/FMI 11
3,4,9,10,22,23,65535 Go to next step

15,255 Go to step 5
8,11 Go to step 9
5,7,20

normal).

side).
[a] If the voltage is greater than 11 volts go to step 9.
harness side).
harness side).
harness side).

119.7 SPN 2791/FMI 11

necessary.

119.8 SPN 2791/FMI 14
The fault description is the EGR actuator (No Failsafe Mode, Motor Off).
Check as follows:

119.8 SPN 2791/FMI 14
3,4,9,10,22,23,65535 Go to next step

15,255 Go to step 5
8,11 Go to step 9
5,7,20

normal).

side).
harness side).
harness side).
harness side).

119.8 SPN 2791/FMI 14

necessary.

119.9 SPN 2791/FMI 15
This fault typically results from high load operation in high ambients. No action is necessary (this
is a silent fault, the fan will be turned on).
NOTE:
This fault is a concern only if the fan on times are excessive but coolant temperatures
are in the normal operating range.
Check as follows:
[a] If SPN 110/FMI 0 is also present, repair the cooling system first. Verify Repairs 219.1.
[b] If only SPN 2791/FMI 15 is present, go to the next step.
2. Visually inspect for signs of exhaust leak in the area of the actuator.
[a] If exhaust leaks are present, repair as necessary. Verify Repairs 219.1.
[b] If no exhaust leaks are present, go to the next step.
3. Remove and inspect the actuator cooler lines and fittings.
[a] If coolant lines or fittings are kinked or plugged, repair/replace the damaged
component. Verify Repairs 219.1.
[b] If coolant lines are not damaged and problem still persists, contact the Detroit Diesel

119.10 SPN 2791/FMI 16
119.10SPN 2791/FMI 16
This fault typically arises from operating under extreme load and high ambient temperatures
and/or high altitude operation.
Check as follows:
[a] If SPN 110/FMI 0 is also present, repair the cooling system first. Verify Repairs 219.1.
[b] If only SPN 2791/FMI 16 is present, go to the next step.
2. Visually inspect for signs of exhaust leak in the area of the actuator.
[a] If exhaust leaks are present, repair as necessary. Verify Repairs 219.1.
[b] If no exhaust leaks are present, go to the next step.
3. Remove and inspect the actuator cooler lines and fittings.
[a] If coolant lines or fittings are kinked or plugged, repair/replace the damaged
component. Verify Repairs 219.1.
[b] If coolant lines are not damaged and problem still persists, contact the Detroit Diesel

119.11SPN 2791/FMI 31
The fault description is the EGR actuator (Unknown Error Code).
Check as follows:

119.11 SPN 2791/FMI 31
3,4,9,10,22,23,65535 Go to next step

15,255 Go to step 5
8,11 Go to step 9
5,7,20

normal).

side).
harness side).
harness side).
harness side).

119.11 SPN 2791/FMI 31

necessary.

120SPN 2791 (MCM) (EPA10)
Section Page
120.1 SPN 2791/FMI 10 .................................................................................... 120- 3

120.1 SPN 2791/FMI 10
This diagnosis is typically EGR Actuator Slow Response

3. Are any other SPN 2791 faults present?
[a] If sockets do not rotate/move freely, replace EGR actuator rod arm.
[b] If sockets move freely, go to step 6.
normal).
[a] If EGR butterfly does not move stop to stop, replace the EGR valve.
[b] If EGR butterfly moves stop to stop, replace the EGR actuator.

120.1 SPN 2791/FMI 10

121SPN 2797
Section Page
121.1 SPN 2797/FMI 3 ....................................................................................... 121- 3

121.2 SPN 2797/FMI 4 ....................................................................................... 121- 4
121.1 SPN 2797/FMI 3
This diagnosis is typically fuel injector #1, 2, or 3 needle control valve circuit has a short to
battery/power.
Check as follows:
1. Disconnect the Front fuel injector Harness 14pin connector.
3. Measure the voltage between pin 1 on the MCM side of the Front fuel injector Harness
14pin connector and ground.
[a] If there is voltage present, repair the short to power between pin 1 of the Front fuel
injector Harness 14pin connector and pin 25 of the 120pin MCM connector.
[b] If there is no voltage present, replace the under valve cover fuel injector harness.
Refer to section .

121.2 SPN 2797/FMI 4
121.2 SPN 2797/FMI 4
This diagnosis is typically fuel injector #1, 2, or 3 needle control valve circuit is shorted to ground.
Check as follows:
2. Inspect the Front fuel injector Harness 14pin connector for bent or spread pins, inspect
the connector seal for damage (signs of water or oil intrusion).
[a] If the water or oil intrusion, bent or spread pins are found, repair as necessary.
[b] If connector shows no signs of damage, go to the next step.

3. Measure the resistance between pin 1 on the valve cover side of the Front fuel injector
Harness 14pin connector and ground. If you are using J-4867110, measure between
fuel injector #1 pin 3 and ground.

8. Measure the resistance between pin 1 of the valve cover side on the Front fuel injector

121.2 SPN 2797/FMI 4
Harness 14pin connector and ground.
[b] If the resistance is less than 3 , replace the under valve cover fuel injector Harness.
Refer to section .
12. Measure the resistance between pin 25 on the 120pin MCM connector and ground. If
you are using J-4867110, measure between fuel injector #1 pin 3 and ground.
[a] If the resistance is less than 3 , repair the short to ground between pin 25 of
the MCM 120pin connector and pin 1 of the Front fuel injector Harness 14pin
[b] If the resistance is greater than 3 , replace the MCM. Refer to section 2.3

122SPN 2798
Section Page
122.1 SPN 2798/FMI 3 ....................................................................................... 122- 3

122.2 SPN 2798/FMI 4 ....................................................................................... 122- 4
122.1 SPN 2798/FMI 3
This diagnosis is typically fuel injector #4, 5, or 6 needle control valve circuit has a short to
battery/power.
Check as follows:
1. Disconnect the Rear fuel injector Harness 14pin connector.
3. Measure the voltage between pin 1 on the MCM side of the Rear fuel injector Harness
[a] If there is voltage present, repair the short to power between pin 1 of the Rear fuel
[b] If there is no voltage present, replace the under valve cover fuel injector harness.
Refer to section .

122.2 SPN 2798/FMI 4
122.2 SPN 2798/FMI 4
This diagnosis is typically fuel injector # 4, 5, or 6 needle control valve circuit is shorted to ground.
Check as follows:
2. Inspect the Rear fuel injector Harness 14pin connector for bent or spread pins, inspect

3. Measure the resistance between pin 1 on the valve cover side of the Rear fuel injector


122.2 SPN 2798/FMI 4
Refer to section .
the MCM 120pin connector and pin 1 of the Rear fuel injector Harness 14pin
[b] If the resistance is greater than 3 , call the Detroit Diesel Customer Support Center
at 3135925800.

123SPN 2900 (CPC)
Section Page
123.1 SPN 2900/FMI 9 ....................................................................................... 123- 3

123.1 SPN 2900/FMI 9

Check as follows:

123.1 SPN 2900/FMI 9

124SPN 3031 (ACM2) (EPA10)
Section Page
124.1 SPN 3031/FMI 3 ....................................................................................... 124- 3

124.2 SPN 3031/FMI 4 ....................................................................................... 124- 4
Figure 124-1 DEF TANK TEMPERATURE/LEVEL SENSOR

124.1 SPN 3031/FMI 3
This diagnostic is typically DEF Tank Temp sensor Circuit Failed High
Check as follows:
[b] If 3031/3 is present go to step 6.
2. Disconnect the DEF Tank Level/Temperature sensor connector.
3. Inspect the DEF Tank Level/Temperature sensor connector for bent, spread or corroded
pins.
5. Measure the voltage between pin 2 of the DEF Tank Level/Temperature sensor connector
and ground.
[a] If voltage is present, repair short to power between pin 2 of the DEF Tank
Level/Temperature sensor connector and pin 102 of the ACM 120-pin connector.
[b] If no voltage is present repair open between pin 2 of the DEF Tank Level/Temperature
sensor connector and pin 102 of the ACM 120-pin connector.
6. Disconnect the DEF Tank Level/Temperature sensor connector.
7. Inspect the DEF Tank Level/Temperature sensor connector for bent, spread or corroded
pins.
8. Measure the voltage between pin 3 of the DEF Tank Level/Temperature sensor connector
and ground.
[a] If the voltage is greater than 3 volts, repair short to power between pin 3 of the
DEF Tank Level/Temperature sensor connector and pin 103 of the ACM 120-pin
connector.
[b] If no voltage is present repair open between pin 3 of the DEF Tank Level/Temperature
sensor connector and pin 103 of the ACM 120-pin connector.

124.2 SPN 3031/FMI 4
124.2 SPN 3031/FMI 4
This diagnostic is typically DEF tank temperature sensor circuit failed low
Check as follows:
2. Disconnect the DEF tank temperature/level sensor.
[b] If connector shows no signs of damage. Go to step 4.
5. Measure the resistance between pin 3 of the DEF tank temperature/level sensor harness
[a] If the resistance is less than 1K ohms, repair short to ground between pin 3 of the
DEF tank temperature/level sensor harness connector and pin 103 of the ACM2
120-pin connector
[b] If the resistance is greater than 1K ohms, replace the DEF tank temperature/level
sensor.

125SPN 3056 (ACM2) (EPA10)
Section Page
125.1 SPN 3056/FMI 2 ....................................................................................... 125- 3

125.1 SPN 3056/FMI 2
This diagnostic is typically SCR Inlet NOx sensor Error

1. Connect DDDL/DDRS.
2. Is SPN 5357 FMI 16 or 18 also present?
[a] Yes, repair those fault codes first.
3. Monitor (chart) the following parameters
ASL102 Engine Speed
AS018 SCR Inlet Temperature
AS019 SCR Outlet Temperature
AS035 SCR Inlet NOx sensor
AS036 SCR Outlet NOx sensor
AS101 NOx Conversion Efficiency
4. Start engine and perform a Parked regeneration, does the NOx Conversion Efficiency rise
above 70% (0.70) during the regeneration?
[a] Yes, clear faults and release vehicle.
[b] No, replace the SCR Inlet NOx sensor. Refer to section .

125.1 SPN 3056/FMI 2

126SPN 3057 (ACM2) (EPA10)
Section Page
126.1 SPN 3057/FMI 2 ....................................................................................... 126- 3

126.1 SPN 3057/FMI 2
This diagnostic is typically SCR Outlet NOx sensor Error

1. Connect DDDL/DDRS.
2. Is SPN 5357 FMI 16 or 18 also present?
[a] Yes, repair those fault codes first.
3. Monitor (chart) the following parameters.
ASL102 Engine Speed
4. Start engine and perform a parked regeneration, does the NOx Conversion Efficiency rise
[b] No, replace the SCR Outlet NOx sensor. Refer to section .

126.1 SPN 3057/FMI 2

127SPN 3058
Section Page
127.1 SPN 3058/FMI 13 ..................................................................................... 127- 3

127.1 SPN 3058/FMI 13
This fault may occur after reprogramming the MCM. It is necessary to reprogram the MCM and
reinstall the PAR file. If the fault does not clear after reprogramming, contact the Detroit Diesel
Customer Support Center (3135925800) for further instructions.

127.1 SPN 3058/FMI 13

128SPN 3064
Section Page
128.1 SPN 3064/FMI 13 ..................................................................................... 128- 3

128.1 SPN 3064/FMI 13
This fault may occur after reprogramming the MCM. It is necessary to reprogram the MCM and
reinstall the PAR file. If the fault does not clear after reprogramming, contact the Detroit Diesel
Customer Support Center (3135925800) for further instructions.

128.1 SPN 3064/FMI 13

129SPN 3216 (ACM2) (EPA10)
Section Page
129.1 SPN 3216/FMI 2 ....................................................................................... 129- 3

129.2 SPN 3216/FMI 3 ....................................................................................... 129- 4
129.3 SPN 3216/FMI 4 ....................................................................................... 129- 5
129.4 SPN 3216/FMI 13 ..................................................................................... 129- 6
129.5 SPN 3216/FMI 21 ..................................................................................... 129- 8
Figure 129-1 SCR Inlet Nox sensor Circuit

129.1 SPN 3216/FMI 2
This diagnostic is typically SCR Inlet NOx Sensor Drift

1. Are any EGR system faults also present?
[a] Yes, repair EGR system faults first.
2. Visually inspect the entire air inlet, CAC and EGR piping and hose for visible signs
of leaks or damage.
[a] If damage or leaks are found repair as necessary.
[b] If no damage is found go to step 3.
3. Perform an idle speed balance test.
[a] If a faulty injector is identified, repair as necessary.
[b] If no injector issues are present go to step 4.
4. Check Aftertreatment system for visible exhaust leaks/damage.
NOTE:
Disregard SPN 3361/5 which will set with the valve unplugged.
6. Disconnect the DEF Metering Unit Dosing valve.

7. Perform High Idle Regeneration, retain the log file and submit to the Detroit Diesel

129.2 SPN 3216/FMI 3
129.2 SPN 3216/FMI 3
This diagnostic is typically SCR Inlet Nox sensor Circuit Failed High
1. Check SPN 3216 FMI 3 DTC Occurrence Counter.
[a] If occurrence counter is 5 or less, clear fault and release vehicle.
[b] If occurrence counter is greater than 5, replace the SCR Inlet NOx sensor.
Refer to section .

129.3 SPN 3216/FMI 4
This diagnostic is typically SCR Inlet Nox sensor Circuit Failed Low.
[b] If occurrence counter is greater than 5, replace the SCR Inlet NOx sensor.
Refer to section .

129.4 SPN 3216/FMI 13
129.4 SPN 3216/FMI 13
This diagnostic is typically SCR Inlet Nox sensor Circuit not available.
NOTE:
If fault occurred during High Idle Regeneration clear fault and release vehicle.
1. Is SPN 3216 FMI 13 currently active?

[a] If occurrence counter is 5 or less, clear fault and release vehicle
[b] If occurrence counter is greater than 5, go to step 3.
3. Disconnect the SCR Inlet NOx sensor.

[a] If the pins are bent, spread, or corroded, repair as necessary. Verify Repairs 219.1.
6. Measure the voltage between pin 1 and 4 on the harness side of the SCR Inlet NOx sensor
connector.
[a] If the voltage is less than 11.5 volts, go to step 7.

7. Measure the voltage between pin 1 on the harness side of the SCR Inlet NOx sensor
connector and engine ground.
[a] If the voltage is less than 11.5 volts, repair the wire between pin 1 on the harness side
of the SCR Inlet NOx sensor connector and pin 50 of the ACM2 120-pin connector.
[b] If the voltage is greater than 11.5 volts, repair the wire between pin 4 on the harness
side of the SCR Inlet NOx sensor connector and pin 51 of the ACM2 120-pin
9. Measure the resistance between pin 2 and 3 on the harness side of the SCR Inlet NOx
sensor connector.
[a] If the resistance is not between 55 and 65 ohms, go to step 10.
[b] If the resistance is between 55 and 65 ohms, replace the SCR Inlet NOx sensor.
Refer to section .
11. Measure the resistance between pin 2 and 3 on the harness side of the SCR Inlet NOx
sensor connector.
[a] If the resistance is less than 1K ohms, repair short between pins 2 and 3 on the
harness side of the SCR Inlet NOx sensor connector and pins 52 and 53 of the ACM2
12. Measure the resistance between pin 2 on the harness side of the SCR Inlet NOx sensor
connector and pin 53 of the ACM2 120-pin connector.
[a] If the resistance is greater than 5 ohms, repair the wire between pin 2 on the harness
[b] If the resistance is less than 5 ohms, go to step 13.
13. Measure the resistance between pin 3 on the harness side of the SCR Inlet NOx sensor
[a] If the resistance is greater than 5 ohms, repair the wire between pin 3 on the harness
[b] If the resistance is less than 5 ohms, replace the SCR Inlet NOx sensor.
Refer to section .

129.5 SPN 3216/FMI 21
129.5 SPN 3216/FMI 21
This diagnostic is typically SCR Inlet NOx Sensor Drift (Low Box)
1. Are any EGR system faults also present?
[a] Yes, repair EGR system faults first.
2. Visually inspect the entire air inlet, CAC and EGR piping and hose for visible signs
of leaks or damage.
[a] If damage or leaks are found repair as necessary.
3. Perform an idle speed balance test.
[a] If a faulty injector is identified, repair as necessary.
[b] If no injector issues are present go to step 4.
NOTE:


130SPN 3226 (ACM2) (EPA10)
Section Page
130.1 SPN 3226/FMI 2 ....................................................................................... 130- 3

130.2 SPN 3226/FMI 3 ....................................................................................... 130- 4
130.3 SPN 3226/FMI 4 ....................................................................................... 130- 5
130.4 SPN 3226/FMI 13 ..................................................................................... 130- 6
130.5 SPN 3226/FMI 21 ..................................................................................... 130- 9
Figure 130-1 SCR Outlet Nox sensor Circuit

130.1 SPN 3226/FMI 2
This diagnostic is typically SCR Outlet NOx Sensor Drift

NOTE:


130.2 SPN 3226/FMI 3
130.2 SPN 3226/FMI 3
This diagnostic is typically SCR Outlet Nox sensor Circuit Failed High.
[b] If occurrence counter is greater than 5, replace the SCR Outlet NOx sensor.
Refer to section .

130.3 SPN 3226/FMI 4
This diagnostic is typically SCR Outlet Nox sensor Circuit Failed Low.
[b] If occurrence counter is greater than 5, replace the SCR Outlet NOx sensor.
Refer to section .

130.4 SPN 3226/FMI 13
130.4 SPN 3226/FMI 13
This diagnostic is typically SCR Outlet Nox sensor Signal Not Available.
Check as follows:
NOTE:
If fault occurred during High Idle Regeneration clear fault and release vehicle.
1. Is SPN 3226 FMI 13 currently active?

[a] If occurrence counter is 5 or less, clear fault and release vehicle
[b] If occurrence counter is greater than 5, go to step 3.
3. Disconnect the SCR Outlet NOx sensor.


6. Measure the voltage between pin 1 and 4 on the harness side of the SCR Outlet NOx
sensor connector.
[a] If the voltage is less than 11.5 volts, go to step 7.
7. Measure the voltage between pin 1 on the harness side of the SCR Outlet NOx sensor
connector and engine ground.
[a] If the voltage is less than 11.5 volts, repair the wire between pin 1 on the harness
side of the SCR Outlet NOx sensor connector and pin 42 of the ACM2 120-pin
[b] If the voltage is greater than 11.5 volts, repair the wire between pin 4 on the harness
side of the SCR outlet NOx sensor connector and pin 43 of the ACM2 120-pin
9. Measure the resistance between pin 2 and 3 on the harness side of the SCR Outlet NOx
sensor connector.
[a] If the resistance is not between 55 and 65 ohms, go to step 10
[b] If the resistance is between 55 and 65 ohms, replace the SCR Outlet NOx sensor.
Refer to section .
11. Measure the resistance between pin 2 and 3 on the harness side of the SCR outlet NOx
sensor connector.
[a] If the resistance is less than 1K ohms, repair short between pins 2 and 3 on the
harness side of the SCR outlet NOx sensor connector and pins 40 and 41 of the
ACM2 120-pin connector. Verify Repairs 219.1.

130.4 SPN 3226/FMI 13
12. Measure the resistance between pin 2 on the harness side of the SCR Outlet NOx sensor
[a] If the resistance is less than 5 ohms, repair the wire between pin 2 on the harness
[b] If the resistance is greater than 5 ohms, go to step 13.
13. Measure the resistance between pin 3 on the harness side of the SCR Outlet NOx sensor
[a] If the resistance is less than 5 ohms, repair the wire between pin 3 on the harness
[b] If the resistance is greater than 5 ohms, replace the SCR Outlet NOx sensor.
Refer to section .

130.5 SPN 3226/FMI 21
This diagnostic is typically SCR Outlet NOx Sensor Drift (High Box).
2. Connect DDDL/DDRS 7.05 or higher
NOTE:


130.5 SPN 3226/FMI 21

131SPN 3236 (ACM2) (EPA10)
Section Page
131.1 SPN 3236/FMI 13 ..................................................................................... 131- 3

131.1 SPN 3236/FMI 13
This diagnostic is typically Exhaust Mass Signal Not Available via CAN.

131.1 SPN 3236/FMI 13

132SPN 3242 (EPA07)
Section Page
132.1 SPN 3242/FMI 2 ....................................................................................... 132- 3

132.2 SPN 3242/FMI 3 ....................................................................................... 132- 9
132.3 SPN 3242/FMI 4 ....................................................................................... 132-11
132.4 SPN 3242/FMI 8 ....................................................................................... 132-12
132.5 SPN 3242/FMI 10 ..................................................................................... 132-15
132.1 SPN 3242/FMI 2
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.
5. Monitor DOC Inlet, DOC Outlet, and DPF Outlet Temperatures. Are the temperatures
within 25C (45F) of each other?
6. Continue idling for 10 minutes, recheck temperatures, and turn ignition OFF. Were the
temperatures now within 25C (45F) of each other?
8. Access the Voltage Service Routine.
9. Select Start Acquiring.

132.1 SPN 3242/FMI 2
10. Monitor DOC Inlet temperature voltage (T_DOC_IN). Continue monitoring and wiggle
the wire harness from the ATD to the MCM. Is there a large deviation in the voltage?

11. Inspect the electrical connections upstream of the MCM (DOC Inlet Temperature sensor,
ATD harness 10-pin connector, VIH 31-pin connector, and MCM 120-pin connector) for
corrosion and spread pins.
[a] If corrosion or damaged or bent pins are found, repair as necessary. Verify Repairs
219.1.
[b] If no corrosion or damage is found, replace the DOC Inlet Temperature sensor.
Refer to section .
12. Monitor the DPF Inlet Pressure sensor (P_DPF_IN) voltage.
13. Is the voltage between 0.44 0.56 volt?
14. Inspect the DPF Inlet Pressure sensor electrical connector for corrosion and spread pins.
219.1.
[b] If no corrosion or damage is found, replace the DPF Inlet Pressure sensor.
Refer to section .
15. Monitor the DPF Outlet Pressure sensor (P_DPF_OUT) voltage.


17. Inspect the DPF Outlet Pressure sensor electrical connector for corrosion and spread pins.
219.1.
[b] If no corrosion or damage is found, replace the DPF Outlet Pressure sensor.
Refer to section .
18. Remove Aftertreatment Device. Refer to section .
19. Inspect face of the removed DPF substrate for contamination.
[a] If coolant contamination is found (white residue on inlet and sweet smell from
exhaust), go to step 20.
[b] If oil contamination is found (oil residue on inlet), go to step 23.

[c] If no coolant or oil contamination is present, go to step 26.
20. Question operator about coolant usage.
21. Visually inspect coolant reservoir for low level. Possible causes for coolant contamination
in Aftertreatment system are:
EGR Cooler
Failed/defective cylinder head gasket, improper head bolt torque, low liner height
Failed Air Compressor cylinder head
Failed fuel cooler (Heavy-Duty Series Engine)
Fuel doser cracked body, missing or failed seals
22. Repair the cause of coolant entry as necessary. Go to step 25.
23. Question operator about excessive oil consumption. Possible causes of excessive oil
consumption are:
Excessive idle time
Defective turbine wheel seal

132.1 SPN 3242/FMI 2
Turbocharger bearing failure

Worn exhaust valve seals
Defective crankcase breather system
Stuck rings
24. Repair the cause of oil contamination and go to step 25.
25. Replace the Diesel Oxidation Catalyst (DOC) and go to step 39.
26. Inspect face of the removed ATD outlet flange for contamination.
[a] If there are signs of excessive soot buildup, go to step 27.
[b] If there are signs of fuel washout, go to step 37.
NOTE:
With fuel washout, there should be a wash of fuel to the outlet and then a fuel trail to the
drain hole. The drain hole is opposite the temperature sensor.
[c] If no soot buildup or fuel washout is found, go to step 41.

27. Inspect for the cause of soot loading. Possible causes are:
Plugged air filter
Stuck intake throttle valve
Air induction system, Charge Air Cooler, and EGR leaks
Exhaust manifold (including bellows) leaks
Turbocharger (including gasket) gasket leaks
Turbocharger compressor and turbine vane damage and oil fouling
Incorrect valve lash and fuel injector timing
28. If the cause of soot loading is found, repair the cause and go to step 39. If no cause
is found, go to step 29.
29. Pressurize the intake manifold and Charge Air Cooler and leak test with soapy water. If
any leaks are found, repair cause of leaks and go to step 39.
30. Turn ignition ON (key ON, engine OFF). Using DDDL 7.X, compare Barometric Pressure
to intake manifold pressure. If readings are not within 4.1 kPa (0.6 psi) of each other,
repair the broken pressure sensor or its connection and go to step 39.
31. Turn ignition ON (key ON, engine OFF). Using DDDL 7.X, compare intake manifold
Temperature to EGR Temperature. If readings are not within 6C (10F) of each other,
repair the broken temperature sensor or its connection and go to step 39.
32. Pressurize the entire exhaust system and leak test with soapy water. If any leaks are
found, repair cause of leaks and go to step 39.
NOTE:
The ATD will leak at the water drain hole in the outlet flange.
33. Run a Turbocharger hysteresis test. If it fails the test, replace the turbocharger For the
DD13 only: refer to section For the DD15 only: refer to section and go to step 39.
34. Using DDDL 7.X, verify the fuel injector codes. If incorrect fuel injector codes are
programmed, reprogram the codes and go to step 39.
35. With the engine running at 1800 rpm, check the fuel pressure at the temperature sensor
port on the fuel pump. If the fuel pressure is not between 483 552 kPa (70 80 psi),
repair the fuel system and go to step 39.
36. Check the Fuel doser injector valve for leaks and perform a fuel doser purge routine to
verify valve integrity. If leaks or integrity concerns are found, replace the fuel doser
injector valve refer to section and go to step 39.
37. Check for a source of fuel washout. Possible clues to fuel washout are:
Performance issues
Hard starting complaints
Improperly functioning fuel injectors
38. Repair cause of fuel washout and go to step 39.
39. Replace the Diesel Particulate Filter.
40. Using DDDL 7.X, reset the ash accumulator.

132.1 SPN 3242/FMI 2
41. Start engine.

42. Access the DPF Regeneration Service routine.
HOT EXHAUST
outside.
43. Select Send Parked Regeneration Start Request.
NOTE:
Regeneration safety entry conditions must be met before a regeneration can begin.

132.2 SPN 3242/FMI 3
Check as follows:
[a] If 3242/3, 3250/3, 3246/3, and 1172/3 are present, go to step 3.
3. Disconnect the turbocharger compressor inlet temperature sensor, refer to the appropriate
workshop manual.
the MCM 120-pin connector and the Turbocharger Compressor Inlet, DOC Inlet,
DOC Outlet, and DPF Outlet Temperature sensors. Verify Repairs 219.1.
[b] If no voltage is present on pin 1 of the intake air sensor, repair the open between
pin 88 of the MCM 120-pin connector and the Turbocharger Compressor Inlet, DOC
Inlet, DOC Outlet, and DPF Outlet Temperature sensors. Verify Repairs 219.1.
5. Disconnect the DOC Inlet Temperature sensor.

132.2 SPN 3242/FMI 3
6. Check resistance between pin 1 and pin 2 of the DOC Inlet Temperature sensor.
Acceptable resistance is listed in Table 132-1.
Temperature C (F) Resistance

0 (32) 202.50
25 (77) 221.60
100 (212) 277.90
600 (1112) 619.80
850 (1562) 768.81
Table 132-1 ATD Temperature sensor Resistance Chart
[a] If resistance is out of range, replace the DOC Inlet Temperature sensor.
Refer to section .
[b] If resistance is within range, go to step 7.
8. Measure voltage between pin 1 and pin 2 of the DOC Inlet Temperature sensor connector.
[a] If the voltage is between 2.75 and 3.25 volts, Verify Repairs 219.1.
9. Measure voltage between pin 2 of DOC Inlet Temperature sensor connector and ground
(battery ground lug by starter).
[a] If the voltage is between 2.75 and 3.25 volts, then repair the open in wire between
pin 88 of the MCM 120-pin connector and pin 1 of the DOC Inlet Temperature
sensor connector. Verify Repairs 219.1.
[b] If the voltage is less 2.75 volts, then repair the open in wire between pin 2 of the
DOC Inlet Temperature sensor connector and pin 89 of the MCM 120-pin connector.

132.3 SPN 3242/FMI 4
Check as follows:
1. Disconnect the DOC Inlet Temperature sensor.

3. Measure the resistance across pins 1 and 2 of the DOC Inlet Temperature sensor connector.
[a] If resistance is less than 5 , repair the short between the MCM 120-pin connector
4. Measure the resistance between pin 1 of the DOC Inlet Temperature sensor harness
connector and ground (battery ground lug by starter).
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the DOC Inlet
Temperature sensor harness connector and ground. Verify Repairs 219.1.
5. Measure the resistance between pin 2 of the DOC Inlet Temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the DOC Inlet
[b] If resistance is greater than 5 , Verify Repairs 219.1.

132.4 SPN 3242/FMI 8
132.4 SPN 3242/FMI 8
This diagnostic condition indicates the MCM has detected an impossible temperature shift on
the DOC Inlet Temperature sensor. The most likely cause is an intermittent wiring problem.
See Figure and Figure for the ATD wiring schematics.
Check as follows:
[a] If fault 3242/3 or 3242/4 is active, troubleshoot this fault first. Verify Repairs 219.1.
[b] If fault 3242/3 or 3242/4 and fault 3242/8 are inactive, go to step 4.
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.
7. Wiggle test the harness while looking for abnormal voltage spikes on T_DOC_IN (pin 89).
[a] If a voltage spike is detected, isolate that section of harness and inspect for wiring
chaffing, corrosion, improper connections, or physical damage. Repair damage as
[b] If no voltage spikes are seen, physically check and clean all harness connectors
between the DOC Inlet Temperature sensor and the MCM. Repair damage as


132.4 SPN 3242/FMI 8

132.5 SPN 3242/FMI 10
Check as follows:
1. Disconnect DOC Inlet Temperature sensor and inspect connector for damaged, bent,
spread, or corroded pins. If temperature sensor connector is OK, connections upstream to
the MCM (ATD harness 10pin connector pin 6, VIH 31-pin connector pin 18, and MCM
120-pin connector pin 89) must also be checked.
[a] If damage is found, repair connector(s) as necessary. Verify Repairs 219.1.
HOT EXHAUST
outside.
[b] If OK, replace DOC Temperature sensor, and perform a parked regeneration.
Refer to section .

132.5 SPN 3242/FMI 10

133SPN 3242 (ACM2) (EPA10)
Section Page
133.1 SPN 3242/FMI 3 ....................................................................................... 133- 3

133.2 SPN 3242/FMI 4 ....................................................................................... 133- 5
133.3 SPN 3242/FMI 8 ....................................................................................... 133- 6
133.4 SPN 3242/FMI 20 ..................................................................................... 133- 7
Figure 133-1 DOC Inlet Temperature sensor Circuit

133.1 SPN 3242/FMI 3
This diagnostic is typically DOC Inlet Temperature sensor circuit failed high.
Check for diesel oxidation catalyst inlet temperature sensor circuit failed high as follows:
1. Disconnect the DOC Inlet Temperature sensor connector.
3. DOC Inlet Temperature Test - Measure the resistance between pin 1 and 2 of the DOC
Inlet Temperature sensor connector (refer to chart for resistance values).
[a] If the resistances are out of range, replace the DOC Inlet Temperature sensor.
Refer to section .
[b] If the resistances are in range, go to step 4.
5. Measure the voltage between pin 2 on the harness side of the DOC Inlet Temperature
sensor connector and ground.
[a] If the voltage is greater than 3 volts, repair the short to power between pin 2 on the
harness side of the DOC Inlet Temperature sensor connector and pin 107 of the
ACM 120-pin connector.
[b] If the voltage is between 2.75 and 3 volts, go to step 6.
[c] If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side
of the DOC Inlet Temperature sensor connector and pin 107 of the ACM 120-pin
connector.

133.1 SPN 3242/FMI 3
6. Measure the voltage between pin 1 on the harness side of the DOC Inlet Temperature
sensor and ground.
[a] If voltage is present, repair the short to power between pin 1 on the harness side of the
DOC Inlet Temperature sensor connector and pin 108 of the ACM 120-pin connector.
[b] If no voltage is present, repair the open between pin 1 on the harness side of the DOC
Inlet Temperature sensor connector and pin 108 of the ACM 120-pin connector.

133.2 SPN 3242/FMI 4
This diagnostic is typically DOC Inlet Temperature sensor failed low.

Check for diesel oxidation catalyst inlet temperature sensor circuit failed low as follows:
2. Disconnect the DOC Inlet Temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DOC Inlet Temperature
[a] If the resistance is less than 1K ohms, repair the wire between pin 2 of the DOC Inlet
Temperature sensor connector and pin 107 of the ACM 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DOC Inlet Temperature sensor.
Refer to section .

133.3 SPN 3242/FMI 8
133.3 SPN 3242/FMI 8
This fault indicates the ACM2 has detected an impossible temperature shift on the DOC Inlet
Temperature sensor. The most likely cause is an intermittent wiring concern. If other DOC
temperature faults are also present diagnose signal spikes first. Refer to schematics below.
Check as follows:
1. Check fault codes.
[a] If SPN 3242/FMI 3 or 4 are active, repair those faults first.
[b] If SPN 3242/FMI 3 or 4 are inactive along with SPN 3242/FMI 8 go to step 2
2. Connect DDDL/DDRS 7.04 SP2 or higher.
4. Using the Instrumentation chart function select DOC Inlet Temp.
5. While wiggle testing the harness look for abnormal voltage spikes on the DOC Inlet
Temperature signal. Once a spike is detected isolate that section of harness and inspect for
wiring chaffing, corrosion, proper connections or physical damage, repair as necessary. If
no spikes are seen physically check and clean all harness connectors between the DOC
Inlet Temp sensor and the ACM2.

133.4 SPN 3242/FMI 20
This diagnostic is typically DOC Temperature Drift - Inlet High or Outlet Low
Check as follows:
1. Check for multiple fault codes.
[a] If 3242/FMI 3, 4, 8 or 3250/FMI 3, 4, 8 are also present, repair those faults first.
[b] If the above faults are not present go to step 2.
3. Compare DOC Inlet Temperature to DOC Outlet Temperature and DPF Outlet
Temperature, is the DOC Inlet temperature within 45F of the DOC Outlet and DPF Outlet
temperatures?
[a] Yes; go to step 4
4. Start the engine
5. Compare DOC Inlet Temperature to DOC Outlet Temperature and DPF Outlet
Temperature, are the DOC Inlet, DOC Outlet and DPF Outlet temperatures within 45F
of each other?
6. Continue idling engine for 10 minutes are the DOC Inlet, DOC Outlet and DPF Outlet
temperatures within 45F of each other?
[a] Yes; clear faults and release vehicle.
7. Turn engine OFF (key OFF, engine OFF).
8. Disconnect the DOC Inlet Temperature sensor harness, inspect harness for bent, spread or
corroded pins.

133.4 SPN 3242/FMI 20
9. Measure the resistance across the DOC Inlet Temperature sensor at pigtail connector (refer
to chart). Is the resistance within range?
[b] No; replace the DOC Inlet Temperature sensor. Refer to section .
10. Disconnect the DOC Outlet Temperature sensor harness, inspect harness for bent, spread
or corroded pins.
11. Measure the resistance across the DOC Outlet Temperature sensor at pigtail connector
(refer to chart). Is the resistance within range?
[a] Yes; clear faults and release vehicle
[b] No; replace the DOC Outlet Temperature sensor. Refer to section

134SPN 3246 (EPA07)
Section Page
134.1 SPN 3246/FMI 0 ....................................................................................... 134- 3

134.2 SPN 3246/FMI 2 ....................................................................................... 134- 7
134.3 SPN 3246/FMI 3 ....................................................................................... 134-13
134.4 SPN 3246/FMI 4 ....................................................................................... 134-15
134.5 SPN 3246/FMI 10 ..................................................................................... 134-16
134.6 SPN 3246/FMI 14 ..................................................................................... 134-17
134.7 SPN 3246/FMI 16 ..................................................................................... 134-23
134.1 SPN 3246/FMI 0
Check as follows:
NOTE:
Do not clear fault codes prior to any repair.
NOTE:
If this fault code requires replacement of the DPF, contact the Detroit Diesel Customer
Support Center at 3135925800 for authorization.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other
applicable safety steps.
NOTE:
This diagnostic procedure requires DDDL 7.03 SP3 or higher. All references to 7.X in
this procedure designate 7.03 SP3 or higher.

[a] If other fault codes are active in addition to 3246/0, troubleshoot the other fault
codes first.
5. Monitor DPF Outlet Temperature. Is the DPF Outlet Temperature is greater than 760C
(1400F)?
ENGINE EXHAUST
exhaust is toxic.
6. Run the engine at 1200 rpm for 10 minutes.

7. Monitor DOC and DPF Outlet Temperatures. Are the DOC and DPF Outlet Temperatures
[a] If yes, go to step 10

134.1 SPN 3246/FMI 0
9. Disconnect DPF Outlet Temperature sensor and inspect connector for damaged, bent,
spread, or corroded pins. If Temperature sensor connector is OK, check connections
upstream of the MCM (ATD harness 10pin connector pin 7, VIH 31-pin connector
pin 19, and MCM 120-pin connector pin 115).
[a] If damage is found, repair connector as necessary. Verify Repairs 219.1.

[b] If no damage is found, replace the DPF Outlet Temperature sensor. Refer to section .
10. Is the engine a Series 60?
11. Perform an Automatic Cylinder Cutout Service Routine using DDDL 7.X.
NOTE:
Detroit Diesel Service Letter 08 TS22 gives assistance with running and analyzing the
Automatic Cylinder Cutout Service Routine.
12. Retain a log file of the Automatic Cylinder Cutout Service Routine.
13. Was a faulty fuel injector identified?
[a] If yes, replace the faulty fuel injector and repeat the Automatic Cylinder Cutout
Service Routine to verify there are no more faulty fuel injectors. Go to step 2.
14. Perform an Idle Speed Balance Test using DDDL 7.X. Retain a log file of the Idle Speed
Balance Test.
15. Was a faulty fuel injector/cylinder identified?

[a] If yes, repair the faulty fuel injector/cylinder and repeat the Idle Speed Balance Test
to verify there are no more faulty fuel injectors/cylinders. Go to step 2.
16. Check the Warranty claim history. If the Intake Throttle Valve or EGR Valve was replaced
within the last 60 days, try to remove the DOC Outlet Temperature sensor.
[a] If the DOC Outlet Temperature sensor came out easily, go to step 17.
[b] If the DOC Outlet Temperature sensor did not come out, replace the DOC and DOC
Outlet Temperature sensor. Go to step 2.
18. Inspect for source of soot loading, possible causes are:
Charge Air Cooler and associated piping leaking or restricted
EGR valve stuck open
Bad Turbocharger actuator (For Series 60, perform a hysteresis test.)
Exhaust Flap stuck or limited in travel (if equipped)
Wastegate stuck (if equipped)
Damaged Turbocharger blades/vanes
Intake Throttle Valve stuck or limited in travel
Exhaust piping leaking prior to ATD
Bad Delta P sensor (Series 60 engines with MCM v61.4 or higher are not so equipped.)
NOTE:
If no soot contamination is found, contact the Detroit Diesel Customer Support Center
at 3135925800 for further instructions. The following electronic files are required
when calling:
DDEC reports
Parked Regeneration log
Fuel injector Cutout log
Idle Speed Balance log
Log of fault codes
1. Repair the cause of soot contamination.

2. Install an ATD test pipe, run engine, and verify there are no further soot issues (no black
smoke present).
3. Replace DPF filter and re-install ATD, go to step 4.

134.1 SPN 3246/FMI 0
HOT EXHAUST
outside.
4. Perform parked regeneration, reset ash accumulators, and E-mail a log file of the
successful regeneration to Detroit Diesel Customer Support Center. Verify Repairs 219.1.

134.2 SPN 3246/FMI 2
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.

134.2 SPN 3246/FMI 2
10. Monitor DPF Outlet temperature voltage (T_DPF_OUT). Continue monitoring and wiggle

11. Inspect the electrical connections upstream of the MCM (DPF Outlet Temperature sensor,
219.1.
[b] If no corrosion or damage is found, replace the DPF Outlet Temperature sensor.
Refer to section .
219.1.
Refer to section .


219.1.
Refer to section .

EGR Cooler
consumption are:
Excessive idle time

134.2 SPN 3246/FMI 2

Stuck rings
25. Replace the DOC and go to step 39.
NOTE:

Plugged air filter
NOTE:
33. Run a Turbocharger hysteresis test. If it fails the test, repair or replace the turbocharger
For the DD13 only: refer to section For the DD15 only: refer to section and go to step 39.
36. Check the fuel doser injector valve for leaks and perform a fuel doser purge routine to
Performance issues
39. Replace the DPF.

134.2 SPN 3246/FMI 2
41. Start engine.

HOT EXHAUST
outside.
NOTE:

134.3 SPN 3246/FMI 3
Check as follows:
[b] If only 3246/3 is present go to step 5.
workshop manual.
5. Disconnect the DPF Outlet Temperature sensor.

134.3 SPN 3246/FMI 3
6. Check resistance between pin 1 and pin 2 of the DPF Outlet Temperature sensor.
Listed in Table 134-1 are the acceptable resistances.

0 (32) 202.50
25 (77) 221.60
100 (212) 277.90
600 (1112) 619.80
850 (1562) 768.81
[a] If resistance is out of range, replace the DPF Outlet Temperature sensor.
Refer to section .
8. Measure voltage between pin 1 and pin 2 of the DPF Outlet Temperature sensor connector.
9. Measure voltage between pin 2 of DPF Outlet Temperature sensor connector and ground
pin 88 of the MCM 120-pin connector and pin 1 of the DPF Outlet Temperature
[b] If the voltage is less 2.75 volts, then repair the open in wire between pin 2 of the DPF
Outlet Temperature sensor connector and pin 89 of the MCM 120-pin connector.

134.4 SPN 3246/FMI 4
Check as follows:
1. Disconnect the DPF Outlet Temperature sensor.

3. Measure the resistance across pins 1 and 2 of the DPF Outlet Temperature sensor
connector.
4. Measure the resistance between pin 1 of the DPF Outlet Temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the DPF Outlet
5. Measure the resistance between pin 2 of the DPF Outlet Temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the DPF Outlet

134.5 SPN 3246/FMI 10
134.5 SPN 3246/FMI 10
Check as follows:
1. Disconnect DPF Outlet Temperature sensor and inspect for damaged, bent, spread, or
corroded pins. If temperature sensor connector is OK, connections upstream to the MCM
(ATD harness 10pin connector pin 7, VIH 31-pin connector pin 19, and MCM 120-pin
connector pin 115) must also be checked.
[a] If damage is found, repair connection(s) as necessary.
[b] If OK, replace DPF Outlet Temperature sensor. Refer to section .

134.6 SPN 3246/FMI 14
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.

134.6 SPN 3246/FMI 14
10. Monitor DPF Outlet temperature voltage (T_DPF_OUT). Continue monitoring and wiggle

11. Inspect the electrical connections upstream of the MCM (DPF Outlet Temperature sensor,
219.1.
[b] If no corrosion or damage is found, replace the DPF Outlet Temperature sensor.
Refer to section .
219.1.
Refer to section .


219.1.
Refer to section .

EGR Cooler
consumption are:
Excessive idle time

134.6 SPN 3246/FMI 14

Stuck rings
NOTE:

Plugged air filter
NOTE:
Performance issues

134.6 SPN 3246/FMI 14
41. Start engine.

HOT EXHAUST
outside.
NOTE:

134.7 SPN 3246/FMI 16
Check as follows:
NOTE:
SPN 3246/FMI 16 is a silent fault (no dashboard warning lamp) indicating the MCM has
detected a DPF Outlet Temperature that is higher than expected.

3. Check for fault code 3246/0 (DPF Outlet Temperature very high).
[a] If code 3246/0 is present, troubleshoot code 3246/0 first and then clear codes.
[b] If code 3246/0 is not present, go to step 4.
4. Check for fault code 3246/8 (DPF Outlet Temperature signal spike).
[a] If code 3246/8 is present, troubleshoot the signal spike fault first and then clear
codes. Verify Repairs 219.1.
[b] If code 3246/8 is not present, go to step 5.
5. Check for fault code 3246/16 (Extended Data Occurrence Counter).
[a] If the Extended Data Occurrence Counter is greater than 5, troubleshoot fault code
3246/0. Refer to section 134.1.
[b] If the Extended Data Occurrence Counter is 5 or less, go to step 6.
ENGINE EXHAUST
exhaust is toxic.
6. Start engine.

134.7 SPN 3246/FMI 16
HOT EXHAUST
outside.
7. Using DDDL 7.X, perform a parked regeneration. After regeneration is complete, clear
codes. Verify Repairs 219.1.

135SPN 3246 (ACM2) (EPA10)
Section Page
135.1 SPN 3246/FMI 3 ....................................................................................... 135- 3

135.2 SPN 3246/FMI 4 ....................................................................................... 135- 5
135.3 SPN 3246/FMI 8 ....................................................................................... 135- 6
135.4 SPN 3246/FMI 20 ..................................................................................... 135- 7
Figure 135-1 DPF Outlet Temperature Circuit

135.1 SPN 3246/FMI 3
This diagnostic is typically DPF Outlet Temperature sensor circuit failed high.
1. Disconnect the DPF Outlet Temperature sensor connector.
3. DPF Outlet Temperature Test - Measure the resistance between pin 1 and 2 of the DPF
Outlet Temperature sensor connector (refer to chart for resistance values).
[a] If the resistances are out of range, replace the DPF Outlet Temperature sensor.
Refer to section .
5. Measure the voltage between pin 2 on the harness side of the DPF Outlet Temperature
[a] If the voltage is greater than 3 volts, repair the short to power between pin 2 on
the harness side of the DPF Outlet Temperature sensor connector and pin 97 of the
of the DPF Outlet Temperature sensor connector and pin 97 of the ACM 120-pin
connector.

135.1 SPN 3246/FMI 3
6. Measure the voltage between pin 1 on the harness side of the DPF Outlet Temperature
sensor and ground.
DPF Outlet Temperature sensor connector and pin 98 of the ACM 120-pin connector.
[b] If no voltage is present, repair the open between pin 1 on the harness side of the DPF
Outlet Temperature sensor connector and pin 98 of the ACM 120-pin connector.

135.2 SPN 3246/FMI 4
This diagnostic is typically DPF Outlet Temperature sensor circuit failed low.
2. Disconnect the DPF Outlet Temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DPF Outlet Temperature
[a] If the resistance is less than 1K ohms, repair the wire between pin 2 of the DPF Outlet
[b] If the resistance is greater than 1K ohms, replace the DPF Outlet Temperature sensor.
Refer to section .

135.3 SPN 3246/FMI 8
135.3 SPN 3246/FMI 8
This diagnostic is typically DPF Outlet Temperature Signal Spike

This fault indicates the ACM2 has detected an impossible temperature shift on the DPF Outlet
Temperature sensor. The most likely cause is an intermittent wiring concern. If other DPF
[a] If SPN 3246 /FMI 3 or 4 are active, repair those faults first.
[b] If SPN 3246/FMI 3 or 4 are inactive along with SPN 3246 FMI 8 go to step 2.
2. Connect DDDL/DDRS 7.04 SP2 or higher
4. Using the Instrumentation chart function select DPF Outlet Temp.
5. While wiggle testing the harness look for abnormal voltage spikes on the DPF Outlet
no spikes are seen physically check and clean all harness connectors between the DPF
Outlet Temp sensor and the ACM2.

135.4 SPN 3246/FMI 20
This diagnostic is typically DPF Temperature Drift - Inlet Low or Outlet High
Check as follows:
This diagnostic is typically DPF Outlet Temperature sensor stuck.
Check as follows:
[a] If 3246 FMI 3/4/8 or 3250 FMI 3/4/8 is also present, repair those faults first.
[b] If the above faults are not present go to step 2.
3. Compare Diesel Oxidation Catalyst (DOC) Outlet Temperature and Diesel Particulate
Filter (DPF) Outlet Temperature; is the DOC Outlet temperature within 45F of the DPF
Outlet temperatures?
4. Start the engine (key ON, engine ON).
5. Compare DOC Outlet Temperature and DPF Outlet Temperature; are the DOC Outlet and
DPF Outlet temperatures within 45F of each other?
6. Continue idling engine for 10 minutes are the DOC Outlet and DPF Outlet temperatures
within 45F of each other?

135.4 SPN 3246/FMI 20
7. Turn engine OFF (key OFF, engine OFF).
8. Disconnect the DOC Outlet Temperature sensor harness, inspect harness for bent, spread
or corroded pins.
9. Measure the resistance across the DOC Outlet Temperature sensor at pigtail connector
[a] Yes go to step 10.
[b] No replace the DOC Inlet Temperature sensor. Refer to section .
10. Disconnect the DPF Outlet Temperature sensor harness, inspect harness for bent, spread or
corroded pins.
11. Measure the resistance across the DPF Outlet Temperature sensor at pigtail connector
[b] No replace the DPF Outlet Temperature sensor. Refer to section .

136SPN 3250 (EPA07)
Section Page
136.1 SPN 3250/FMI 0 ....................................................................................... 136- 3

136.2 SPN 3250/FMI 2 ....................................................................................... 136- 7
136.3 SPN 3250/FMI 3 ....................................................................................... 136-14
136.4 SPN 3250/FMI 4 ....................................................................................... 136-16
136.5 SPN 3250/FMI 8 ....................................................................................... 136-17
136.6 SPN 3250/FMI 10 ..................................................................................... 136-20
136.7 SPN 3250/FMI 14 ..................................................................................... 136-21
136.8 SPN 3250/FMI 31 ..................................................................................... 136-28
136.1 SPN 3250/FMI 0
Check as follows:
NOTE:
Do not perform a Parked Regeneration prior to running this diagnostic. The
contamination evidence will be eliminated during the regeneration.
NOTE:
This diagnostic procedure requires DDDL 7.03 SP3 or higher. All references to 7.X in
this procedure designate 7.03 SP3 or higher.

[a] If fault codes other than 3250/0 are active, troubleshoot the other fault codes first.
NOTE:
Do no troubleshoot fault codes 3246/0 and 3246/16 first as they can be related to the
cause of 3250/0.
[b] If only 3250/0 and related fault codes are present, go to step 5.
5. Monitor DOC Outlet Temperature.
[a] If the temperature is greater than 760C (1400F), go to step 8.
[b] If the temperature is less than 760C (1400F), go to step 6.
ENGINE EXHAUST
exhaust is toxic.
6. With DDDL 7.X connected, run the engine at 1200 rpm for 10 minutes.
7. Monitor DOC Inlet and Outlet Temperatures. Are the temperatures within 25C (45F)
of each other?

136.1 SPN 3250/FMI 0
9. Disconnect DOC Outlet Temperature sensor and inspect connector for damaged, bent,
spread, or corroded pins. If Temperature sensor connector is OK, check connections
upstream of the MCM (ATD harness 10pin connector pin 5, VIH 31-pin connector
pin 17, and MCM 120-pin connector pin 29). See Figure .
[a] If harness damage is found, repair as necessary,

[b] If no harness damage is found, replace the DOC Outlet Temperature sensor.
Refer to section .
10. Is the engine a Series 60?
11. Perform an Automatic Cylinder Cutout Service Routine using DDDL 7.X.
NOTE:
Detroit Diesel Service Letter 08 TS22 gives assistance with running and analyzing the
Automatic Cylinder Cutout Service Routine.
12. Retain a log file of the Automatic Cylinder Cutout Service Routine.
13. Was a faulty fuel injector identified?
[a] If yes, replace the faulty fuel injector, refer to section repeat the Automatic Cylinder
Cutout Service Routine to verify repairs, and go to step 26.

14. Perform an Idle Speed Balance Test using DDDL 7.X. Retain the log file.
15. Was a faulty fuel injector/cylinder identified?
[a] If yes, repair the faulty fuel injector/cylinder, repeat the Idle Speed Balance Test
to verify repair. Go to step 26.
16. Remove the ATD.
17. Disassemble the ATD and inspect the inlet face of the DPF substrate for contamination.
[a] If coolant contamination is found (white residue on inlet face of the DPF and a sweet
smell from exhaust), go to step 18.
[b] If oil contamination is found (oil residue or paste on DPF Inlet face or an oil lacquer
on the Inlet Flange), go to step 21.
[c] If fuel contamination is found (Inlet Flange washed clean), go to step 23.
[d] If no contamination is found, obtain pictures of the Inlet Flange, DOC Outlet face,
and DPF Inlet and Outlet faces .Contact the Detroit Diesel Customer Support Center
at 3135925800 with these pictures and the log files from the Automatic Cylinder
Cutout Service Routine or the Idle Speed Balance Test.
EGR Cooler leaks
Failed Fuel Cooler (HDE)
Fuel doser body cracked, missing or failed seals
20. Repair the cause of coolant entry as necessary and go to step 25.

136.1 SPN 3250/FMI 0
consumption are:
Turbocompound failure (Axial Power Turbine air seal)
Defective Crankcase Breather system
NOTE:
If fault code sets right after fuel injector replacement, then this is the most likely cause.
23. Inspect the ATD components for fuel contamination.

Failure to drain cylinder head during fuel injector replacement
Use of non-recommended fuels and fuel additives
Low turbocharger boost
Engine brake stuck on
24. Repair the cause of fuel contamination and go to step 25.
25. Install the ATD.
NOTE:
HOT EXHAUST
outside.
26. Perform a parked regeneration and E-mail all log files from this troubleshooting procedure
to the Detroit Diesel Customer Support Center.
[a] If the regeneration is successful, go to step 27
NOTE:
The parked regeneration is successful if the DOC Out Temperature is within 100C
(180F) of the DOC Model Delay.
[b] If the regeneration is not successful, go to step 16.

27. Replace DOC and DPF, re-install ATD, and go to step 28.
28. Perform a parked regeneration, reset ash accumulators, and E-mail a log file of the
successful regeneration to Detroit Diesel Customer Support Center. Verify Repairs 219.1.

136.2 SPN 3250/FMI 2
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.

136.2 SPN 3250/FMI 2
10. Monitor DOC Outlet temperature voltage (T_DOC_OUT). Continue monitoring and
wiggle the wire harness from the ATD to the MCM, see Figure . Is there a large deviation
in the voltage?

11. Inspect the electrical connections upstream of the MCM (DOC Outlet Temperature sensor,
219.1.
[b] If no corrosion or damage is found, replace the DOC Outlet Temperature sensor.
Refer to section .
219.1.
Refer to section .


219.1.
Refer to section .

EGR Cooler
consumption are:

136.2 SPN 3250/FMI 2
Excessive idle time

Stuck rings

NOTE:

Plugged air filter

136.2 SPN 3250/FMI 2

NOTE:
Performance issues
41. Start engine.

HOT EXHAUST
outside.
NOTE:

136.3 SPN 3250/FMI 3
136.3 SPN 3250/FMI 3
Check as follows:
workshop manual.
5. Disconnect the DOC Outlet Temperature sensor.
6. Check resistance between pin 1 and pin 2 of the DOC Outlet Temperature sensor.
Acceptable resistance is listed in Table 136-1.

0 (32) 202.50
25 (77) 221.60
100 (212) 277.90
600 (1112) 619.80
850 (1562) 768.81
[a] If resistance is out of range, replace the DOC Outlet Temperature sensor.
Refer to section .
8. Measure voltage between pin 1 and pin 2 of the DOC Outlet Temperature sensor connector.

9. Measure voltage between pin 2 of DOC Outlet Temperature sensor connector and ground
pin 88 of the MCM 120-pin connector and pin 1 of the DOC Outlet Temperature
[b] If the voltage is less 2.75 volts, then repair the open in wire between pin 2 of
the DOC Outlet Temperature sensor connector and pin 29 of the MCM 120-pin

136.4 SPN 3250/FMI 4
136.4 SPN 3250/FMI 4
Check as follows:
1. Disconnect the DOC Outlet Temperature sensor.
3. Measure the resistance across pins 1 and 2 of the DOC Outlet Temperature sensor
connector.
4. Measure the resistance between pin 1 of the DOC Outlet Temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the DOC Outlet
5. Measure the resistance between pin 2 of the DOC Outlet Temperature sensor harness
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the DOC Outlet

136.5 SPN 3250/FMI 8
the DOC Outlet Temperature sensor. The most likely cause is an intermittent wiring problem.
See Figure 136-1 and Figure 136-2 for the ATD wiring schematics.
Figure 136-1 Vertical Aftertreatment Device Wiring Diagram

136.5 SPN 3250/FMI 8
Figure 136-2 Horizontal Aftertreatment Device Wiring Diagram
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.


7. Wiggle test the harness while looking for abnormal voltage spikes on T_DOC_OUT
(pin 29).
between the DOC Outlet Temperature sensor and the MCM. Repair damage as

136.6 SPN 3250/FMI 10
136.6 SPN 3250/FMI 10
Check as follows:
1. Disconnect DOC Outlet Temperature sensor and inspect connector for damaged, bent,
spread, or corroded pins. If temperature sensor connector is OK, connections upstream to
the MCM (ATD harness 10pin connector pin 5, VIH 31-pin connector pin 17, and MCM
120-pin connector pin 29) must also be checked.
[a] If damage is found, repair connector(s) as necessary. Verify Repairs 219.1.

[b] If OK, replace DOC Outlet Temperature sensor. Refer to section .

136.7 SPN 3250/FMI 14
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.

136.7 SPN 3250/FMI 14
wiggle the wire harness from the ATD to the MCM. Is there a large deviation in the
voltage?

219.1.
Refer to section .
219.1.
Refer to section .


219.1.
Refer to section .

EGR Cooler
consumption are:

136.7 SPN 3250/FMI 14
Excessive idle time

Stuck rings

NOTE:

136.7 SPN 3250/FMI 14
Plugged air filter
NOTE:
Performance issues

41. Start engine.

HOT EXHAUST
outside.
NOTE:

136.8 SPN 3250/FMI 31
136.8 SPN 3250/FMI 31
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.

wiggle the wire harness from the ATD to the MCM. Is there a large deviation in the
voltage?

219.1.
Refer to section .
219.1.
Refer to section .

136.8 SPN 3250/FMI 31

219.1.
Refer to section .

EGR Cooler
consumption are:

Excessive idle time

Stuck rings

136.8 SPN 3250/FMI 31
NOTE:

Plugged air filter
NOTE:
Performance issues

136.8 SPN 3250/FMI 31
41. Start engine.

HOT EXHAUST
outside.
NOTE:

137SPN 3250 (ACM2) (EPA10)
Section Page
137.1 SPN 3250/FMI 3 ....................................................................................... 137- 3

137.2 SPN 3250/FMI 4 ....................................................................................... 137- 5
137.3 SPN 3250/FMI 8 ....................................................................................... 137- 6
137.4 SPN 3250/FMI 14 ..................................................................................... 137- 7
Figure 137-1 DOC Outlet Temperature Circuit

137.1 SPN 3250/FMI 3
This diagnostic is typically DOC Outlet Temperature sensor circuit failed high.
1. Disconnect the DOC Outlet Temperature sensor connector.
3. DOC Outlet Temperature Test - Measure the resistance between pin 1 and 2 of the DOC
[a] If the resistances are out of range, replace the DOC Outlet Temperature sensor.
Refer to section .
5. Measure the voltage between pin 2 on the harness side of the DOC Outlet Temperature
harness side of the DOC Outlet Temperature sensor connector and pin 27 of the
of the DOC Outlet Temperature sensor connector and pin 27 of the ACM 120-pin
connector.

137.1 SPN 3250/FMI 3
6. Measure the voltage between pin 1 on the harness side of the DOC Outlet Temperature
sensor and ground.
DOC Outlet Temperature sensor connector and pin 73 of the ACM 120-pin connector.
[b] If no voltage is present, repair the open between pin 1 on the harness side of the DOC

137.2 SPN 3250/FMI 4
This diagnostic is typically DOC Outlet Temperature Circuit failed low.

2. Disconnect the DOC Outlet Temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the DOC Outlet Temperature
[a] If the resistance is less than 1K ohms, repair the wire between pin 2 of the DOC
[b] If the resistance is greater than 1K ohms, replace the DOC Outlet Temperature
sensor. Refer to section .

137.3 SPN 3250/FMI 8
137.3 SPN 3250/FMI 8
This diagnostic is typically DOC Outlet Temperature Signal Spike

This fault indicates the ACM2 has detected an impossible temperature shift on the DOC Inlet
Temperature sensor. The most likely cause is an intermittent wiring concern. If other DOC
[a] If SPN 3242/FMI 3 or 4 are active, repair those faults first.
[b] If SPN 3242/FMI 3 or 4 are inactive along with SPN 3242 FMI 8 go to step 2.
4. Using the Instrumentation chart function select DOC Inlet Temp.
5. While wiggle testing the harness look for abnormal voltage spikes on the DOC Inlet
no spikes are seen physically check and clean all harness connectors between the DOC
Inlet Temp sensor and the ACM2.

137.4 SPN 3250/FMI 14
This diagnostic is typically Abnormal DOC Temp Rise 2
NOTE:
Excessive idle times may lead to this fault due to high HC accumulation on the DOC.
1. Connect DDDL 7.05 or higher.

3. Verify ACM software level is v8.5 or higher.
4. Check for fault 3250/0 (DOC Outlet Temperature Very High).
[a] If fault 3250/0 is present, troubleshoot 3250/0 first, then clear codes and verify repairs.
[b] If fault 3250/0 is not present go to step 5.
5. Check for fault 3250/8 (DOC Outlet Temperature Signal Spike).
[a] If fault 3250/8 is present, troubleshoot the signal spike fault first, then clear codes
and verify repairs.
[b] If fault 3250/8 is not present, go to step 6.
6. Check 3250/14 fault code extended data occurrence counter.
[a] If the 3250/14 occurrence counter is greater than 5, follow troubleshooting procedure
for SPN 3250 FMI 0.
[b] If occurrence counter is 5 or less, go to step 7.
7. Using DDDL/DDRS perform a stationary regen, after regen completes clear faults and
verify repair.

137.4 SPN 3250/FMI 14

138SPN 3251 (EPA07)
Section Page
138.1 SPN 3251/FMI 0 ....................................................................................... 138- 3

138.2 SPN 3251/FMI 1 ....................................................................................... 138- 5
138.3 SPN 3251/FMI 16 ..................................................................................... 138- 7
138.1 SPN 3251/FMI 0
Check as follows:
1. Disconnect the DPF Inlet Pressure hose assembly.
NOTE:
Do not start the engine.

6. Monitor the DPF Inlet Pressure sensor voltage (P_DPF_IN).
8. Inspect the electrical connections upstream of the MCM (sensor, ATD harness 10-pin
connector, VIH 31-pin connector, and MCM 120-pin connector) for corrosion and spread
pins.
219.1.
Refer to section .
10. Inspect the DPF Inlet Pressure hose and fittings for kinks, blockage, and restrictions.
[a] If blockage or damage is found, repair the DPF Inlet Pressure hose and fittings as
[b] If no obstructions are found, reconnect the DPF Inlet Pressure hose assembly.
ENGINE EXHAUST
exhaust is toxic.
11. Start engine.


138.1 SPN 3251/FMI 0
HOT EXHAUST
outside.
NOTE:
14. When regeneration is complete, clear all fault codes.

15. Road test vehicle.
[a] If no fault codes appear, testing is complete. Verify Repairs 219.1..
[b] If the fault code returns, go to step 16.
16. Remove ATD.
17. Perform a DPF filter inspection for excessive soot loading. Possible causes of soot
contamination are:
Charge Air Cooler and associated piping
Turbocharger actuator (Perform nozzle sweep test.)
18. Make necessary repairs for soot loading. Replace DPF filter and re-install ATD.

138.2 SPN 3251/FMI 1
Check as follows:
1. Check exhaust system for signs of black smoke
[a] If black smoke, go to step 5.
[b] If no black smoke, go to step 2.
2. Visually inspect exhaust system after the ATD for physical damage.
[a] If damage is found, repair as necessary. Verify Repairs 219.1.
3. Inspect DPF Outlet Pressure hose and connections for leaks, kinks, or plugging.
[a] If damage is found, repair as necessary. Verify Repairs 219.1.
4. Using DDDL 7.X Voltage Service Routine, monitor DPF Inlet and DPF Outlet voltages
with key ON engine OFF.
[a] If voltages are between 0.44 0.56 volt, go to step 5.
[b] If a voltage is greater than 0.56 volt, replace suspect sensor. Verify Repairs 219.1.
[c] If voltage is less than 0.44 volt, inspect electrical connections upstream to the MCM
(sensor, ATD harness 10pin connector pins 3 and 4, VIH 31pin connector pins 30
and 31, and MCM 120pin connector pins 118 and 30) for corrosion or spread pins.
If connector damage is found, repair as necessary. If no corrosion or damage is
found, replace the suspect sensor. Verify Repairs 219.1.
6. Inspect face of the removed DOC substrate for contamination.
[a] If coolant contamination is found (white residue on inlet of ATD pipe sweet smell
from exhaust), go to step 7.
[b] If oil contamination is found (oil residue on inlet of ATD pipe), go to step 10.
[c] If fuel contamination is found (inlet pipe to ATD washed clean), go to step 12.
[d] If soot contamination, go to step 14.
EGR Cooler

138.2 SPN 3251/FMI 1
consumption are:
Excessive idle time
Worn valve seals
Stuck rings
Engine oil over filled
11. Repair the cause of oil contamination. Go to step 16.
12. Inspect for source of fuel contamination. Possible cause of fuel contamination are:
Cylinder head not drained when performing fuel injector replacement (if code sets
right after fuel injector replacement this is the most likely cause)
Fuel injector tip failure (perform fuel injector balance test)
Fuel injector circuit failure
Fuel doser valve stuck open
Use of non-recommended fuels and/or additives
13. Repair the cause of fuel contamination. Go to step 16.
14. Inspect for source of soot loading, possible causes are:
15. Repair the cause of soot contaminations. Go to step 16.
16. Replace DPF filter and re-install ATD.
HOT EXHAUST
outside.
17. Perform parked regeneration.

138.3 SPN 3251/FMI 16
Check as follows:
1. Disconnect the DPF Inlet Pressure hose assembly.
NOTE:
Do not start the engine.

8. Inspect the electrical connections upstream of the MCM (sensor, ATD harness 10-pin
pins.
219.1.
Refer to section .
10. Inspect the DPF Inlet Pressure hose and fittings for kinks, blockage, and restrictions.
[a] If blockage or damage is found, repair the DPF Inlet Pressure hose and fittings as
ENGINE EXHAUST
exhaust is toxic.
11. Start engine.


138.3 SPN 3251/FMI 16
HOT EXHAUST
outside.
NOTE:
14. When regeneration is complete, clear all fault codes.

[a] If no fault codes appear, testing is complete. Verify Repairs 219.1.
[b] If the fault code returns, go to step 16.
16. Remove ATD.
17. Perform a DPF filter inspection for excessive soot loading. Possible causes of soot
contamination are:
18. Make necessary repairs for soot loading, replace DPF filter, and re-install ATD.

139SPN 3251 (ACM2) (EPA10)
Section Page
139.1 SPN 3251/FMI 0 ....................................................................................... 139- 3

139.2 SPN 3251/FMI 2 ....................................................................................... 139- 4
Figure 139-1 DPF Pressure sensor Circuit

139.1 SPN 3251/FMI 0
This diagnostic is typically DPF Pressure out of range very high.

Check as follows:

139.2 SPN 3251/FMI 2
139.2 SPN 3251/FMI 2
This diagnostic is typically DOC Inlet Pressure (Not Plausible)

1. Visually inspect entire exhaust system for signs of leaks or damage.
3. Using SCR Voltage Service Routine, monitor the DOC Inlet Pressure (pin 87) and DPF
Outlet Pressure (pin 72) voltages with key on engine off.
4. Are the DOC Inlet and DPF Outlet pressure sensors voltages between .44 to .56 volts?
[b] If the voltage is greater than .56 volts, replace the suspect sensor.
[c] If the voltage is less than .44 volts, inspect electrical connections between suspect
sensor connector and ACM for bent, spread, or corroded pins. Repair as necessary.
5. Inspect the DOC and DPF Pressure sensor tubes and elbows for leaks, kinks, or blockage.
[a] If leaks, kinks, or blockage is found, repair as necessary.
6. Obtain a log file with the following conditions:
Start the engine and run at idle for 1 minute.
Raise engine speed to 1500 RPM for 1 minute.
Contact the Detroit Diesel Customer Support Center at 3135925800 with the log
file information for further instructions.

140SPN 3361 (ACM2) (EPA10)
Section Page
140.1 SPN 3361/FMI 0 ....................................................................................... 140- 3

140.2 SPN 3361/FMI 1 ....................................................................................... 140- 6
140.3 SPN 3361/FMI 3 ....................................................................................... 140- 7
140.4 SPN 3361/FMI 4 ....................................................................................... 140- 8
140.5 SPN 3361/FMI 5 ....................................................................................... 140- 9
Figure 140-1 DEF Dosing Valve Circuit

140.1 SPN 3361/FMI 0
This diagnostic is typically DEF pressure duty cycle high.

Check as follows:
1. Visually check all DEF supply and air lines for physical damage, (kinks, cracks, leaks,
disconnects).
[a] If leakage is found repair as necessary.
[b] If no leakage is found, go to step 2.
2. Connect DDDL 7.04 SP5 or higher.
4. Compare DEF Pressure and DEF Air Pressure to Ambient Air Pressure (Baro).
5. Are the pressures within 4 PSI of Ambient Air Pressure (Baro)?
[b] No, replace the out of range sensor, go to step 6.
6. Disconnect the DEF tank return line from the DEF pump.
7. Visually watch the DEF tank return line outlet on the pump while running the SCR Air
Pressure test (60 second duration).
8. Does DEF fluid discharge from the pump return outlet during the test?
[a] Yes, replace the DEF Pump pneumatic switching valve Refer to section and filter
screen refer to section .
[b] No, reconnect the DEF pump tank return line go to step 9.

140.1 SPN 3361/FMI 0
9. Disconnect the DEF aerosol outlet line from the DEF Metering Unit.
10. Visually watch the DEF aerosol line outlet on the metering unit while running the SCR
11. Does DEF fluid discharge from the port during the test?
[a] Yes, replace the DEF Metering Unit. Refer to section .
[b] No, reconnect aerosol line, go to step 12.
12. Completely discharge pressure from DEF pump module air bladder.
13. Using a suitable air pressure regulator, regulate shop air to 55 psi.

14. Using clean, dry, and oil free shop air, a standard air fitting and an air pressure gauge;
re-inflate the DEF pump module air bladder to 40-46 psi (2.8-3.2 bar) through the
Schrader valve(1), go to step 15.
15. Perform a DEF Quantity Test service routine and record the amount of DEF fluid level
dispensed. The amount of DEF delivered will vary depending on the diagnostic tool
version. If using DDRS/DDDL version 7.05 or earlier, is the dispensed DEF Fluid Level
between 44 and 59mL? If using DDRS/DDDL version 7.05SP1 or later, is the dispensed
DEF Fluid Level between 102 and 138mL?
[a] Yes; clear all faults and release vehicle.
[b] No; retain log file from DEF Quantity Test and contact the Customer Support Center
for further instruction.

140.2 SPN 3361/FMI 1
140.2 SPN 3361/FMI 1
This diagnostic is typically DEF pressure duty cycle low.

Check as follows:
[a] If SPN 3361 FMI 3,4 or 5 is also present repair those faults first.
[b] If the above faults are not present, go to step 2.
2. Connect DDDL 7.04 SP5 or higher.
4. Compare DEF Pressure to Ambient Air Pressure (Baro) and DEF Air Pressure.
5. Is DEF Pressure within 4 PSI of Ambient Air Pressure (Baro) and DEF Air Pressure?
[b] No; replace the DEF Pressure sensor. Refer to section .
[a] Yes, clear fault codes and release vehicle.
7. Turn ignition OFF (key OFF, engine OFF).
8. Disconnect DEF Metering Unit Doser fuel injector harness connector.
9. Inspect harness connector for bent, spread or corroded pins.
[b] If no pin damage is found, replace the DEF metering unit. Refer to section .

140.3 SPN 3361/FMI 3
This diagnostic is typically DEF Dosing Valve Circuit Failed High.

1. Connect to DDDL/DDRS 7.04 SP5 or higher.
3. Perform DEF Quantity Test (Note: Stop the test after 30 seconds).
4. Does the fault become active?
5. Repeat DEF Quantity Test 2 additional times (stopping the test after 30 seconds). The
ignition must be cycled between each test. Does the fault become active?
[b] No; clear the fault and release the vehicle.
6. Disconnect replace the DEF fuel doser injector valve harness connector.
7. Inspect the harness for bent, spread, or corroded pins.
[b] If connector shows no signs of damage, repair the short to battery voltage between
pin 1 of replace the DEF fuel doser injector valve connector and pin 28 of the ACM2
120-pin connector.

140.4 SPN 3361/FMI 4
140.4 SPN 3361/FMI 4
This diagnostic is typically DEF Dosing Valve Circuit Failed Low.

Check as follows:
1. Ensure the ignition is OFF (key OFF, engine OFF).
2. Disconnect replace the DEF fuel doser injector valve harness connector.
[b] If connector shows no signs of damage, go to step 4
5. Measure the resistance between pin 1 on the harness side of replace the DEF fuel doser
injector valve connector and ground.
[a] If the resistance is less than 1K ohms, repair the wire between pin 1 of replace the
DEF fuel doser injector valve connector and pin 28 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DEF fuel doser injector valve.
Refer to section .

140.5 SPN 3361/FMI 5
This diagnostic is typically DEF Dosing Valve Circuit Failed Open.

Check as follows:
[a] If 4353/5 is present with 3361/5, repair the open between pin 3 of the ACM2 120-pin
connector and the Diffuser Heater/DEF Dosing Valve.
2. Disconnect replace the DEF fuel doser injector valve connector.
5. Measure the voltage between pin 2 on the harness side of replace the DEF fuel doser
injector valve connector and ground.
[b] If the voltage is less than 11.75 volts, repair the wire between pin 2 on the harness
side of replace the DEF fuel doser injector valve and pin 3 of the ACM2 120-pin
6. Measure the voltage between pin 1 of replace the DEF fuel doser injector valve harness
[a] If the voltage is between 2.25 and 2.50 volts, replace the DEF diffuser heater.
Refer to section .
[b] If the voltage is not between 2.25 and 2.50 volts, repair the wire between pin 1 of
replace the DEF fuel doser injector valve harness connector and pin 28 of the ACM2

140.5 SPN 3361/FMI 5

141SPN 3363 (ACM2) (EPA10)
Section Page
141.1 SPN 3363/FMI 0 ....................................................................................... 141- 3

141.2 SPN 3363/FMI 1 ....................................................................................... 141- 4
141.3 SPN 3363/FMI 3 ....................................................................................... 141- 5
141.4 SPN 3363/FMI 4 ....................................................................................... 141- 6
141.5 SPN 3363/FMI 5 ....................................................................................... 141- 7
Figure 141-1 DEF Coolant Valve Circuit

141.1 SPN 3363/FMI 0
This diagnostic is typically DEF tank temperature high.

Check as follows:
NOTE:
Output State Check test can be ran only once per key cycle
3. Perform Output State Check service routine. Does fault SPN 3363/FMI 3, 4 or 5 become
active during the routine?
[a] Yes, repair those faults first, clear codes and release vehicle.
4. Using DDDL/DDRS monitor parameter AS021 DEF Tank Temperature.
5. Remove the DEF tank filler cap. Using an external thermometer (ex. Infrared temperature
gun) compare the actual DEF temperature (liquid) to the DDDL/DDRS reported tank
temperature. Is the AS021 DEF Tank Temperature 120F higher than the externally
measured temperature?
6. Disconnect the DEF Tank header harness connector, inspect connector harness for bent,
spread or corroded pins.
[b] If no pin damage is found, replace the DEF tank header assembly. Refer to section .
7. Disconnect the DEF Tank header harness connector, inspect connector harness for bent,
[b] If no pin damage is found, replace the DEF tank header assembly. Refer to section .

141.2 SPN 3363/FMI 1
141.2 SPN 3363/FMI 1
This diagnostic is typically DEF tank temperature low.

Check as follows:
1. Are there any cooling system issues or complaints?
[a] Yes, service cooling system issues or complaints?
NOTE:
Output State Check test can be ran only once per key cycle
4. Perform Output State Check service routine. Does fault SPN 3363 FMI 3, 4 or 5 become
active during the routine?
[a] Yes, repair those faults first, clear codes and release vehicle.
5. Using DDDL/DDRS monitor parameter AS021 DEF Tank Temperature.
6. Remove the DEF tank filler cap. Using an external thermometer (ex. Infrared temperature
gun) compare the actual DEF temperature (liquid) to the DDDL/DDRS reported tank
temperature. Is the reported AS021 DEF Tank Temperature 50F (10C) lower than the
externally measured temperature?
7. Disconnect the DEF Tank header temperature/level harness connector, inspect connector
harness for bent, spread or corroded pins.
[b] If no pin damage is found, replace the DEF Tank header assembly. Refer to section .
8. Disconnect the DEF Tank header coolant valve harness connector, inspect connector
harness for bent, spread or corroded pins.
[b] If no pin damage is found, replace the DEF Tank header assembly. Refer to section .

141.3 SPN 3363/FMI 3
This diagnostic is typically DEF Coolant Valve Circuit Failed High

Check as follows:
3. Perform Output Component Test.
5. Repeat Output Component Test 3 times. The ignition must be cycled between each test.
Does the fault become active?
[b] No, clear the fault and release the vehicle.
6. Disconnect the DEF Coolant Valve harness connector.
[b] If connector shows no signs of damage, repair the short to battery (12 volts) between
pin 1 of the DEF Coolant Valve harness connector and pin 8 and 34 of the ACM2
120-pin connector.

141.4 SPN 3363/FMI 4
141.4 SPN 3363/FMI 4
This diagnostic is typically DEF Coolant Valve Circuit Failed Low.

Check as follows:
2. Disconnect the DEF Coolant Valve connector.
[b] If the connector shows no signs of damage, go to next step 4.
5. Measure the resistance between pin 1 on the harness side of the DEF Coolant Valve
[a] If the resistance is less than 1K ohms, repair the wire between pin 1 of the DEF
Coolant Valve connector and pin 8 and 34 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DEF Coolant Valve.

141.5 SPN 3363/FMI 5
This diagnostic is typically DEF Coolant Valve Circuit Failed Open.

Check as follows:
1. Disconnect the DEF Coolant Valve connector.
4. Measure the voltage between pin 2 on the harness side of the DEF Coolant Valve
side of the DEF Coolant Valve and pin 19 of the ACM2 120-pin connector.
5. Measure the voltage between pin 1 on the harness side of the DEF Coolant Valve
the DEF Coolant Valve connector and pin 8 and 34 of the ACM2 120-pin connector.
[a] If the resistance is greater than 5 ohms, repair the wire between pin 1 of the DEF
Coolant Valve connector and pin 8 of the ACM2 120-pin connector. Verify Repairs
219.1.
[a] If the resistance is greater than 5 ohms, repair the wire between pin 1 of the DEF
Coolant Valve connector and pin 34 of the ACM2 120-pin connector. Verify Repairs
219.1.
[b] If the resistance is less than 5 ohms, replace the DEF Coolant Valve. Verify Repairs
219.1.

141.5 SPN 3363/FMI 5

142SPN 3464 (EPA07)
Section Page
142.1 SPN 3464/FMI 14 ..................................................................................... 142- 3

142.1 SPN 3464/FMI 14
This diagnostic is typically an Intake Air Throttle Control electrical fault.

Check as follows:
1. Clear all code(s) using DDDL 7.X.
5. Is SPN 3464/FMI 14 active?
NOTE:
With the MCM disconnected, multiple faults will also be active.
[a] If yes, contact the Detroit Diesel Customer Support Center at 3135925800.
7. Reconnect the MCM 120-pin connector.
8. Disconnect the intake throttle valve.
10. Measure the voltage between pin 5 of the intake throttle valve connector and ground.
[a] If the voltage is greater than 1.0 volt, repair short to power between pin 5 of the intake
throttle valve connector and pin 101 of the MCM 120-pin connector. Verify Repairs
219.1.
[b] If the voltage is less than 1.0 volt, go to step 11.
11. Measure the voltage between pin 4 of the intake throttle valve connector and ground.
[a] If the voltage is greater than 1.0 volt, repair short to power between pin 4 of the intake
219.1.
[b] If the voltage is less than 1.0 volt, go to step 12.
14. Measure the voltage between pins 4 and 5 of the intake throttle valve connector.
[a] If the resistance is less than 3 , repair short between pins 4 and 5 of the intake
throttle valve connector and pins 100 and 101 of the MCM 120-pin connector.

142.1 SPN 3464/FMI 14
15. Measure the resistance between pin 5 of the intake throttle valve connector and ground.
[a] If the resistance is less than 3 , repair short to ground between pin 5 of the intake
219.1.
16. Measure the resistance between pin 4 of the intake throttle valve connector and ground.
[a] If the resistance is less than 3 , repair short to ground between pin 4 of the intake
219.1.
[b] If the resistance is greater than 3 , contact the Detroit Diesel Customer Support
Center at 3135925800.

143SPN 3364 (ACM2) (EPA10)
Section Page
143.1 SPN 3364/FMI 1 ....................................................................................... 143- 3

143.2 SPN 3364/FMI 2 ....................................................................................... 143- 6
143.3 SPN 3364/FMI 17 ..................................................................................... 143- 9
143.1 SPN 3364/FMI 1
This diagnostic is typically Improper DEF Quality Final Warning

1. SPN 4364/FMI 1 and or 18 (SCR NOx Conversion Efficiency) may also be present.
2. Using a refractometer from the Diesel Exhaust Fluid (DEF) Test Kit W060589001900,
measure the DEF percentage. Is DEF percentage between 28 and 36%?
[b] No; refer to appropriate manual for DEF tank cleaning/flushing procedure, then
go to step 3.
ASL102 Engine Speed

143.1 SPN 3364/FMI 1
disconnects).
[a] If damage is found, repair as necessary, go to step 11.
8. Remove DEF Air Pressure and Temperature sensors.
9. Remove the DEF Inlet delivery line and DEF Air Supply line and from metering unit.
Remove DEF Nozzle from the ATD box.
10. Flush warm water into DEF Air Pressure and Temp sensor cavitys in the DEF metering
unit until water flows from the DEF Inlet and DEF Nozzle, re-install sensors and repeat
Quantity test, if test fails repeat flushing procedure, go to step 11.
ASL102 Engine Speed
12. Start engine and perform Parked regeneration, does the NOx Conversion Efficiency rise

[b] No; retain log file from Parked regen and contact the Detroit Diesel Customer
Support Center at 3135925800 for further instructions.

143.2 SPN 3364/FMI 2
143.2 SPN 3364/FMI 2
This diagnostic is typically Improper DEF Quality

go to step 3
ASL102 Engine Speed

disconnects).
[b] No; go to step 8
ASL102 Engine Speed

143.2 SPN 3364/FMI 2

143.3 SPN 3364/FMI 17
This diagnostic is typically Improper DEF Quality Warning

go to step 3.
ASL102 Engine Speed

143.3 SPN 3364/FMI 17
disconnects).
7. Perform DEF Quantity Test service routine, and record amount of DEF fluid level
dispensed.
8. Is the dispensed DEF Fluid Level between 102 and 138mL?
ASL102 Engine Speed


143.3 SPN 3364/FMI 17

144SPN 3471 (MCM) (EPA10)
Section Page
144.1 SPN 3471/FMI 1 ....................................................................................... 144- 3

144.2 SPN 3471/FMI 3 ....................................................................................... 144- 4
144.3 SPN 3471/FMI 4 ....................................................................................... 144- 5
144.4 SPN 3471/FMI 5 ....................................................................................... 144- 6
Figure 144-1 Dosing Valve Circuit

144.1 SPN 3471/FMI 1
This diagnostic is typically Electronic Dosing Valve (EDV) failed self test. Contact the Detroit
Diesel Customer Support Center at 3135925800 for further details.

144.2 SPN 3471/FMI 3
144.2 SPN 3471/FMI 3
This diagnostic is typically EDV short to power.

Check as follows:
1. Disconnect the Electronic Dosing Valve (EDV) connector.
3. Measure the voltage between pin 1 of the EDV connector and ground (battery ground
lug by starter).
[a] If the voltage is greater than 4.5 volts, repair short to power between pin 1 of the
EDV connector and pin 65 of the MCM 120-pin connector. Verify Repairs 219.1.
[b] If voltage is less than 4.5 volts, go to step 4.
4. Turn the ignition switch to the OFF position.
6. Measure the resistance between pin 1 and pin 2 of the EDV connector.
[a] If the resistance is less than 5 , repair short between EDV connector and pins 1
and 2 and MCM 120-pin connector pins 64 and 65. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , replace the electronic dosing valve.

144.3 SPN 3471/FMI 4
This diagnostic is typically EDV sensor short to ground.

1. Disconnect the EDV sensor.
3. Measure the resistance between pin 1 of the EDV sensor harness connector and ground
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the EDV sensor
harness connector and ground.
4. Measure the resistance between pin 2 of the EDV sensor harness connector and ground
[a] If resistance is less than 5 , repair the short circuit between pin 2 of the EDV sensor
harness connector and ground. Verify Repairs 219.1.
[b] If resistance is greater than 5 , replace EDV. Verify Repairs 219.1.

144.4 SPN 3471/FMI 5
144.4 SPN 3471/FMI 5
This diagnostic is typically EDV sensor open circuit.
Check as follows:
1. Turn vehicle ignition switch ON.
2. Read multiple codes.
[a] If fault code 3482/5 is active in addition to 3471/5, repair open circuit between pin 64
of the MCM 120-pin connector and the EDV, pin 2 and Fuel Cutoff Valve (FCV),
pin 2 sensors.
[b] If only fault code 3471/5 is active, go to step 4.
3. Disconnect the EDV sensor.
4. Measure the resistance across pin 1 and pin 2 of the EDV sensor.
[a] If resistance is greater than 20 , replace the EDV sensor. Verify Repairs 219.1.
[b] If resistance is less than 20 , go to step 5.
6. Measure voltage between pin 2 of the EDV sensor harness connector and ground (battery
ground lug by starter).
[a] If the voltage is between 11.5 and 12.5 volts, then repair the open between pin 1
of the EDV sensor harness connector and pin 65 of the MCM 120-pin connector.
[b] If the voltage is less 4.5 volts, then repair open circuit between pin 2 of the EDV
sensor harness connector and pin 64 of the MCM 120-pin connector. Verify Repairs
219.1.

145SPN 3480 (MCM) (EPA10)
Section Page
145.1 SPN 3480/FMI 1 ....................................................................................... 145- 3

145.2 SPN 3480/FMI 2 ....................................................................................... 145- 5
145.3 SPN 3480/FMI 14 ..................................................................................... 145- 7
145.4 SPN 3480/FMI 16 ..................................................................................... 145- 8
145.5 SPN 3480/FMI 31 ..................................................................................... 145- 9
145.1 SPN 3480/FMI 1
This diagnostic is typically low Doser Fuel Line Pressure.

2. Visually inspect HC doser block assembly fuel lines for external leaks.
NOTE:
One drop of fuel can cause a failure.
[a] If external leaks are present, repair as necessary. Verify Repairs 219.1.
[b] If no external leaks are present, go to step 3.
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.
5. Using DDDL 7.X, perform a Doser Fuel Line Purge Service Routine.
NOTE:
Only run the Doser Fuel Line Purge Service Routine one time.
6. Once the fuel cutoff goes to 100%, begin monitoring the Fuel Compensation Pressure.
NOTE:
The pressures listed in this procedure for Fuel Compensation Pressure are absolute
pressures, which is gauge pressure plus approximately 100 kPa (14.5 psi).
[a] If Fuel Compensation Pressure is between 69 448 kPa (10 65 psi), perform a low
fuel pressure test. Make repairs as needed and go to step 7.
[b] If Fuel Compensation Pressure is less than 69 kPa (10 psi), replace the HC doser
block assembly. Refer to section . Go to step 7.
[c] If Fuel Compensation Pressure is between 448 665 kPa (65 95 psi), replace the
fuel doser injector valve. Refer to section .Go to step 7.

145.1 SPN 3480/FMI 1
HOT EXHAUST
outside.
7. Using DDDL 7.X, initiate a parked regeneration.

[a] If fault code 3480/1 becomes active, replace the HC doser block assembly.
Refer to section .
NOTE:
The regeneration will abort if fault code 3480/1 becomes active.
[b] If the regeneration completes itself, Verify Repairs 219.1.

[a] If fault code 3480/1 becomes active, repeat step 2 through step 6. If the fault code
3480/1 still becomes active, contact the Detroit Diesel Customer Support Center
at 3135925800.

145.2 SPN 3480/FMI 2
This diagnostic is typically abnormal Doser Fuel Line Pressure.

NOTE:
ENGINE EXHAUST
exhaust is toxic.
3. Start engine.
4. Using DDDL 7.X, perform Doser Fuel Line Purge Service Routine.
NOTE:
Only run this service routine once.
NOTE:
[a] If Fuel Compensation Pressure is greater than or equal to 993 kPa (144 psi), replace
the HC doser block assembly. Refer to section . Go to step 6.
[c] If Fuel Compensation Pressure is between 69 448 kPa (10 65 psi), perform a low
fuel pressure test. Make repairs as needed verify repairs 219.1 and go to step 6.
[d] If Fuel Compensation Pressure is between 665 993 kPa (95 144 psi), perform a
high fuel pressure test. Make repairs as needed verify repairs 219.1 and go to step 6.
[e] If Fuel Compensation Pressure is between 448 665 kPa (65 95 psi), replace the
fuel doser injector valve. Refer to section . Go to step 6.

145.2 SPN 3480/FMI 2
HOT EXHAUST
outside.

Refer to section .
NOTE:
[b] If the regeneration completes itself. Verify Repairs 219.1.

at 3135925800.

145.3 SPN 3480/FMI 14
This diagnostic is typically Doser Fuel Line Pressure sensor failed self test.
1. Replace the HC doser block assembly. Refer to section .
HOT EXHAUST
outside.
4. Perform parked regeneration. After regeneration is complete, verify repairs 219.1.

145.4 SPN 3480/FMI 16
145.4 SPN 3480/FMI 16
This diagnostic is typically high Doser Fuel Line Pressure.

ENGINE EXHAUST
exhaust is toxic.
3. Start engine.
4. Using DDDL 7.X, perform a Doser Fuel Line Purge Service Routine.
NOTE:
Only run the Doser Fuel Line Purge Service Routine one time.
5. Once the Fuel Cutoff Valve goes to 100%, begin monitoring the Fuel Compensation
Pressure.
NOTE:
[a] If Fuel Compensation Pressure is between 665 993 kPa (95 144 psi), perform a
high fuel pressure test. Make repairs as needed Verify Repairs 219.1 and go to step 6.
[b] If Fuel Compensation Pressure is greater than or equal to 993 kPa (144 psi), replace
the HC doser block assembly.Refer to section . Go to step 6.
HOT EXHAUST
outside.

145.5 SPN 3480/FMI 31
This diagnostic is typically Fuel Cutoff Valve Pressure plausibility error.

1. Visually inspect entire fuel system for external leaks.
[a] If external leaks are present, repair as necessary. Verify Repairs 219.1. Go to step 6.
ENGINE EXHAUST
exhaust is toxic.
3. Start engine.
HOT EXHAUST
outside.

5. Once the Fuel Cutoff Valve goes to 100%, begin monitoring the Fuel Compensation
Pressure. After the Fuel Compensation Pressure readings are obtained, abort regeneration.
NOTE:
block assembly. Refer to section . Verify Repairs 219.1. Go to step 6.
fuel pressure test. Make repairs as needed verify repairs 219.1 and go to step 6.
high fuel pressure test. Make repairs as needed and go to step 6.

145.5 SPN 3480/FMI 31

146SPN 3482 (MCM) (EPA10)
Section Page
146.1 SPN 3482/FMI 3 ....................................................................................... 146- 3

146.2 SPN 3482/FMI 4 ....................................................................................... 146- 4
146.3 SPN 3482/FMI 5 ....................................................................................... 146- 5
146.4 SPN 3482/FMI 7 ....................................................................................... 146- 6
146.1 SPN 3482/FMI 3
This diagnostic is typically Fuel Cutoff Valve (FCV) short to power.

1. Disconnect the FCV connector.
3. Measure the voltage between pin 1 of the FCV connector and ground (battery ground
lug by starter).
[a] If the voltage is greater than 4.5 volts, repair short to power between pin 1 of the FCV
connector and pin 69 of the MCM 120-pin connector. Verify Repairs 219.1.
[b] If voltage is less than 4.5 volts, go to step 4.
6. Measure the resistance between pin 1 and pin 2 of the FCV connector.
[a] If the resistance is less than 5 , repair short between FCV connector and pins 1
and 2 and MCM 120-pin connector pins 64 and 69. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , replace the HC doser block assembly.
Refer to section .

146.2 SPN 3482/FMI 4
146.2 SPN 3482/FMI 4
This diagnostic is typically FCV sensor short to ground.

1. Disconnect the FCV sensor.
3. Measure the resistance between pin 1 of the FCV sensor harness connector and ground
[a] If resistance is less than 5 , repair the short circuit between pin 1 of the FCV sensor
[b] If resistance is less than 5 , repair the short circuit between pin 2 of the FCV sensor

146.3 SPN 3482/FMI 5
This diagnostic is typically Fuel Cutoff Valve (FCV) sensor open circuit.
Check as follows:
1. Turn vehicle ignition switch ON.
2. Read multiple codes.
[a] If fault code 3471/5 is active in addition to 3482/5, repair open circuit between
pin 64 of the MCM 120-pin connector and the EDV, pin 2 and FCV, pin 2 sensors.
[b] If only fault code 3482/5 is active, go to step 4.
3. Disconnect the FCV sensor.
4. Measure the resistance across pin 1 and pin 2 of the FCV sensor.
[a] If resistance is greater than 20 , replace the HC doser block assembly.
Refer to section .
6. Measure the voltage between pin 2 of the FCV sensor harness connector and ground
[a] If the voltage is between 11.5 and 12.5 volts, repair the open between pin 1 of
the FCV sensor harness connector and pin 69 of the MCM 120-pin connector.
[b] If the voltage is less 11.5 volts, repair open circuit between pin 2 of the FCV sensor
harness connector and pin 64 of the MCM 120-pin connector. Verify Repairs 219.1.

146.4 SPN 3482/FMI 7
146.4 SPN 3482/FMI 7
This diagnostic is typically Fuel Cutoff Valve failed self test.

1. Replace the HC doser block assembly. Refer to section .
HOT EXHAUST
outside.
4. Perform a parked regeneration. After regeneration is complete, Verify Repairs 219.1.

147SPN 3509 (MCM) (EPA07)
Section Page
147.1 SPN 3509/FMI 3 ....................................................................................... 147- 3

147.2 SPN 3509/FMI 4 ....................................................................................... 147- 4
147.1 SPN 3509/FMI 3
This diagnosis typically means the 5 V sensor supply bank 1 circuit failed high.
This fault indicates that the MCM detects a short to power (voltage > 5.3) on any of the MCM
pins listed in Table 147-1.
Component MCM Pin

Charge Air Cooler Outlet Pressure sensor 58
Inlet Air Delta P, Intake Throttle Valve 103
Inlet Air Delta P, Intake Throttle Valve 117
Table 147-1 MCM Pins for Short to Power Check
Inspect the harness and repair as necessary. Verify Repairs 219.1.

147.2 SPN 3509/FMI 4
147.2 SPN 3509/FMI 4
This diagnosis typically means the 5 V sensor supply bank 1 circuit failed low.
This fault indicates that the MCM detects a short to ground (voltage < 4.7) on either of the MCM
Component MCM Pin

Charge Air Cooler Outlet Pressure sensor, 58
Fuel Rail Pressure sensor
EGR Delta P, Intake Throttle Valve 117
Table 147-2 MCM Pins for Short to Ground Check

148SPN 3509 (ACM2) (EPA10)
Section Page
148.1 SPN 3509/FMI 3 ...................................................................................... 148- 3

148.2 SPN 3509/FMI 4 ...................................................................................... 148- 4
148.1 SPN 3509/FMI 3
This diagnostic is typically ACM2 sensor Supply 1 Short to Battery.
NOTE:
Additional faults (SPN 3610 FMI 3 DPF Outlet Pressure Circuit Failed High and SPN
3609 FMI 3 DPF Inlet Pressure Circuit Failed High) may also be present.

2. Disconnect the DOC Inlet pressure sensor connector.
[b] If the connector shows no signs of damage, go to step 4.
4. Measure the voltage between pin 3 on the harness side of the DOC Inlet Pressure sensor
[a] If the voltage is greater than 5.5 volts, repair the short to battery between pin 3 of the
DOC Inlet pressure sensor connector and pin 117 of the ACM2 120-pin connector.
[b] If the voltage is less than 5.5 volts, repair the short to battery between pin 1 of the
DOC Inlet pressure sensor connector and pin 88 of the ACM2 120-pin connector.

148.2 SPN 3509/FMI 4
148.2 SPN 3509/FMI 4
This diagnostic is typically ACM2 sensor Supply 1 Short to Ground.

2. Disconnect the DOC Inlet Pressure sensor connector.
5. Measure the resistance between pin 3 on the harness side of the DOC Inlet Pressure sensor
[a] If the resistance is less than 1K ohms, repair the wire between pin 3 of the DOC Inlet
Pressure sensor connector and pin 117 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DOC Inlet Pressure sensor.
Refer to section .

149SPN 3510 (EPA07)
Section Page
149.1 SPN 3510/FMI 2 ....................................................................................... 149- 3

149.2 SPN 3510/FMI 3 ....................................................................................... 149- 5
149.3 SPN 3510/FMI 4 ....................................................................................... 149- 7
149.1 SPN 3510/FMI 2
This fault indicates that the throttle pedal supply is receiving erratic data.
Check as follows:
3. Measure the voltage between pins 1 and 3 of the AP harness connector.
[b] If the voltage is less than 4.5, go to step 4.
4. Measure the voltage between pins 1 of the AP harness connector and ground.
[a] If the voltage is between 4.5 and 5.5 volts, repair the open circuit between pin 3 of
[b] If the voltage is less than 4.5, repair the open circuit between pin 1 of the AP harness

149.1 SPN 3510/FMI 2

7. Measure the resistance between pin 2 of the AP harness connector and pin 7 of the CPC
#1 connector.
[a] If the resistance is greater than 3 , repair the open between pin 2 of the AP harness

149.2 SPN 3510/FMI 3
SPN 3510/Fmi 3 CPC (for MCM Diagnostics see below)

The typical diagnosis for this fault is high voltage.
Check as follows:
3. Measure the voltage between pins 1 and 3 of the AP harness connector.
4. Measure the voltage between pins 1 of the AP harness connector and ground.
[a] If the voltage is between 4.5 and 5.5 volts, repair the open circuit between pin 3 of
[b] If the voltage is less than 4.5, repair the open circuit between pin 1 of the AP harness
7. Measure the resistance between pin 2 of the AP harness connector and pin 7 of the CPC
#1 connector.
[a] Measure the resistance between pin 2 of the AP harness connector and pin 7 of the
CPC #1 connector. Verify Repairs 219.1.

149.2 SPN 3510/FMI 3
SPN 3510/Fmi 3 MCM (for CPC Diagnostics see above)

pins listed in the Table.
Component MCM Pin

TSS, Fuel Line Pressure sensor, Fuel Compensation Pressure
82
sensor, Engine Oil Pressure sensor
Turbocharger Inlet Pressure/Temp sensor, DPF Inlet and
85
Outlet Pressure sensors
Fuel Line Pressure sensor, Fuel Compensation Pressure sensor 104
Engine Oil Pressure sensor, Turbocharger Inlet Pres-
105
sure/Temperature sensor

149.3 SPN 3510/FMI 4
SPN 3510/Fmi 3 CPC (for MCM Diagnostics see below)

The typical diagnosis for this fault is voltage low.
Check as follows:
1. Disconnect the Accelerator Pedal (AP) connector.
2. Disconnect the #1 connector of the CPC.
3. Measure the resistance between pin 1 and pin 3 of the AP connector.
4. Measure the resistance between pin 2 and 3 of the AP connector.
[a] If the resistance is less than 5 , repair the short between wires 7 and 14 of the
CPC #! connector. Verify Repairs 219.1.
5. Measure the resistance between pin 1 of the AP connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin 1 of the AP
6. Measure the resistance between pin 2 of the AP connector and ground.
[a] If the resistance is less than 5 , repair the short circuit between pin 2 of the AP
[b] If the resistance is greater than 5 , replace the Accelerator Pedal. Verify Repairs
219.1.

149.3 SPN 3510/FMI 4
SPN 3510/Fmi 3 MCM (for CPC Diagnostics see above)

This diagnosis typically means the 5 V sensor supply bank 2 circuit failed low.
This fault indicates that the MCM detects a short to ground (voltage < 4.7) on either of the MCM
Component MCM Pin

TSS, Fuel Line Pressure sensor, Fuel Compensation Pressure
82
sensor, Engine Oil Pressure sensor
Turbocharger Inlet Pressure/Temp sensor, DPF Inlet and
85
Outlet Pressure sensors
Table 149-2 MCM Pins for Short to Ground Check

150SPN 3510 (ACM2) (EPA10)
Section Page
150.1 SPN 3510/FMI 3 ....................................................................................... 150- 3

150.2 SPN 3510/FMI 4 ....................................................................................... 150- 4
150.1 SPN 3510/FMI 3
This diagnostic is typically ACM2 sensor Supply 2 Short to Battery.
NOTE:
Additional faults (SPN 4335 FMI 3 DEF Air Pressure sensor Circuit Failed High and SPN
4334 FMI 3 DEF Pressure sensor Circuit Failed High) may also be present.

2. Disconnect the DEF Pressure sensor connector.
4. Measure the voltage between pin 3 on the harness side of the DEF Pressure sensor
[a] If the voltage is greater than 5.5 volts, repair the short to battery between pin 3 of the
DEF Pressure sensor connector and pin 84 of the ACM2 120-pin connector.
[b] If the voltage is less than 5.5 volts, repair the short to battery between pin 2 of the
DEF Pressure sensor connector and pin 99 of the ACM2 120-pin connector.

150.2 SPN 3510/FMI 4
150.2 SPN 3510/FMI 4
This diagnostic is typically ACM2 sensor Supply 2 Short to Ground.

2. Disconnect the DEF Pressure sensor connector.
5. Measure the resistance between pin 3 on the harness side of the DEF Pressure sensor
connector and ground
Pressure sensor connector and pin 84 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DEF Pressure sensor.
Refer to section .

151SPN 3511
Section Page
151.1 SPN 3511/FMI 3 ....................................................................................... 151- 3

151.1 SPN 3511/FMI 3
Component MCM Pin

DOC Outlet Temperature sensor 29
DOC Inlet Temperature sensor, DOC Outlet Temperature
88
sensor, DPF Outlet Temperature sensor
DOC Inlet Temperature sensor 89
DPF Outlet Temperature sensor 115

151.1 SPN 3511/FMI 3

152SPN 3511 (MCM) (EPA10)
Section Page
152.1 SPN 3511/FMI 4 ....................................................................................... 152- 3

152.1 SPN 3511/FMI 4
This diagnosis typically 3V sensor Supply Bank 1 Circuit Failed Low

This code indicated an MCM internal failure. Replace the MCM. Refer to section 2.3.

152.1 SPN 3511/FMI 4

153SPN 3512
Section Page
153.1 SPN 3512/FMI 3 ....................................................................................... 153- 3

153.1 SPN 3512/FMI 3
Component MCM Pin

Fuel Temperature sensor, Engine Coolant 55
Temperature sensor
Fuel Temperature sensor 77
Engine Oil Temperature/Pressure sensor 108
Engine Coolant Temperature sensor 110

153.1 SPN 3512/FMI 3

154SPN 3512 (MCM) (EPA10)
Section Page
154.1 SPN 3512/FMI 4 ....................................................................................... 154- 3

154.1 SPN 3512/FMI 4
This diagnosis typically 3V sensor Supply Bank 2 Circuit Failed Low.

This code indicated an MCM internal failure. Replace the MCM. Refer to section 2.3.

154.1 SPN 3512/FMI 4

155SPN 3536
Section Page
155.1 SPN 3536/FMI 18 ..................................................................................... 155- 3

155.1 SPN 3536/FMI 18
This diagnostic is typically Inlet Manifold Pressure Low

1. Inspect entire air intake system including the Charge Air Cooler for leaks and/or
restrictions.
[a] If air intake system leaks or restrictions are found, repair as necessary.
[b] If no air intake system leaks are found go to step 2.
4. Compare intake manifold pressure to Ambient Pressure (Baro).
[a] If the intake manifold pressure is within 0.5 Ambient Pressure (Baro) go to step 5.
[b] If the intake manifold pressure is NOT within 0.5 Ambient Pressure (Baro) replace
the intake manifold pressure sensor. Refer to section 3.5.1.
5. Disconnect Intake manifold pressure sensor.
6. Inspect intake manifold pressure sensor connector for bent, spread or corroded pins.
[a] If damage is found repair connector as necessary.
[b] If no damage is found replace the intake manifold pressure sensor. Refer to section
3.5.1.

155.1 SPN 3536/FMI 18

156SPN 3556
Section Page
156.1 SPN 3556/FMI 1 ....................................................................................... 156- 3

156.2 SPN 3556/FMI 18 ..................................................................................... 156- 5
156.1 SPN 3556/FMI 1
This diagnostic is typically Regen Temperature - Out of Range Low
1. Connect to DDDL/DDRS 7.05 or greater.

2. Is there any fuel system or dosing system faults present?
[a] If yes, repair these faults first.
3. Are there any exhaust leaks present?
[a] If yes, repair exhaust leaks first.
4. Turn the ignition on (key ON, engine OFF).
5. Monitor the DOC Inlet and DOC Outlet Temperature sensors.
6. Is the DOC Outlet temperature within 45F of the DOC Inlet temperature?
7. Start the engine and raise engine RPM to 1200 for 10 minutes.
9. Turn the engine OFF (key OFF, engine OFF).

156.1 SPN 3556/FMI 1
10. Disconnect the DOC Outlet temperature sensor.

11. Inspect for bent, spread, or corroded pins.
12. Check the DOC Outlet temperature sensor resistance.
13. Is the DOC Outlet temperature sensor resistance within specification?
[b] If no, replace the DOC Outlet Temperature sensor.
14. Start the engine (key ON, engine ON).
15. Perform an Idle Speed Balance test. Is a faulty injector identified?
[a] If yes, replace the suspect injector.
16. Inspect the Doser Block Assembly and lines for fuel leaks. (Note: One drop may cause
and issue).
[a] If leaks are found, repair the leaks.
17. Perform High Idle Regeneration. (Note: Retain the regen log file).
18. View the log file of the regeneration.
19. Is the fuel compensation pressure between 80 92 psi.
[b] If no, refer to Diagnostic Tests - Fuel System Checks for further fuel pressure
diagnostics.
20. Is the Fuel Doser Injection Status rise and maintain above 30%?
[a] If yes, replace the Doser Injector Valve.
[b] If no, retain the log file and contact the call the Detroit Diesel Customer Support
Center at 3135925800.

156.2 SPN 3556/FMI 18
This diagnostic is typically Regen Temperature - Out of Range Low
1. Connect to DDDL/DDRS 7.05 or greater.

2. Is there any fuel system or dosing system faults present?
[a] If yes, repair these faults first.
3. Are there any exhaust leaks present?
[a] If yes, repair exhaust leaks first.
4. Turn the ignition on (key ON, engine OFF).
5. Monitor the DOC Inlet and DOC Outlet Temperature sensors.
7. Start the engine and raise engine RPM to 1200 for 10 minutes.
9. Turn the engine OFF (key OFF, engine OFF).

156.2 SPN 3556/FMI 18
10. Disconnect the DOC Outlet temperature sensor.

11. Inspect for bent, spread, or corroded pins.
12. Check the DOC Outlet temperature sensor resistance.
13. Is the DOC Outlet temperature sensor resistance within specification?
[b] If no, replace the DOC Outlet Temperature sensor.
14. Start the engine (key OFF, engine ON).
15. Perform an Idle Speed Balance test. Is a faulty injector identified?
[a] If yes, replace the suspect injector.
16. Inspect the Doser Block Assembly and lines for fuel leaks. (Note: One drop may cause
and issue).
[a] If leaks are found, repair the leaks.
17. Perform High Idle Regeneration. (Note: Retain the regen log file).
18. View the log file of the regeneration.
19. Is the fuel compensation pressure between 80 92 psi.
[b] If no, refer to Diagnostic Tests - Fuel System Checks for further fuel pressure
diagnostics.
20. Is the Fuel Doser Injection Status rise and maintain above 30%?
[a] If yes, replace the Doser Injector Valve.
[b] If no, retain the log file and contact the call the Detroit Diesel Customer Support
Center at 3135925800.

157SPN 3563
Section Page
157.1 SPN 3563/FMI 20 ..................................................................................... 157- 3

157.1 SPN 3563/FMI 20
This diagnostic is typically Ambient and Inlet Manifold Pressure Difference (low box).
2. Compare inlet manifold pressure to barometric pressure.
3. Is the inlet manifold pressure within 0.5 psi of barometric pressure?
[b] No; replace the intake manifold pressure sensor. Refer to section 3.5.1.

area.
4. Start the engine.

5. At idle compare inlet manifold pressure to barometric pressure.
6. Is the inlet manifold pressure within 0.5 psi of barometric pressure?
[b] No; intake manifold pressure sensor. Refer to section 3.5.1.
7. Perform Charge Air Cooler inspection and leak test. Refer to OEM literature for procedure.
[a] If inspection and/or leak test fail, repair as necessary.
[b] If Charge Air Cooler inspection passes, obtain DDDL log file of failure and contact
the Customer Support Center at 313-592-5800 for further diagnostic assistance.

157.1 SPN 3563/FMI 20

158SPN 3563 (MCM) (EPA10)
Section Page
158.1 SPN 3563/FMI 3 ....................................................................................... 158- 3

158.2 SPN 3563/FMI 4 ....................................................................................... 158- 4
158.1 SPN 3563/FMI 3
This diagnostic is typically intake manifold pressure circuit failed high

1. Disconnect the intake manifold pressure sensor.
4. Measure the voltage between pin 1 of the intake manifold pressure sensor harness
[a] If the voltage is greater than 5 volts, repair the short to battery between pin 1 of the
intake manifold pressure sensor harness connector and pin 87 of the MCM 120-pin
connector
[b] If the voltage is less than 5 volts, go to step 5.
5. Measure the voltage between pin 2 and 4 of the intake manifold pressure sensor harness
connector.
[a] If voltage is present, replace the intake manifold pressure sensor. Refer to section
3.5.1.
[b] If no voltage is present, repair the open between pin 4 of the intake manifold pressure
sensor harness connector and pin 102 of the MCM 120-pin connector.

158.2 SPN 3563/FMI 4
158.2 SPN 3563/FMI 4
This diagnostic is typically intake manifold pressure circuit failed low

1. Disconnect the intake manifold pressure sensor harness connector.
4. Measure the voltage between pins 2 and 4 of the intake manifold pressure sensor harness
connector.
[a] If voltage is present, go to step 5.
[b] If no voltage is present, repair the open between pin 2 of the intake manifold pressure
sensor connector and pin 58 of the MCM 120-pin connector.
sensor harness connector and pin 87 of the MCM 120-pin connector.
[a] If the resistance is greater than 5 ohms, repair the open between pin 1 on the harness
side of the intake manifold pressure sensor harness connector and pin 87 of the MCM
120-pin connector.
sensor harness connector and ground
[a] If the resistance is less than 1K ohms, repair the short to ground between pin 1 of
the intake manifold pressure sensor harness connector and pin 87 of the MCM
120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the intake manifold pressure sensor.

159SPN 3597 (EPA07)
Section Page
159.1 SPN 3597/FMI 4 ....................................................................................... 159- 3

159.1 SPN 3597/FMI 4
This diagnosis is typically Proportional Valve Bank 1 circuit failed low.
Check as follows:
2. Disconnect the front valve cover fuel injector harness connector.

159.1 SPN 3597/FMI 4

4. Remove the valve cover and disconnect the wires from the low engine brake solenoid.
[a] If the resistance is greater than 1 , replace the engine brake solenoid.
[b] If the resistance is less than 1 , replace the front under valve cover fuel injector
7. Measure the resistance between pin 14 on the engine harness side of the fuel injector
[a] If the resistance is less than 1 , go to the next step.
8. Disconnect the engine 31pin connector.
9. Again measure the resistance between pin 14 on the engine harness side of the fuel injector
[a] If the resistance is less than 1 , repair short to ground between pin 91 of the MCM
120pin connector and the valve cover fuel injector harness connector or the 31 pin
[b] If the resistance is greater than 1 , repair short to ground between pin 22 of the
31pin connector on the vehicle side of the harness and the fan control solenoid.
10. Disconnect the Air Seal Pressure Regulator Valve connector.
11. Measure the resistance between pin 2 of the Air Seal Pressure Regulator Valve connector
and ground.
[a] If the resistance is less than 1 , repair short to ground between pin 93 of the
MCM 120pin connector and the Air Seal Pressure Regulator Valve connector.
[b] If resistance is greater than 1 , replace the Air Seal Pressure Regulator Valve.

160SPN 3597 (EPA10)
Section Page
160.1 SPN 3597/FMI 3 ....................................................................................... 160- 3

160.2 SPN 3597/FMI 4 ....................................................................................... 160- 4
160.1 SPN 3597/FMI 3
This diagnosis is typically High Side Digital Output 1 Circuit Failed High
NOTE:
High Side Digital Output 1 is the voltage supply to the following components, DEF Pump,
DEF Air Valve, Diffuser Heater and the DEF Injection Valve.
1. Disconnect the DEF Pump, DEF Air Valve, Diffuser Heater and the DEF Injection Valve
(disregard the additional faults set with components disconnected).
2. Inspect the above component harness connectors for bent, spread or corroded pins.
3. Turn the ignition ON and clear fault codes, does the fault become active?
[a] Yes, replace the ACM.
[b] No, repair harness short to battery between ACM pins 1, 3 or 5 and pin 2 of the
corresponding components.
7. Reconnect the above components one at a time, clearing the fault code after each
connection. When fault becomes active, replace the corresponding component.

160.2 SPN 3597/FMI 4
160.2 SPN 3597/FMI 4
This diagnosis is typically High Side Digital Output 1 Circuit Failed Low
NOTE:
High Side Digital Output 1 is the voltage supply to the following components, DEF Pump,
DEF Air Valve, Diffuser Heater and the DEF Injection Valve.
1. Disconnect the DEF Pump, DEF Air Valve, Diffuser Heater and the DEF Injection Valve
(disregard the additional faults set with components disconnected).
[b] No, repair harness short to ground between ACM pins 1, 3 or 5 and pin 2 of the

161SPN 3598
Section Page
161.1 SPN 3598/FMI 4 ...................................................................................... 161- 3

161.1 SPN 3598/FMI 4
This diagnostic is typically Proportional Valve Bank 2 circuit has failed low.
Check as follows:
2. Disconnect the Rear Valve Cover fuel injector Harness connector.
3. Measure the resistance between pin 14 on the engine side of the Valve Cover fuel injector
Harness connector and ground.
[a] If the resistance is less than 5 , repair the short to ground between the Rear Valve
Cover fuel injector Harness and the medium (rear) engine brake solenoid.
4. Disconnect the EGR Valve connector.
5. Measure the resistance between pin 1 of the EGR Valve and ground.
NOTE:
This measurement is ON the EGR Valve.
[a] If the resistance is less than 5 , replace the EGR Valve. For the DD15 ONLY:

161.1 SPN 3598/FMI 4
7. Measure the resistance between pin 1 of the EGR Valve Harness connector and ground.
[a] If the resistance is less than 5 , repair the short to ground between pin 62 of the
MCM 120pin connector and the EGR Valve/Rear Valve Cover fuel injector Harness
connectors. Verify Repairs 219.1.
8. Disconnect the Fuel Cutoff Valve connector.
9. Measure the resistance between pin 2 of the Fuel Cutoff Valve Harness connector and
ground.
Refer to section .
10. Disconnect the Electronic Dosing Valve connector.
11. Measure the resistance between pin 2 of the Electronic Dosing Valve connector and
ground.
the MCM 120pin connector and the Electronic Dosing Valve/Fuel Cutoff Valve
Refer to section .

162SPN 3598 (MCM) (EPA10)
Section Page
162.1 SPN 3598/FMI 3 ....................................................................................... 162- 3

162.1 SPN 3598/FMI 3
This diagnostic is typically proportional valve bank 2 circuit failed high

Rear Jake Brake Solenoid and pin 62 of the MCM 120-pin connector.
[b] If no voltage is present, go to step 4.
4. Measure the voltage between pin 64 of the MCM and ground.
Electronic Dosing Valve and pin 64 of the MCM 120-pin connector.
[b] If no voltage is present, replace the MCM. Refer to section 2.3.

162.1 SPN 3598/FMI 3

163SPN 3599 (MCM) (EPA10)
Section Page
163.1 SPN 3599/FMI 3 ....................................................................................... 163- 3

163.2 SPN 3599/FMI 4 (MCM) (ACM) ............................................................... 163- 4
163.1 SPN 3599/FMI 3
This diagnostic is typically High Side Digital Output 3 Circuit Failed High
NOTE:
High Side Digital Output 3 is the voltage supply to the following components, doser
heater and Line Heaters 1, 2, 3 and 4
1. Disconnect the doser heater and Line Heaters 1, 2, 3 and 4 (disregard the additional faults
set with components disconnected).
[b] No go to step 7.
4. Turn the ignition OFF (key OFF, ignition OFF).
[b] No, repair harness short to battery between ACM pins 9, 15, 39 and pin 2 of the

163.2 SPN 3599/FMI 4 (MCM) (ACM)
163.2 SPN 3599/FMI 4 (MCM) (ACM)
This diagnostic is typically High Side Digital Output 3 Circuit Failed Low
NOTE:
High Side Digital Output 3 is the voltage supply to the following components, doser
heater and Line Heaters 1, 3 and 4.
1. Disconnect the doser heater and Line Heaters 1, 3 and 4 (disregard the additional faults set
with components disconnected).
[b] No, repair harness short to ground between ACM pins 9, 15 or 39 and pin 2 of the

164SPN 3603 (CPC)
Section Page
164.1 SPN 3603/FMI 9 ....................................................................................... 164- 3

164.1 SPN 3603/FMI 9
This diagnostic is typically the J1939 ESS message is missing.

Check as follows:

164.1 SPN 3603/FMI 9

165SPN 3609 (EPA07)
Section Page
165.1 SPN 3609/FMI 2 ....................................................................................... 165- 3

165.2 SPN 3609/FMI 3 ....................................................................................... 165- 5
165.3 SPN 3609/FMI 4 ....................................................................................... 165- 7
165.4 SPN 3609/FMI 8 ....................................................................................... 165- 9
165.5 SPN 3609/FMI 10 ..................................................................................... 165-12
165.6 SPN 3609/FMI 20 ..................................................................................... 165-14
165.7 SPN 3609/FMI 21 ..................................................................................... 165-16
165.1 SPN 3609/FMI 2
Check as follows:
1. Disconnect DPF Inlet Pressure hose assembly.
3. Turn ignition ON (key ON, engine OFF)
NOTE:
Do not start engine.

8. Inspect electrical connections upstream of the MCM (sensor, ATD harness 10-pin
pins.
219.1.
Refer to section .
10. Inspect the hose and fittings for kinks, blockages, and restrictions.
[a] If hose or fitting damage is found, repair as necessary. Verify Repairs 219.1.
ENGINE EXHAUST
exhaust is toxic.
11. Start engine.

165.1 SPN 3609/FMI 2
HOT EXHAUST
outside.

13. Select Send Parked Regeneration Start Request. When regeneration is complete, clear
all fault codes.
NOTE:

[a] If no fault codes appear, testing is complete. Verify Repairs 219.1.
[b] If the fault code returns, contact the Detroit Diesel Customer Support Center at
3135925800.

165.2 SPN 3609/FMI 3
Check as follows:
[a] If 3609/3 and 3610/3, are present, go to step 3.
3. Disconnect the DPF Inlet Pressure sensor.
4. Measure the voltage between pin 1 of the DPF Inlet Pressure sensor and ground (battery
[a] If the voltage is present, repair the short to power between pin 114 of the MCM
120-pin connector and the DPF Inlet and DPF Outlet Pressure sensors. Verify Repairs
219.1.
[b] If no voltage is present on pin 1 of the DPF Inlet Pressure sensor, repair the open
between pin 114 of the MCM 120-pin connector and DPF Inlet, pin 1 and DPF
Outlet, pin 1 pressure sensors. Verify Repairs 219.1.
5. Disconnect DPF Inlet Pressure sensor connector.

165.2 SPN 3609/FMI 3

8. Measure the resistance across pins 2 and 3 of the DPF Inlet Pressure sensor connector.
[b] If the resistance is greater than 5 , repair short to power on circuit between the
MCM 120-pin connector pin 118 and the DPF Inlet Pressure sensor connector pin 2.

165.3 SPN 3609/FMI 4
Check as follows:
[a] If 3609/4 and 3610/4 are present, repair the open in circuit between pin 85 of the
MCM 120-pin connector and pin 3 of the DPF Inlet Pressure sensors. Verify Repairs
219.1.

3. Measure the resistance between the DPF Inlet Pressure sensor pins 2 and 3.
[a] If the resistance is greater than 150 , replace the DPF Inlet Pressure sensor.
Refer to section .
5. Measure the voltage between the DPF Inlet Pressure sensor pins 1 and 3.
6. Measure the voltage between the DPF Inlet Pressure sensor pin 3 and ground (battery
[a] If the voltage is greater than 4.75 volts, repair the open between pin 114 of the MCM
120-pin connector and DPF Inlet Pressure sensor pin 1. Verify Repairs 219.1.
[b] If the voltage is less than 4.75 volts, repair the open between pin 85 of the MCM
120-pin connector and DPF Inlet Pressure sensor pin 3. Verify Repairs 219.1.

165.3 SPN 3609/FMI 4
9. Measure the resistance between the DPF Inlet Pressure sensor harness connector pin 1
and 2.
[a] If the resistance is less than 5 , repair the short in wires of the MCM 120-pin
connector pins 114 and 118 and DPF Inlet Pressure sensor harness connector pins 1
and 2. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , repair the open between the DPF Inlet Pressure
sensor harness connector pin 2 and MCM 120-pin connector pin 118.

165.4 SPN 3609/FMI 8
the DPF Outlet Temperature sensor. The most likely cause is an intermittent wiring problem.
See Figure 165-1 and Figure 165-2 for the ATD wiring schematics.
Figure 165-1 Vertical Aftertreatment Device Wiring Diagram

165.4 SPN 3609/FMI 8
Figure 165-2 Horizontal Aftertreatment Device Wiring Diagram
Check as follows:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.


7. Wiggle test the harness while looking for abnormal voltage spikes on T_DPF_OUT (pin
115).
between the DPF Outlet Temperature sensor and the MCM. Repair damage as

165.5 SPN 3609/FMI 10
165.5 SPN 3609/FMI 10
Check as follows:
2. Inspect connector for corrosion and damaged or bent pins. If pressure sensor connector
is OK, check connections upstream to the MCM (ATD harness 10pin connector pin 3,
VIH 31-pin connector pin 31, and MCM 120-pin connector pin 118). While harness is
being inspected, also look for defeat devices (switches and resistors which are not factory
installed).
[a] If harness corrosion or damaged or bent pins are found, repair as necessary.
[b] If defeat device is found, contact the Detroit Diesel Customer Support Center at
3135925800 for instructions.
[c] If harness inspection is OK, go to step 3.
3. Remove the DPF Inlet Pressure hose assembly.
4. Inspect the pressure sensor hose and fittings for kinks, plugging.
[a] If plugged, clean the pressure sensor hose and fittings. If kinked, replace the pressure
sensor hose assembly.
[b] If OK, go to step 5.
5. Clear codes.

ENGINE EXHAUST
exhaust is toxic.
6. Start engine.
HOT EXHAUST
outside.
7. Using DDDL 7.X, perform a parked regeneration. After regeneration is complete, testing
is done.

165.6 SPN 3609/FMI 20
165.6 SPN 3609/FMI 20
Check as follows:
1. Remove the DPF Inlet Pressure hose assembly from the pressure sensor and ATD.
NOTE:


9. Inspect connector for corrosion and damaged or bent pins. If the pressure sensor connector
installed).
[c] If harness inspection is OK, replace the DPF Inlet Pressure sensor and go to step 10.
sensor hose assembly. Verify Repairs 219.1.
11. Reconnect the DPF Inlet Pressure connector.
12. Re-install the DPF Inlet Pressure hose assembly on the pressure sensor and ATD.
13. Clear codes.
ENGINE EXHAUST
exhaust is toxic.
14. Start engine.
HOT EXHAUST
outside.
is done. Verify Repairs 219.1.

165.7 SPN 3609/FMI 21
165.7 SPN 3609/FMI 21
Check as follows:
1. Inspect exhaust system including ATD V-band clamps and DPF Inlet Pressure hoses
for external leaks.
[a] If external leaks are found, repair as necessary. Verify Repairs 219.1.
[b] If no external leaks are found, go to step 2.
2. Remove the DPF Inlet Pressure hose assembly from the pressure sensor and ATD.
NOTE:


is OK, check connections upstream to the MCM (ATD harness 10pin connector, VIH
31-pin connector, and MCM 120-pin connector). While harness is being inspected, also
look for defeat devices (switches, resistors which are not factory installed).
[a] If harness corrosion or damaged or bent pins are found, repair as necessary, go to step
11.
3135925800.
12. Clear codes.
ENGINE EXHAUST
exhaust is toxic.
13. Start engine.
HOT EXHAUST
outside.

165.7 SPN 3609/FMI 21

166SPN 3609 (ACM2) (EPA10)
Section Page
166.1 SPN 3609/FMI 3 ....................................................................................... 166- 3

166.2 SPN 3609/FMI 4 ....................................................................................... 166- 4
Figure 166-1 DPF Inlet Pressure sensor Circuit

166.1 SPN 3609/FMI 3
This diagnostic is typically DPF Inlet Pressure sensor circuit failed high.
[a] If 3609/3, 3610/3 and 3509/3 are present, repair short to power between pin 1 of the
DOC Inlet Pressure sensor and pin 88 of the ACM2. Verify Repairs 219.1.
[b] If 3609/3 and 3610/3 are present, repair open between pin 1 of the DOC Inlet Pressure
sensor and pin 88 of the ACM2. Verify Repairs 219.1.
[c] If only 3609 is present, go to step 2.
2. Disconnect the DOC Inlet Pressure sensor.
4. Measure the voltage between pin 2 of the DOC Inlet Pressure sensor and ground.
[a] If voltage is present, repair short to power between pin 2 of the DOC Inlet Pressure
7. Measure the resistance between pin 2 of the DOC Inlet Pressure sensor and pin 87 of
the ACM2.
[a] If the resistance is greater than 5 ohms repair the wire between pin 2 of the DOC Inlet
Pressure sensor and pin 87 of the ACM2. Verify Repairs 219.1.
[b] If the resistance is less than 5 ohms, replace the DOC Inlet Pressure sensor.
Refer to section .

166.2 SPN 3609/FMI 4
166.2 SPN 3609/FMI 4
This diagnostic is typically DPF Inlet Pressure sensor circuit failed low.
[a] If SPN 3609/4 and 3610/4 are present, repair open between ACM2 pin 117 and
DOC/DPF Pressure sensors pin 3.
3. Disconnect the DOC inlet pressure sensor.
4. Inspect the DOC inlet pressure sensor harness for bent, spread, or corroded pins.
6. Measure the resistance between pin 2 of the DOC inlet pressure sensor and ground.
[a] If the resistance is less than 1k ohms, repair short to ground between pin 2 of the
DOC inlet pressure sensor and pin 87 of the ACM2 120-pin connector.
7. Measure the resistance between pin 2 of the DOC inlet pressure sensor and pin 87 of the
ACM2 120-pin connector.
[a] If the resistance is greater than 3 ohms repair wire between pin 2 of the DOC inlet
pressure sensor and pin 87 of the ACM2 120-pin connector.
[b] If the resistance is less than 3 ohms, replace the DOC inlet pressure sensor.
Refer to section .

167SPN 3610 (EPA07)
Section Page
167.1 SPN 3610/FMI 2 ....................................................................................... 167- 3

167.2 SPN 3610/FMI 3 ....................................................................................... 167- 6
167.3 SPN 3610/FMI 4 ....................................................................................... 167- 8
167.4 SPN 3610/FMI 10 ..................................................................................... 167-10
167.5 SPN 3610/FMI 14 ..................................................................................... 167-11
167.6 SPN 3610/FMI 20 ..................................................................................... 167-13
167.1 SPN 3610/FMI 2
Check as follows:
NOTE:

5. Monitor the DPF Outlet Pressure sensor voltage (P_DPF_OUT).
7. Disconnect DPF Outlet Pressure sensor connector.

167.1 SPN 3610/FMI 2
8. Inspect connector for corrosion and damaged or bent pins. If pressure sensor connector is
OK, check connections upstream to the MCM (ATD harness 10pin connector pin 4, VIH
31-pin connector pin 30 and MCM 120-pin connector pin 30). While harness is being
inspected, also look for defeat devices (switches, resistors which are not factory installed).
9. Remove the DPF Outlet Pressure hose assembly.

11. Clear codes
ENGINE EXHAUST
exhaust is toxic.
12. Start engine.

HOT EXHAUST
outside.

167.2 SPN 3610/FMI 3
167.2 SPN 3610/FMI 3
Check as follows:
3. Disconnect the DPF Outlet Pressure sensor.
4. Measure the voltage between pin 1 of the DPF Outlet Pressure sensor and ground (battery
of the MCM 120-pin connector and the DPF Inlet and DPF Outlet Pressure sensors.
[b] If no voltage is present on pin 1 of the DPF Outlet Pressure sensor, repair the open
between pin 114 of the MCM 120-pin connector and DPF Inlet and DPF Outlet
Pressure sensors. Verify Repairs 219.1.


8. Measure the resistance across pins 2 and 3 of the DPF Outlet Pressure sensor connector.
[b] If the resistance is greater than 5 , repair short to power on circuit between the
MCM 120-pin connector pin 30 and the DPF Outlet Pressure sensor connector pin 2.

167.3 SPN 3610/FMI 4
167.3 SPN 3610/FMI 4
Check as follows:
[a] If 3610/4 and 3609/4 are present, repair the open in circuit between pin 85 of
the MCM 120-pin connector and pins 3 of the DPF Outlet Pressure sensors.

3. Measure the resistance between the DPF Outlet Pressure sensor pins 2 and 3.
[a] If the resistance is greater than 150 , replace the DPF Outlet Pressure sensor.
Refer to section .
5. Measure the voltage between the DPF Outlet Pressure sensor pins 1 and 3.
6. Measure the voltage between the DPF Outlet Pressure sensor pin 3 and ground (battery
[a] If the voltage is greater than 4.75 volts, repair the open between pin 114 of the MCM
120-pin connector and DPF Outlet Pressure sensor pin 1. Verify Repairs 219.1.
[b] If the voltage is less than 4.75 volts, repair the open between pin 85 of the MCM
120-pin connector and DPF Outlet Pressure sensor pin 3. Verify Repairs 219.1.


9. Measure the resistance between the DPF Outlet Pressure sensor harness connector pin 1
and 2.
[a] If the resistance is less than 5 , repair the short in wires of the MCM 120-pin
connector pins 114 and 30 and DPF Outlet Pressure sensor harness connector pins 1
and 2. Verify Repairs 219.1.
[b] If the resistance is greater than 5 , repair the open between the DPF Outlet Pressure
sensor harness connector pin 2 and MCM 120-pin connector pin 30. Verify Repairs
219.1.

167.4 SPN 3610/FMI 10
167.4 SPN 3610/FMI 10
This diagnostic is typically DPF Outlet Pressure sensor stuck. Contact the Detroit Diesel
Customer Support Center at 3135925800 for further details.

167.5 SPN 3610/FMI 14
Check as follows:
1. Remove the DPF Outlet Pressure hose assembly from the pressure sensor and ATD.
NOTE:


167.5 SPN 3610/FMI 14
installed).
sensor hose assembly.
11. Reconnect DPF Outlet Pressure sensor connector.
13. Clear codes.
ENGINE EXHAUST
exhaust is toxic.
14. Start engine.
HOT EXHAUST
outside.

167.6 SPN 3610/FMI 20
Check as follows:
1. Remove the DPF Outlet Pressure hose assembly from the pressure sensor and ATD.
NOTE:


167.6 SPN 3610/FMI 20
installed).
[c] If harness inspection is OK, replace DPF Outlet Pressure sensor refer to section
and go to step 10.
11. Re-install the DPF Outlet Pressure hose assembly on the pressure sensor and ATD.
12. Clear codes.
ENGINE EXHAUST
exhaust is toxic.
13. Start engine.
HOT EXHAUST
outside.

168SPN 3610 (ACM2) (EPA10)
Section Page
168.1 SPN 3610/FMI 2 ....................................................................................... 168- 3

168.2 SPN 3610/FMI 3 ....................................................................................... 168- 4
168.3 SPN 3610/FMI 4 ....................................................................................... 168- 5
Figure 168-1 DPF Pressure sensor Circuit

168.1 SPN 3610/FMI 2
This diagnostic is typically DPF Inlet Pressure - Not Plausible

Outlet Pressure (pin 72) voltages with key on engine off.
6. Obtain a log file with the following conditions:
Start the engine and run at idle for 1 minute.
Raise engine speed to 1500 RPM for 1 minute.
Contact the Detroit Diesel Customer Support Center at 3135925800 with the log
file information for further instructions.

168.2 SPN 3610/FMI 3
168.2 SPN 3610/FMI 3
This diagnostic is typically DPF Outlet Pressure sensor circuit failed high.
[a] If 3610/3, 3609/3 and 3509/3 are present, repair short to power between pin 1 of the
DPF Outlet Pressure sensor and pin 88 of the ACM2.
[b] If 3610/3 and 3609/3 are present, repair open between pin 1 of the DPF Outlet
Pressure sensor and pin 88 of the ACM2.
[c] If only 3610 is present, go to step 2.
2. Disconnect the DPF Outlet Pressure sensor.
4. Measure the voltage between pin 2 of the DPF Outlet Pressure sensor and ground.
[a] If voltage is present, repair short to power between pin 2 of the DPF Outlet Pressure
7. Measure the resistance between pin 2 of the DPF Outlet Pressure sensor and pin 72 of
the ACM2.
[a] If the resistance is greater than 5 ohms repair the wire between pin 2 of the DPF
Outlet Pressure sensor and pin 72 of the ACM2. Verify Repairs 219.1.
[b] If the resistance is less than 5 ohms, replace the DPF Outlet Pressure sensor.
Refer to section .

168.3 SPN 3610/FMI 4
This diagnostic is typically DPF Outlet Pressure sensor circuit failed low.
[a] If SPN 3610/4 and 3609/4 are present, repair open between ACM2 pin 117 and
DOC/DPF pressure sensors pin 3.
3. Disconnect the DPF outlet pressure sensor.
4. Inspect the DPF outlet pressure sensor harness for bent, spread, or corroded pins.
6. Measure the resistance between pin 2 of the DPF outlet pressure sensor and ground.
[a] If the resistance is less than 1k ohms, repair short to ground between pin 2 of the DPF
outlet pressure sensor and pin 72 of the ACM2 120-pin connector.
7. Measure the resistance between pin 2 of the DPF outlet pressure sensor and pin 72 of the
ACM2 120-pin connector.
[a] If the resistance is greater than 3 ohms repair wire between pin 2 of the DPF outlet
pressure sensor and pin 72 of the ACM2 120-pin connector.
[b] If the resistance is less than 3 ohms, replace the DPF outlet pressure sensor.
Refer to section .

168.3 SPN 3610/FMI 4

169SPN 3659 (EPA07)
Section Page
169.1 SPN 3659/FMI 14 ..................................................................................... 169- 3

169.1 SPN 3659/FMI 14
SPN 3659/FMI 14 is typically an open circuit, short to ground or short to power.
Check as follows:
[a] If fault code 168/1 is active, service 168/1 first.
[b] If fault 3660/14 and 3661/14 are active in addition to 3659/14, go to the next step.
[c] If only fault code 3659/14 is active, go to step 10.

169.1 SPN 3659/FMI 14
5. Measure the resistance between pins 5 and 8 on the valve cover side of the Front fuel
injector Harness. If using J-4867110, measure between fuel injector #1 pins 1 and 2.
Front fuel injector Harness 14pin connector.

[b] If the resistance is greater than 3 , repair the open between pin 13 of the MCM
120pin connector and pin 5 of the Front fuel injector Harness 14pin connector.
connector.
[a] If the resistance is greater than 3 , replace the MCM. Refer to section 2.3.
[b] If the resistance is less than 3 , repair the short to power between battery positive
and pin 13 of the MCM 120pin connector.


Harness and pin 1 of the fuel injector #1 harness connector. If using J-4867110, measure
between fuel injector #1 pin 1 and the fuel injector #1 harness connector pin 1.
Harness and ground. If using J-4867110, measure between fuel injector #1 pin 2 and
ground.
[a] If the resistance is greater than 3 , replace fuel injector #1. Refer to section .
Refer to section .
ground.
[a] If the resistance is greater than 3 , repair the short to ground between pin 14 of
the 120pin MCM connector and pin 8 of the Front fuel injector Harness 14pin
ground.
Refer to section .

169.1 SPN 3659/FMI 14

170SPN 3659 (EPA10)
Section Page
170.1 SPN 3659/FMI 6 ....................................................................................... 170- 3

170.1 SPN 3659/FMI 6
Fuel injector Cylinder #1 Amplifier Control Valve, Valve Shorted Circuit

Check as follows:
1. Disconnect the front rocker cover 14 pin fuel injector harness connector.
connector.
Refer to section .

170.1 SPN 3659/FMI 6

171SPN 3660 (EPA07)
Section Page
171.1 SPN 3660/FMI 14 ..................................................................................... 171- 3

171.1 SPN 3660/FMI 14
Check as follows:

171.1 SPN 3660/FMI 14
[a] If the resistance is greater than 3 , repair the open between pin 13 of the MCM
connector.


ground.
Refer to section .
ground.
ground.
Refer to section .

171.1 SPN 3660/FMI 14

172SPN 3660 (EPA10)
Section Page
172.1 SPN 3660/FMI 6 ....................................................................................... 172- 3

172.1 SPN 3660/FMI 6

Check as follows:
cover fuel injector 14 pin connector.
5 and 9 of the front rocker cover fuel injector harness 14 pin connector and pins 13
connector.
Refer to section .

172.1 SPN 3660/FMI 6

173SPN 3661 (EPA07)
Section Page
173.1 SPN 3661/FMI 14 ..................................................................................... 173- 3

173.1 SPN 3661/FMI 14
Check as follows:
[a] If fault code 168/1 is active, service 168/1 first. Verify Repairs 219.1.

173.1 SPN 3661/FMI 14

[b] If the resistance is greater than 3 , repair the open between pin 13 of the MCM
connector.
12. Measure the resistance between pin 5 and pin 12 on the valve cover side of the fuel
injector harness. If using J-4867110, measure between fuel injector #3 pins 1 and 2.


ground.
Refer to section .
ground.
ground.
Refer to section .

173.1 SPN 3661/FMI 14

174SPN 3661 (EPA10)
Section Page
174.1 SPN 3661/FMI 6 ....................................................................................... 174- 3

174.1 SPN 3661/FMI 6

Check as follows:
3. Measure the resistance between pins 5 and 12 on the engine harness side of the front
rocker cover fuel injector 14-pin connector.
connector.
Refer to section .

174.1 SPN 3661/FMI 6

175SPN 3662 (EPA07)
Section Page
175.1 SPN 3662/FMI 14 ..................................................................................... 175- 3

175.1 SPN 3662/FMI 14
This diagnosis is typically an open circuit, short to ground or short to power.
Check as follows:

175.1 SPN 3662/FMI 14
Rear fuel injector Harness 14pin connector.
120pin connector and pin 5 of the Rear fuel injector Harness 14pin connector.
connector.
[a] If the resistance is less than 3 , repair the short to power between battery positive
and pin 7 of the 120pin MCM connector. Verify Repairs 219.1.


Harness and pin 1 on the #4 fuel injector harness connector. If using J-4867110, measure
between fuel injector #4 pin 1 and pin 1 on the #4 fuel injector harness connector.
ground.
[a] If the resistance is less than 3 , replace the under valve cover fuel injector harness.
Refer to section .
[b] If the resistance is greater than 3 , replace fuel injector #4. Refer to section .
ground.
MCM 120pin connector and pin 8 of the Rear fuel injector Harness connector.
ground.
Refer to section .

175.1 SPN 3662/FMI 14

176SPN 3662 (EPA10)
Section Page
176.1 SPN 3662/FMI 6 ....................................................................................... 176- 3

176.1 SPN 3662/FMI 6

Check as follows:
5 and 8 of the rear rocker cover fuel injector harness 14-pin connector and pins 7 and
4 of the MCM 120-pin connector. Verify Repairs 219.1.
connector.
Refer to section .

176.1 SPN 3662/FMI 6

177SPN 3663 (EPA07)
Section Page
177.1 SPN 3663/FMI 14 ..................................................................................... 177- 3

177.1 SPN 3663/FMI 14
Check as follows:
4. Inspect the Rear fuel injector Harness 14pin connector for bent or spread pins. Inspect

177.1 SPN 3663/FMI 14
connector.


Harness and pin 1 on the fuel injector #5 harness connector. If using J-4867110, measure
between fuel injector #5 pin 1 and pin 1 on the fuel injector #5 harness connector.
ground.
Refer to section .
ground.
ground.
Refer to section .

177.1 SPN 3663/FMI 14

178SPN 3663 (EPA10)
Section Page
178.1 SPN 3663/FMI 6 ....................................................................................... 178- 3

178.1 SPN 3663/FMI 6

Check as follows:
5 and 9 of the rear rocker cover fuel injector harness 14-pin connector and pins 7 and
8 of the MCM 120-pin connector. Verify Repairs 219.1.
resistance between pins 5 and 9 of the rear rocker cover fuel injector harness 14- pin
connector.
Refer to section .

178.1 SPN 3663/FMI 6

179SPN 3664 (EPA07)
Section Page
179.1 SPN 3664/FMI 14 ..................................................................................... 179- 3

179.1 SPN 3664/FMI 14
Check as follows:

179.1 SPN 3664/FMI 14
connector.


15. Measure the resistance between pin 5 on the valve cover side of the rear fuel injector
harness and pin 1 on the #6 fuel injector harness connector. If using J-4867110, measure
between fuel injector #6 pin 1 and pin 1 on the fuel injector #6 harness connector.
harness and pin 1 of the fuel injector #6 harness connector. If using J-4867110, measure
harness and ground. If using J-4867110, measure between fuel injector #6 pin 2 and
ground.
Refer to section .
ground.
ground.
Refer to section .

179.1 SPN 3664/FMI 14

180SPN 3664 (EPA10)
Section Page
180.1 SPN 3664/FMI 6 ....................................................................................... 180- 3

180.1 SPN 3664/FMI 6

Check as follows:
connector.
Refer to section .

180.1 SPN 3664/FMI 6

181SPN 3695 (CPC)
Section Page
181.1 SPN 3695/FMI 9 ....................................................................................... 181- 3

181.2 SPN 3695/FMI 13 ..................................................................................... 181- 4
181.3 SPN 3695/FMI 14 ..................................................................................... 181- 5
181.4 SPN 3695/FMI 19 ..................................................................................... 181- 6
181.1 SPN 3695/FMI 9
This diagnostic is typically one of the following:

DPF Regen Inhibit Switch message stopped arriving
DPF Regen Force Switch message stopped arriving
Check as follows:
these first.

181.2 SPN 3695/FMI 13
181.2 SPN 3695/FMI 13
This diagnostic is typically one of the following: .

DPF Regen Inhibit Switch message contains a Signal Not Valid (SNV) indicator
DPF Regen Force Switch message contains a Signal Not Valid (SNV) indicator
Check as follows:
these first.

181.3 SPN 3695/FMI 14

DPF Regen Inhibit Switch message not received this ignition cycle
DPF Regen Force Switch message not received this ignition cycle
Check as follows:
these first.

181.4 SPN 3695/FMI 19
181.4 SPN 3695/FMI 19

DPF Regen Inhibit Switch message contains a data error indicator
DPF Regen Force Switch message contains a data error indicator
Check as follows:
these first.

182SPN 3711 (EPA07)
Section Page
182.1 SPN 3711/FMI 31 ..................................................................................... 182- 3

182.1 SPN 3711/FMI 31
This diagnostic is typically (HIR Regen (aborted) Low Exhaust Temp

If fault code 3242 DOC Inlet Temperature FMI any is present, repair first. This is a silent fault
code (no dash lamps illuminated) The fault indicates that the HIR was aborted due to DOC Inlet
temperature not reaching the minimum 536F to complete a High Idle Regen. Retain log file
if customer assistance is required.
Possible issues:
Exhaust Leaks
Intake Throttle Valve perform intake throttle service routine to see if commanded
position can be achieved
Intake manifold Leaks
Charge Air Cooler (CAC) leaks
Doc Inlet Temperature sensor compare DOC In to DOC Out and DPF Out temperature
sensors with key ON engine OFF

182.1 SPN 3711/FMI 31

183SPN 3711 (ACM2) (EPA10)
Section Page
183.1 SPN 3711/FMI 31 ..................................................................................... 183- 3

183.1 SPN 3711/FMI 31
This diagnostic is typically HIR Regen (aborted) Low Exhaust Temp

If fault code 3242 DOC Inlet Temperature FMI any is present, repair first. The fault indicates that
the HIR was aborted due to DOC Inlet temperature not reaching the minimum 518F to initiate
dosing during a High Idle Regen. CEL lamp and MIL ON until fault is resolved or successful
regen completed. Retain log file if customer assistance is required.
Possible issues:
Intake Throttle Valve perform intake throttle service routine to see if commanded
position can be achieved
Exhaust Leaks
Intake manifold Leaks
Charge Air Cooler leaks
Jake Brake operation
DOC Inlet Temperature sensor compare DOC In to DOC Out and DPF Out temperature
sensors with key ON, engine OFF.

183.1 SPN 3711/FMI 31

184SPN 3713 (EPA07)
Section Page
184.1 SPN 3713/FMI 31 ..................................................................................... 184- 3

184.1 SPN 3713/FMI 31
This diagnostic is typically (HIR Regen (aborted) Low Regen Temp

This is a silent fault code (no dash lamps illuminated) The fault indicates that the High Idle
Regen (HIR) was aborted due to DOC Outlet temperature not reaching the expected temperature
to complete a HIR.
Possible issues:
Low Fuel Compensation Pressure
Low Engine Fuel Pressure
DOC Outlet Temperature not responding
DOC push out

184.1 SPN 3713/FMI 31

185SPN 3713 (ACM2) (EPA10)
Section Page
185.1 SPN 3713/FMI 31 ..................................................................................... 185- 3

185.1 SPN 3713/FMI 31
This diagnostic is typically HIR Regen (aborted) Low Regen Temp

The fault indicates that the HIR was aborted due to DOC Outlet temperature not reaching the
expected target temperature to complete a High Idle Regen. If there are any other Regen or
fuel system related faults address those first. CEL lamp and MIL ON until fault is resolved or
successful regen completed. Retain log file if customer assistance is required.
Possible issues:
Low Fuel Compensation Pressure
Exhaust Leaks
Fuel Leaks
Sticking doser valve (check name) (high doser line pressure)
DOC Outlet Temperature not responding

185.1 SPN 3713/FMI 31

186SPN 3716 (EPA07)
Section Page
186.1 SPN 3716/FMI 31 ..................................................................................... 186- 3

186.1 SPN 3716/FMI 31
This diagnostic is typically (HIR Regen (aborted) Low Coolant Temp

This is a silent fault code (no dash lamps illuminated) The fault indicates that the High Idle Regen
(HIR) was aborted due to coolant temperature not reaching the minimum 140F to initiate a HIR.
If engine fails to reach 140F, refer to the workshop manual for cooling system diagnostics.

186.1 SPN 3716/FMI 31

187SPN 3716 (MCM2) (EPA10)
Section Page
187.1 SPN 3716/FMI 31 ..................................................................................... 187- 3

187.1 SPN 3716/FMI 31
This diagnostic is typically HIR Regeneration (aborted) Low Coolant Temp

The fault indicates that the High Idle Regeneration (HIR) was aborted due to the coolant
temperature not reaching the minimum 140F to initiate a High Idle Regeneration. The Amber
Warning Lamp (AWL) lamp comes on for approximately 15 seconds during the regeneration then
goes out and the regeneration aborts. If engine fails to reach 140F refer to workshop manual for
cooling system diagnostics.

187.1 SPN 3716/FMI 31

188SPN 3719 (MCM-EPA07) (ACM2-EPA10)
Section Page
188.1 SPN 3719/FMI 0 ....................................................................................... 188- 3

188.2 SPN 3719/FMI 15 ..................................................................................... 188- 4
188.3 SPN 3719/FMI 16 ..................................................................................... 188- 5
188.4 SPN 3719/FMI 31 ..................................................................................... 188- 6
188.1 SPN 3719/FMI 0
This diagnostic is typically Soot Level very high.

Check as follows:
HOT EXHAUST
outside.
1. Perform a parked regeneration.

2. Clear codes following completion of regeneration.
NOTE:
Do not interrupt regeneration once it has been initiated.
NOTE:
When this code is detected, the operator has two minute's to execute the entry conditions,
cycle clutch switch (manual trans), cycle parking brake, cycle neutral switch (auto trans),
then initiate regeneration request. If this procedure is not completed within this time limit,
the engine will shut down and the regeneration procedure must be restarted.

188.2 SPN 3719/FMI 15
188.2 SPN 3719/FMI 15
This diagnostic condition is a silent code that logs when the DPF Regeneration Lamp is flashing
in Regen Zone 3.
NOTE:
This code is informational only and used by service to help understand which dash lights
illuminated during normal service. A stationary regeneration is required if the fault code
is active. No action is required for an inactive fault code.

188.3 SPN 3719/FMI 16
This diagnostic is typically Soot Level high.
NOTE:
When this code is detected, the operator has two minute's to execute the entry conditions,
cycle clutch switch (manual trans), cycle parking brake, cycle neutral switch (auto trans),
then initiate regeneration request. If this procedure is not completed within this time limit,
the engine will shut down and the regeneration procedure must be restarted.
Perform a parked regeneration. Clear codes following completion of regeneration.
HOT EXHAUST
outside.
NOTE:
Do not interrupt regeneration once it has been initiated.

188.4 SPN 3719/FMI 31
188.4 SPN 3719/FMI 31
This diagnostic condition is a silent code that logs when the DPF Regeneration Lamp is flashing
in Regen Zone 2.
NOTE:
This code is informational only and used by service to help understand which dash lights
illuminated during normal service. A stationary regeneration is required if the fault code
is active. No action is required for an inactive fault code.

189SPN 3720
Section Page
189.1 SPN 3720/FMI 15 ..................................................................................... 189- 3

189.2 SPN 3720/FMI 16 ..................................................................................... 189- 4
189.1 SPN 3720/FMI 15
This fault indicates that the DPF has reached the end of its service life and must be replaced.
Replace DPF and perform Ash Accumulator reset using DDDL.

189.2 SPN 3720/FMI 16
189.2 SPN 3720/FMI 16
This fault indicates that the DPF has reached the end of its service life and must be replaced.
Replace DPF and perform Ash Accumulator reset using DDDL.

190SPN 3936 (ACM2) (EPA10)
Section Page
190.1 SPN 3936/FMI 18 ..................................................................................... 190- 3

190.1 SPN 3936/FMI 18
This diagnostic is typically DPF Pressure - Out of Range Low.

Outlet Pressure (pin 72) voltages with key ON engine OFF.
6. Obtain a log file with the following conditions while monitoring DOC Inlet and DPF
Outlet Pressures and contact the Customer Support Center for further instructions:
[a] Start the engine and run at idle for 1 minute
[b] Raise engine speed to 1500 RPM for 1 minute
[c] Perform a High Idle Regen

190.1 SPN 3936/FMI 18

191SPN 4076
Section Page
191.1 SPN 4076/FMI 3 ....................................................................................... 191- 3

191.2 SPN 4076/FMI 4 ....................................................................................... 191- 5
191.1 SPN 4076/FMI 3
This diagnostic is typically the engine coolant inlet temperature circuit has failed high.
Check as follows:
[a] If 110/3, 174/3, 175/3 and 4076/3 are present, go to step 6.
2. Disconnect the engine coolant inlet temperature sensor.
4. Measure the voltage between pins 1 and 2 of the engine coolant inlet temperature sensor
harness connector.
[a] If the voltage is between 2.8 and 3 volts, replace the engine coolant inlet temperature
5. Measure voltage between pin 2 of the engine coolant inlet temperature sensor and ground.
[a] If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the
engine coolant inlet temperature sensor connector and pin 80 of the MCM 120pin
[b] If the voltage is less than 2.8 volts, repair the wire between pin 2 of the engine coolant
inlet temperature sensor connector and pin 55 of the MCM 120pin connector.

191.1 SPN 4076/FMI 3
harness connector.
MCM pins: 77, 80, 108 or 110. Verify Repairs 219.1.

191.2 SPN 4076/FMI 4
The code is typically the engine coolant inlet temperature Circuit Failed Low
Repair the short to ground between pin 2 of the Engine engine coolant inlet sensor harness

191.2 SPN 4076/FMI 4

192SPN 4077 (MCM-EPA07) (ACM2-EPA10)
Section Page
192.1 SPN 4077/FMI 0 ....................................................................................... 192- 3

192.2 SPN 4077/FMI 1 ....................................................................................... 192- 5
192.3 SPN 4077/FMI 3 ....................................................................................... 192- 7
192.4 SPN 4077/FMI 4 ....................................................................................... 192- 8
192.5 SPN 4077/FMI 14 ..................................................................................... 192- 9
192.1 SPN 4077/FMI 0
This diagnostic is typically high Doser Fuel Line Pressure.

1. Shut off engine, apply the parking brake, chock the wheels, and perform any other
applicable safety measures.
ENGINE EXHAUST
exhaust is toxic.
3. Start engine.
NOTE:
NOTE:
[b] If Fuel Compensation Pressure is between 665 993 kPa (95 144 psi), perform a
HOT EXHAUST
outside.

192.1 SPN 4077/FMI 0

Refer to section . Go to step 7.
NOTE:

7. Using DDDL 7.X, perform Doser Fuel Line Purge Service Routine. Go to step 8.
NOTE:

4077/0 still becomes active, obtain a DDDL log file and contact the Detroit Diesel

192.2 SPN 4077/FMI 1
This diagnostic is typically abnormal Doser Fuel Line Pressure.

NOTE:
ENGINE EXHAUST
exhaust is toxic.
3. Start engine.
NOTE:
NOTE:
[e] If Fuel Compensation Pressure is between 448 665 kPa (65 95 psi), replace the

192.2 SPN 4077/FMI 1
HOT EXHAUST
outside.

Refer to section .
NOTE:

at 3135925800.

192.3 SPN 4077/FMI 3
This diagnostic is typically Fuel Line Pressure (FLP) sensor circuit failed high.
[a] If 4077/3 and 94/3 are present, repair the open in circuit between pin 104 of the MCM
120-pin connector and pins 1 of the fuel pressure sensors. Verify Repairs 219.1.
2. Disconnect FLP sensor connector.
4. Measure the resistance across pins 1 and 4 of the FLP sensor connector.
[b] If the resistance is greater than 5 , repair the short to power on circuit between the
MCM 120-pin connector pin 111 and the FLP sensor connector pin 4. Verify Repairs
219.1.

192.4 SPN 4077/FMI 4
192.4 SPN 4077/FMI 4
This diagnostic is typically FLP sensor circuit failed low.

[a] If 4077/4 and 94/4 are present, repair the open in circuit between pin 82 of the MCM
120-pin connector and pins 3 of the fuel pressure sensors.
2. Disconnect the FLP sensor.
3. Measure the resistance between FLP sensor pins 1 and 4.
Refer to section .
4. Measure the resistance between FLP sensor pins 1 and 3.
Refer to section .
6. Measure the voltage between FLP sensor pins 1 and 4.
7. Measure the voltage between FLP sensor pin 1 and ground (battery ground lug by starter).
[a] If the voltage is greater than 4.75 volts, repair open circuit between pin 104 of the
MCM 120-pin connector and FLP sensor pin 4. Verify Repairs 219.1.
[b] If the voltage is less than 4.75 volts, repair open circuit between pin 82 of the MCM
120-pin connector and FLP sensor pin 2. Verify Repairs 219.1.
9. Measure the resistance between FLP sensor harness connector pins 1 and 4.
[a] If the resistance is less than 5 , repair short in wires between the MCM 120-pin
connector pins 104 and 111 and FLP sensor harness connector pins 1 and 4.
[b] If the resistance is greater than 5 , repair open circuit between the FLP sensor
harness connector pin 4 and MCM 120-pin connector pin 104. Verify Repairs 219.1.

192.5 SPN 4077/FMI 14
This diagnostic is typically Doser Fuel Line Pressure failed self test.
2. Visually inspect Doser Block assembly and fuel doser injector valve fuel lines for external
leaks.
NOTE:
ENGINE EXHAUST
exhaust is toxic.
4. Start engine.
NOTE:
It may take more than one purge attempt to completely purge all of the air from the fuel
line, Do not exceed three purge attempts.
5. Using DDDL 7.X, perform a fuel doser Purge Service Routine.

6. Once the fuel cutoff gets to 100%, begin monitoring the Fuel Compensation Pressure and
Doser Fuel Line Pressure.
NOTE:
[a] If Fuel Compensation Pressure is between 69 448 kPa (10 65 psi), perform a low
[b] If Fuel Compensation Pressure is less than 69 kPa (10 psi), replace the fuel
compensation pressure sensor and go to step 8.
fuel doser fuel injector valve and go to step 7.

192.5 SPN 4077/FMI 14
HOT EXHAUST
outside.

[a] If 4077/14 becomes active during regeneration (regeneration will abort), replace the
Doser Block assembly Refer to section and go to step 8.
[b] If regeneration successfully completes, clear active codes and Verify Repairs 219.1.
[a] If 4077/14 becomes active during regeneration, repeat step 2 through step 6. If
at 3135925800.
[b] If regeneration successfully completes, clear active codes and Verify Repairs 219.1.

193SPN 4100
Section Page
193.1 SPN 4100/FMI 13 ..................................................................................... 193- 3

193.1 SPN 4100/FMI 13
This diagnostic is typically MCM/ACM Software Not Compatible.

This fault indicates the vehicle contains incompatible MCM/ACM software versions. Clear fault,
if fault becomes active, MCM/ACM software must be reprogrammed to the correct level. If fault
does not become active, release the vehicle.

193.1 SPN 4100/FMI 13

194SPN 4193 (MCM) (EPA10)
Section Page
194.1 SPN 4193/FMI 2 ....................................................................................... 194- 3

194.2 SPN 4193/FMI 3 ....................................................................................... 194- 4
194.3 SPN 4193/FMI 4 ....................................................................................... 194- 6
194.4 SPN 4193/FMI 10 ..................................................................................... 194- 7
194.1 SPN 4193/FMI 2
This diagnostic is typically coolant inlet temperature not plausible.

pins.
is out of range.
Resistance
Nominal
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95

194.2 SPN 4193/FMI 3
194.2 SPN 4193/FMI 3
This diagnostic is typically engine coolant inlet temperature circuit failed high.
1. Disconnect the engine coolant inlet temperature sensor.

harness connector.
[a] If the voltage is between 2.8 and 3 volts, replace the engine coolant inlet temperature

5. Measure voltage between pin 2 of the engine coolant inlet temperature sensor and ground.
[a] If the voltage is between 2.8 and 3 volts, repair the wire between pin 1 of the engine
coolant inlet temperature sensor connector and pin 55 of the MCM 120pin connector.
[b] If the voltage is less than 2.8 volts, repair the wire between pin 2 of the engine coolant
inlet temperature sensor connector and pin 80 of the MCM 120pin connector.
harness connector.
MCM pins: 77, 80, 108 or 110.
sensors.

194.3 SPN 4193/FMI 4
194.3 SPN 4193/FMI 4
This diagnostic is typically engine coolant inlet temperature circuit failed low
1. Disconnect the engine coolant inlet temperature sensor connector.

4. Measure the resistance between pin 1 and 2 on the coolant inlet temperature sensor
connector.
[a] If the resistance is less than 1k ohms, repair the short to ground between pin 2 of
the engine coolant inlet sensor harness connector and pin 80 of the MCM 120pin
connector.
[b] If the resistance is greater than 1k ohms, replace the engine coolant inlet temperature

194.4 SPN 4193/FMI 10
This diagnostic is typically coolant temperature sensors not plausible

pins.
is out of range.
Resistance
Nominal
0 32 5872.8 5496.4 6249.2 2.56 2.51 2.61
10 50 3769 3640.3 3897.7 2.37 2.33 2.41
20 68 2480.7 2260.0 2701.4 2.14 2.05 2.22
30 86 1693.2 1613.4 1773.0 1.89 1.83 1.95
35 95 1401.1 1338.4 1463.8 1.75 1.69 1.81
40 104 1166.8 1117.5 1216.1 1.62 1.56 1.67
50 122 829.5 798.2 860.8 1.36 1.30 1.41
60 140 593.8 574.5 613.1 1.12 1.07 1.17
70 158 435.4 423.1 447.7 0.91 0.86 0.95

194.4 SPN 4193/FMI 10

195SPN 4258
Section Page
195.1 SPN 4258/FMI 3 ....................................................................................... 195- 3

195.2 SPN 4258/FMI 4 ....................................................................................... 195- 5
195.1 SPN 4258/FMI 3
This diagnosis is typically fuel injector #1, 2, or 3 amplifier control valve circuit is shorted to
battery/power.
Check as follows:

195.1 SPN 4258/FMI 3
[b] If there is no voltage present, go to the next step.
[a] If there is voltage present, repair the short to power between pin 4 of the Front
fuel injector Harness connector and pin 10 of the 120pin MCM connector.
[b] If there is no voltage present, repair the short to power between pin 6 of the Front
fuel injector Harness connector and pin 12 of the 120pin MCM connector.

195.2 SPN 4258/FMI 4
This diagnosis is typically fuel injector #1, 2, or 3 amplifier control valve circuit is shorted to
ground.
Check as follows:

195.2 SPN 4258/FMI 4


Refer to section .
12. Measure the resistance between pin 5 of the harness side of the Front fuel injector Harness
[b] If the resistance is less than 3 , repair the short to ground between pin 13 of
15. Measure the resistance between pin 12 of the harness side of the Front fuel injector
[b] If the resistance is less than 3 , repair the short between pin 12 of the MCM 120pin
connector and pin 12 of the Front fuel injector Harness 14pin connector.

195.2 SPN 4258/FMI 4

196SPN 4257 (EPA10)
Section Page
196.1 SPN 4257/FMI 3 ....................................................................................... 196- 3

196.2 SPN 4257/FMI 4 ...................................................................................... 196- 5
196.1 SPN 4257/FMI 3
This diagnostic is typically fuel injector amplifier control valve cylinder 1,2,3 shorted to battery.


196.1 SPN 4257/FMI 3
[b] If there is no voltage present, go to step 4.
injector Harness connector and pin 10 of the 120pin MCM connector.
[b] If there is no voltage present, repair the short to power between pin 6 of the Front fuel
injector Harness connector and pin 12 of the 120pin MCM connector.

196.2 SPN 4257/FMI 4
This diagnostic is typically fuel injector amplifier control valve cylinder 1,2,3 shorted to ground
1. Disconnect the Front fuel injector Harness 14-pin connector.

2. Inspect the Front fuel injector Harness 14-pin connector for bent or spread pins, inspect

196.2 SPN 4257/FMI 4


Refer to section .
connector.
[a] If the resistance is greater than 3 , go to the next step. Go to step 14.
connector.
connector.
15. Measure the resistance between pin 12 of the harness side of the Front fuel injector
connector and pin 12 of the Front fuel injector Harness 14pin connector.

196.2 SPN 4257/FMI 4

197SPN 4259
Section Page
197.1 SPN 4259/FMI 3 ....................................................................................... 197- 3

197.2 SPN 4259/FMI 4 ....................................................................................... 197- 5
197.1 SPN 4259/FMI 3
This diagnosis is typically fuel injector #4, 5, or 6 amplifier control valve circuit has a short to
battery/power.
Check as follows:

197.1 SPN 4259/FMI 3
[b] If there is no voltage present, go to step 4.
injector Harness connector and pin 8 of the 120pin MCM connector. Verify Repairs
219.1.
[b] If there is no voltage present, repair the short to power between pin 12 of the
Rear fuel injector Harness connector and pin 6 of the 120pin MCM connector.

197.2 SPN 4259/FMI 4
This diagnosis is typically fuel injector #4, 5, or 6 amplifier control valve circuit has a short
to ground.
Check as follows:
1. Verify MCM software is V13.x or higher.
[a] If MCM software is v13.x or higher, go to step 2.
[b] If the MCM software version is not 13.x or higher, reprogram the MCM to latest
software version. After reprogramming, start engine and increase rpm to 1500 for
two minutes, if fault does not re-occur, release vehicle. If fault becomes active during
the test, proceed with troubleshooting.
2. Disconnect the Rear fuel injector Harness 14-pin connector.

197.2 SPN 4259/FMI 4

5. Remove the Rocker Cover. Refer to section .

Refer to section .
13. Measure the resistance between pin 5 of the harness side of the Rear fuel injector Harness
[b] If the resistance is less than 3 , repair the short to ground between pin 7 of the MCM
connector and pin 12 of the Rear fuel injector Harness 14pin connector.

197.2 SPN 4259/FMI 4

198SPN 4334 (ACM2) (EPA10)
Section Page
198.1 SPN 4334/FMI 2 ....................................................................................... 198- 3

198.2 SPN 4334/FMI 3 ....................................................................................... 198- 4
198.3 SPN 4334/FMI 4 ....................................................................................... 198- 5
198.4 SPN 4334/FMI 7 ....................................................................................... 198- 6
Figure 198-1 DEF Pressure sensor Circuit

198.1 SPN 4334/FMI 2
This diagnostic is typically DEF Pressure sensor Drift.

1. Connect DDDL 7.04SP2 or higher.
5. Remove DEF Pressure sensor, and re-connect harness to connector.
6. Again compare DEF Pressure to Ambient Air Pressure (Baro) and DEF Air Pressure.
[b] No, replace the DEF Pressure sensor. Refer to section .
8. Remove DEF Pressure sensor, DEF Air Pressure sensor, air supply line, air inlet screen
and nozzle supply hose from the metering unit.
9. Flush warm water into cavitys illustrated below until water flows from the aerosol outlet.
Reconnect components, clear faults and release vehicle.

198.2 SPN 4334/FMI 3
198.2 SPN 4334/FMI 3
This diagnostic is typically DEF Pressure sensor Circuit Failed High.

1. Check for Multiple codes.
[a] If SPN 4334/3, 4335/3 and 3510/3 are present, repair short to voltage (greater
than 5.0v) between pin 3 of the DEF Pressure sensor and pin 99 of the ACM2.
[b] If SPN 4334/3 and 4335/3 are present, repair open between pin 3 of the DEF Pressure
[c] If only SPN 4334/3 is present go to step 2.
2. Disconnect the DEF Pressure sensor.
3. Turn the ignition ON (key ON engine OFF).
4. Measure the voltage between pin 1 on the harness side of the DEF Pressure sensor and
ground.
[a] If the voltage is greater than 5.0v, repair short to battery between pin 1 of the DEF
[b] If the voltage is between 4.75 and 4.9, replace the DEF Pressure sensor.
Refer to section .
[c] If the voltage is less than 4.75, repair wire between pin 1 of the DEF Pressure sensor
and pin 100 of the ACM2. Verify Repairs 219.1.

198.3 SPN 4334/FMI 4
This diagnostic is typically DEF Pressure sensor Circuit Failed Low.

[a] If SPN 4334/4, 4335/4 and 3510/3 are present, repair short to voltage (greater
than 5.0v) between pin 3 of the DEF Pressure sensor and pin 84 of the ACM2.
[b] If SPN 4334/4, 4335/4 and 3510/4 are present, repair short to ground between pin 3
of the DEF Pressure sensor and pin 84 of the ACM2. Verify Repairs 219.1.
2. Disconnect the DEF Pressure sensor.
4. Measure the resistance between pin 3 on the harness side of the DEF Pressure sensor
and ground.
[a] If the resistance is less than 1k ohms, repair wire between pin 1 of the DEF Pressure
[b] If the resistance is greater than 1k ohms, replace the DEF Pressure sensor.
Refer to section .

198.4 SPN 4334/FMI 7
198.4 SPN 4334/FMI 7
This diagnostic is typically DEF Pressure Low.

1. Connect DDDL/DDRS 7.04SP5 or higher.
2. Are any other SCR component or circuit faults also present on the items listed below?
Air Valve
DEF Pump
DEF Pressure sensor
DEF Air Pressure sensor
DEF Tank level/zone faults
[a] Yes; repair those faults first, then go to step 7.
disconnects)
6. Is DEF Pressure within 4.3 PSI of Ambient Air Pressure (Baro) and DEF Air Pressure?
[b] No; replace the DEF Pressure sensor, refer to section , go to step 7.
7. Perform SCR Pressure Test (60 seconds) and record results. Refer to chart below for
next action.
DEF Air Pressure DEF Pressure Action

18-29 psi 66 72 psi Clear faults and release vehicle
18-29 psi Less than 65 psi Go to step 8

8. Disconnect the DEF tank return line from the DEF pump.
9. Visually watch the DEF tank return line outlet on the pump while running the SCR Air
10. Does DEF fluid discharge from the pump return outlet during the test?
[a] Yes, replace the DEF Pump pneumatic switching valve refer to section and filter
screen refer to section . Go to step 7.
[b] No, reconnect the DEF pump tank return line. Go to step 11.
11. Disconnect the DEF Pump Inlet Supply Line from the DEF Pump.

198.4 SPN 4334/FMI 7
12. Remove the DEF pump module inlet screen by using a back up wrench to hold the insert
(3) on the DEF pump module, remove the DEF inlet connector (1) from the DEF pump
module. Using a small pick, pull the filter (2) out of the DEF pump module (screen is
a pressed fit).
13. Inspect the DEF inlet screen for blockage.

[a] If blockage is found, replace screen go to step 7.
14. Disconnect the DEF Inlet Supply Line from the DEF Metering Unit.

15. Remove the DEF metering unit inlet screen (2) by removing the fitting (1).
16. Inspect the DEF Metering Unit inlet screen for blockage.
[a] If blockage is found, replace screen go to step 7.
[b] If no blockage is found, obtain log file containing pressure test of fault code and
contact the Detroit Diesel Customer Support Center at 3135925800.

198.4 SPN 4334/FMI 7

199SPN 4335 (ACM2) (EPA10)
Section Page
199.1 SPN 4335/FMI 1 ....................................................................................... 199- 3

199.2 SPN 4335/FMI 2 ....................................................................................... 199- 4
199.3 SPN 4335/FMI 3 ....................................................................................... 199- 5
199.4 SPN 4335/FMI 4 ....................................................................................... 199- 6
199.5 SPN 4335/FMI 7 ....................................................................................... 199- 7
199.6 SPN 4335/FMI 14 ..................................................................................... 199- 9
199.7 SPN 4335/FMI 31 .................................................................................... 199-10
Figure 199-1 DEF Air Pressure Circuit

199.1 SPN 4335/FMI 1
DEF Air Pressure Not Detected - from vehicle supply

1. Start engine and ensure vehicle air pressure is above 100 psi.
2. Does the vehicle air pressure reach and maintain 100 psi?
[b] No, refer to OEM literature for Air Compressor diagnostic and leak checks.
4. Visually/audibly inspect air feed line from air tank to Air Pressure Limit Valve and from
valve to DEF Pump and Metering Unit for leaks, kinks or damage.
5. Disconnect the DEF Metering Unit air supply line.
6. Connect an appropriate air pressure gauge (0200 psi) to the DEF Pump Module Air
Supply line.
9. While monitoring air pressure gauge, perform SCR Pressure Test (60 seconds).
10. Is the air pressure between 78 and 85 psi?
[a] Yes, repeat this test 3 more times, if results are the same, clear fault and release
vehicle.
[b] No, replace the Air Pressure Limit Valve.

199.2 SPN 4335/FMI 2
199.2 SPN 4335/FMI 2
This diagnostic is typically DEF Air Pressure sensor Drift

3. Compare DEF Air Pressure to Ambient Air Pressure (Baro) and DEF Pressure.
4. Is DEF Air Pressure within 2 PSI of Ambient Air Pressure (Baro) and DEF Pressure?
5. Remove DEF Air Pressure sensor, and re-connect harness to connector.
6. Again compare DEF Air Pressure to Ambient Air Pressure (Baro) and DEF Pressure.
7. Is DEF Air Pressure within 2 PSI of Ambient Air Pressure (Baro) and DEF Pressure?
[b] No; replace the DEF Air Pressure sensor.
8. Remove DEF Air Pressure sensor. Refer to section .
9. Remove DEF aerosol line from DEF metering unit.
10. Pour warm water into DEF Air Pressure sensor cavity (1) in the DEF metering unit until
water flows from the DEF Aerosol Hose outlet (2). Reconnect components, clear faults
and release vehicle.

199.3 SPN 4335/FMI 3
This diagnostic is typically DEF Air Pressure sensor Circuit Failed High.
[a] If SPN 4335/3, 4334/3 and 3510/3 are present, repair short to voltage (greater than
5.0v) between pin 3 of the DEF Air Pressure sensor and pin 99 of the ACM2.
[b] If SPN 4335/3 and 4334/3 are present, repair open between pin 3 of the DEF Air
2. Disconnect the DEF Air Pressure sensor.
3. Turn the ignition ON (key ON engine OFF).
4. Measure the voltage between pin 1 on the harness side of the DEF Air Pressure sensor
and ground.
[a] If the voltage is greater than 5.0v, repair short to battery between pin 1 of the DEF
Air Pressure sensor and pin 74 of the ACM2. Verify Repairs 219.1.
[b] If the voltage is between 4.75 and 4.9, replace the DEF Air Pressure sensor.
Refer to section .
[c] If the voltage is less than 4.75, repair wire between pin 1 of the DEF Air Pressure

199.4 SPN 4335/FMI 4
199.4 SPN 4335/FMI 4
This diagnostic is typically DEF Air Pressure sensor Circuit Failed Low.
[a] If SPN 4335/4, 4334/4 and 3510/3 are present, repair short to voltage (greater than
5.0v) between pin 3 of the DEF Air Pressure sensor and pin 84 of the ACM2.
[b] If SPN 4335/4, 4334/4 and 3510/4 are present, repair short to ground between pin 3
of the DEF Air Pressure sensor and pin 84 of the ACM2. Verify Repairs 219.1.
2. Disconnect the DEF AIR Pressure sensor.
4. Measure the resistance between pin 3 on the harness side of the DEF Air Pressure sensor
and ground.
[a] If the resistance is less than 1k ohms, repair wire between pin 1 of the DEF AIR
[b] If the resistance is greater than 1k ohms, replace the DEF Air Pressure sensor.
Refer to section .

199.5 SPN 4335/FMI 7
This diagnostic is typically DEF Air Pressure Low.

1. Start engine and ensure vehicle air pressure is above 100 psi.
2. Does the vehicle air pressure reach and maintain 100 psi?
[b] No; refer to OEM literature for Air Compressor diagnostic and leak checks.
4. Visually/audibly inspect air feed line from air tank to DEF Air Valve, DEF Pump and DEF
Metering Unit for leaks, kinks or damage.
5. Remove the DEF Nozzle. Refer to section .
6. Inspect DEF Nozzle tip for damage, (missing broken off ).
[a] If tip damage is found, replace the DEF Nozzle. Refer to section .
[b] If no tip damage is found re-install nozzle, go to step 7.
9. Compare Ambient Air Pressure (Baro) to DEF Air Pressure and DEF Pressure.
10. Is DEF Air Pressure with 4.3 PSI of Ambient Air Pressure (Baro) and DEF Pressure?
11. Remove DEF Air Pressure sensor, and re-connect harness to connector.
12. Again compare Ambient Air Pressure (Baro) to DEF Air Pressure and DEF Pressure.
13. Is DEF Air Pressure with 4.3 PSI of Ambient Air Pressure (Baro) and DEF Pressure?
[b] No; replace the DEF Air Pressure sensor. Refer to section .
14. Remove DEF Air Pressure sensor.
15. Remove DEF aerosol line from DEF metering unit.

199.5 SPN 4335/FMI 7
16. Pour warm water into DEF Air Pressure sensor cavity (1) in the DEF metering unit until
water flows from the aerosol outlet (2).

199.6 SPN 4335/FMI 14
This diagnostic is typically DEF information ONLY.

If SPN 3361/7 is present along with SPN 4335/14, repair SPN 3361/7 first. SPN 4335/14 is a
silent fault (no dash lamps illuminated). This information indicates the ACM2 will initiate a DEF
Metering Unit flushing procedure.

199.7 SPN 4335/FMI 31
199.7 SPN 4335/FMI 31
This diagnostic is typically DEF information ONLY.

If SPN 3361/7 is present along with SPN 4335/31, repair SPN 3361/7 first. SPN 4335/31 is a
silent fault (no dash lamps illuminated). This information indicates the ACM2 will initiate a DEF
Metering Unit flushing procedure.

200SPN 4336 (ACM2) (EPA10)
Section Page
200.1 SPN 4336/FMI 3 ....................................................................................... 200- 3

200.2 SPN 4336/FMI 4 ....................................................................................... 200- 4
200.3 SPN 4336/FMI 5 ....................................................................................... 200- 5
Figure 200-1 DEF Air Valve Circuit

200.1 SPN 4336/FMI 3
This diagnostic is typically DEF Air Valve Circuit Failed High.

Check as follows:
1. 1. Connect to DDDL/DDRS 7.04 SP4 or higher.
[b] No, go to step 5
6. Disconnect the DEF Air Valve harness connector
pin 1 of the DEF Air Valve harness connector and pin 26 of the ACM 120-pin
connector.

200.2 SPN 4336/FMI 4
200.2 SPN 4336/FMI 4
This diagnostic is typically DEF Air Valve Circuit Failed Low.

Check as follows:
2. Disconnect the DEF Air Valve harness connector.
5. Measure the resistance between pin 1 on the harness side of the DEF Air Valve connector
and ground.
[a] If the resistance is less than 1K ohms, repair the wire between 1 on the
harness side of the DEF Air Valve connector and pin 26 of the ACM 120-pin
[b] If the resistance is greater than 1K ohms, replace the DEF Air Valve. Verify Repairs
219.1.

200.3 SPN 4336/FMI 5
This diagnostic is typically DEF Air Valve Circuit Failed Open.

Check as follows:
1. Disconnect the DEF Air Valve harness connector.
4. Measure the voltage between pin 2 on the harness side of the DEF Air Valve connector
and ground.
side of the DEF Air Valve connector and pin 5 of the ACM2 120-pin connector.
5. Measure the voltage between pin 1 of the DEF Air Valve harness connector and ground.
[a] If the voltage is between 2.25 and 2.50 volts, replace the DEF Air Valve.
[b] If the voltage is not between 2.25 and 2.50 volts, repair the wire between pin 1 of the
DEF Air Valve connector and pin 26 of the ACM2 120-pin connector. Verify Repairs
219.1.

200.3 SPN 4336/FMI 5

201SPN 4337 (ACM2) (EPA10)
Section Page
201.1 SPN 4337/FMI 2 ....................................................................................... 201- 3

201.2 SPN 4337/FMI 3 ....................................................................................... 201- 4
201.3 SPN 4337/FMI 4 ....................................................................................... 201- 6
Figure 201-1 DEF Dosing Unit Temperature Circuit

201.1 SPN 4337/FMI 2
This diagnostic is typically DEF Dosing Unit Temperature Drift

Check as follows:
1. Disconnect the DEF Metering Unit Temperature sensor.
2. Inspect the DEF Metering Unit Temperature sensor harness connector for bent, spread or
corroded pins.
[a] If pin damage is found, repair connector as necessary.
[b] If no pin damage is found, replace the DEF Metering Unit Temperature sensor.

201.2 SPN 4337/FMI 3
201.2 SPN 4337/FMI 3
This diagnostic is typically DEF Temperature sensor Circuit Failed High.
1. Disconnect the DEF Temperature sensor connector.

3. DEF Temperature sensor Test - Measure the resistance between pin 1 and 2 of the DEF
Temperature sensor connector.
[a] If the resistances are out of range, replace the DEF Temperature sensor.
Refer to section .
5. Measure the voltage between pin 2 on the harness side of the DEF Temperature sensor
harness side of the DEF Temperature sensor connector and pin 85 of the ACM2
[c] If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness
side of the DEF Temperature sensor connector and pin 85 of the ACM2 120-pin

6. Measure the voltage between pin 1 on the harness side of the DEF Temperature sensor
and ground.
[a] If voltage is present, repair the short to power between pin 1 on the harness side of
the DEF Temperature sensor connector and pin 86 of the ACM2 120-pin connector.
[b] If no voltage is present, repair the open between pin 1 on the harness side of the
DEF Temperature sensor connector and pin 86 of the ACM2 120-pin connector.

201.3 SPN 4337/FMI 4
201.3 SPN 4337/FMI 4
This diagnostic is typically DEF Temperature sensor Circuit Failed Low.

2. Disconnect the DEF Temperature sensor harness connector.
5. Measure the resistance between pin 1 on the harness side of the DEF Temperature sensor
Temperature sensor connector and pin 86 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the DEF Temperature sensor.
Refer to section .

202SPN 4353 (ACM2) (EPA10)
Section Page
202.1 SPN 4353/FMI 3 ....................................................................................... 202- 3

202.2 SPN 4353/FMI 4 ....................................................................................... 202- 4
202.3 SPN 4353/FMI 5 ....................................................................................... 202- 5
202.1 SPN 4353/FMI 3
This diagnostic is typically Diffuser Heater Circuit Failed High

Check as follows:
2. Turn ignition ON (key ON, engine OFF)..
3. Perform Output Component Test
6. Disconnect the Diffuser Heater harness connector
8. Measure the resistance across the Diffuser Heater.
[a] If the resistance is NOT between 9 and 13.5 ohms, replace the Diffuser Heater.
Refer to section .
[b] If the resistance is between 9 and 13.5 ohms, repair the short to battery (12 volts)
between pin 1 of the Diffuser Heater harness connector and pin 22 of the ACM
120-pin connector.

202.2 SPN 4353/FMI 4
202.2 SPN 4353/FMI 4
This diagnostic is typically Diffuser Heater circuit low.

Check as follows:
2. Disconnect the Diffuser Heater harness connector.
5. Measure the resistance between pin 1 on the harness side of the Diffuser Heater connector
and ground.
[a] If the resistance is less than 1K ohms, repair the wire between pin 1 of the Diffuser
Heater connector and pin 22 of the ACM2 120-pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 1K ohms, replace the Diffuser Heater. Refer to section
.

202.3 SPN 4353/FMI 5
This diagnostic is typically Diffuser Heater circuit open.

Check as follows:
[a] If 3361/5 is present with 4353/5, repair the open between pin 3 of the ACM2 120-pin
connector and the Diffuser Heater/DEF Dosing Valve. Verify Repairs 219.1.
2. Disconnect the Diffuser Heater connector.
4. Turn the ignition ON (key OFF, engine OFF).
5. Measure the voltage between pin 2 on the harness side of the Diffuser Heater connector
and ground.
side of the Diffuser Heater and pin 3 of the ACM2 120-pin connector. Verify Repairs
219.1.
6. Measure the voltage between pin 1 of the Diffuser Heater harness connector and ground.
[a] If the voltage is between 2.25 and 2.50 volts, replace the Diffuser Heater.
Refer to section .
the Diffuser Heater harness connector and pin 22 of the ACM2 120-pin connector.

202.3 SPN 4353/FMI 5

203SPN 4354 (ACM2) (EPA10)
Section Page
203.1 SPN 4354/FMI 3 ....................................................................................... 203- 3

203.2 SPN 4354/FMI 4 ...................................................................................... 203- 4
203.3 SPN 4354/FMI 5 ....................................................................................... 203- 5
Figure 203-1 Line Heater #1 Circuit

203.1 SPN 4354/FMI 3
This SPN is typically Line Heater #1 Circuit Failed High

3. Perform Output Component Test
6. Disconnect the Line Heater #1 harness connector
pin 1 of the Line Heater #1 harness connector and pin 6 of the ACM2 120-pin
connector.

203.2 SPN 4354/FMI 4
203.2 SPN 4354/FMI 4
This SPN is typically line heater #1 circuit failed low

2. Disconnect the line heater #1 connector.
5. Measure the resistance between pin 1 on the harness side of the line heater #1 connector
and ground.
[a] If the resistance is less than 1k ohms, repair the wire between pin 1 of the line heater
#1 connector and pin 6 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1k ohms, replace the line heater #1. Refer to
OEM procedures.

203.3 SPN 4354/FMI 5
This SPN is typically line heater #1 open circuit.

Check as follows:
[a] If 4354/5 and 4355/5 are present, repair open between pin 9 of the ACM2 120-pin
connector and pin 2 of Line Heaters 1 and 2. Verify Repairs 219.1.
2. Disconnect Line Heater 1.
4. Measure the voltage between pin 2 on the harness side of Line Heater 1 connector and
ground.
[a] If the voltage is greater than 11.75v, go to step 5.
[b] If the voltage is less than 11.75, repair wire between pin 2 on the harness side of Line
Heater 1 connector and pin 9 of the ACM2. Verify Repairs 219.1.
ground.
[b] If the voltage is not between 2.25 and 2.50, repair wire between pin 1 on the harness
side of Line Heater 1 connector and pin 6 of the ACM2. Verify Repairs 219.1.
6. Measure the resistance on the heating element side of Line Heater 1. Resistance should be
approximately 15 ohms per meter (39 inches). If resistance is not with this range, replace
the line heating element. Verify Repairs 219.1.

203.3 SPN 4354/FMI 5

204SPN 4355 (ACM2) (EPA10)
Section Page
204.1 SPN 4355/FMI 3 ....................................................................................... 204- 3

204.2 SPN 4355/FMI 4 ....................................................................................... 204- 4
204.3 SPN 4355/FMI 5 ...................................................................................... 204- 5

204.1 SPN 4355/FMI 3
This SPN is typically Line Heater #2 Circuit Failed High

Check as follows:
6. Disconnect the Line Heater #2 harness connector.
connector.

204.2 SPN 4355/FMI 4
204.2 SPN 4355/FMI 4
This SPN is typically line heater #2 circuit failed low

Check as follows:
and ground.
[b] If the resistance is greater than 1k ohms, replace the line heater #2.

204.3 SPN 4355/FMI 5
This SPN is typically line heater #2 open circuit.

Check as follows:
[a] If 4355/5 and 4354/5 are present, repair open between pin 9 of the ACM2 120-pin
connector and pin 2 of Line Heaters 1 and 2. Verify Repairs 219.1.
ground.
ground.

204.3 SPN 4355/FMI 5

205SPN 4356 (ACM2) (EPA10)
Section Page
205.1 SPN 4356/FMI 3 ....................................................................................... 205- 3

205.2 SPN 4356/FMI 4 ...................................................................................... 205- 4
205.3 SPN 4356/FMI 5 ....................................................................................... 205- 5

205.1 SPN 4356/FMI 3
This diagnostic is typically Line Heater #3 Circuit Failed High

Check as follows:
6. Disconnect the Line Heater #3 harness connector.
connector.

205.2 SPN 4356/FMI 4
205.2 SPN 4356/FMI 4
This diagnostic is typically line heater #3 circuit failed low

Check as follows:
and ground.
[b] If the resistance is greater than 1k ohms, replace the line heater #3.

205.3 SPN 4356/FMI 5
This diagnostic is typically line heater #3 open circuit.

Check as follows:
ground.
ground.

205.3 SPN 4356/FMI 5

206SPN 4358 (ACM2) (EPA10)
Section Page
206.1 SPN 4358/FMI 3 ....................................................................................... 206- 3

206.2 SPN 4358/FMI 4 ....................................................................................... 206- 4
206.3 SPN 4358/FMI 5 ....................................................................................... 206- 5
206.1 SPN 4358/FMI 3
This diagnostic is typically DEF doser heater Circuit Failed High

Check as follows:
6. Disconnect the DEF doser heater harness connector.
8. Measure the resistance across the doser heater.
[a] If the resistance is NOT between 6.5 and 10.5 ohms, replace the doser heater.
Refer to section .
[b] If the resistance is between 6.5 and 10.5 ohms, repair the short to battery (12 volts)
between pin 1 of the DEF doser heater harness connector and pin 16 of the ACM
120-pin connector.

206.2 SPN 4358/FMI 4
206.2 SPN 4358/FMI 4
This diagnostic is typically DEF doser heater Circuit Failed Low.

Check as follows:
2. Disconnect the DEF doser heater harness connector.
5. Measure the resistance between pin 1 on the harness side of the DEF doser heater harness
[a] If the resistance is less than 1K ohms, repair wire between pin 1 of the DEF doser
heater connector and pin 16 of the ACM2 120-pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 1K ohms, replace the DEF doser heater.
Refer to section .

206.3 SPN 4358/FMI 5
This diagnostic is typically DEF doser heater Circuit Failed Open.

Check as follows:
1. Disconnect the DEF doser heater connector.
4. Measure the voltage between pin 2 on the harness side of the DEF doser heater connector
and ground.
[b] If the voltage is less than 11.75 volts, repair the wire between pin 2 on the harness side
of the DEF doser heater and pin 39 of the ACM2 120-pin connector. Verify Repairs
219.1.
5. Measure the voltage between pin 1 on the harness side of the DEF doser heater connector
and ground.
[a] If the voltage is between 2.25 and 2.50 volts, replace the DEF doser heater.
Refer to section .
[b] If the voltage is not between 2.25 and 2.50 volts, repair the wire between pin 1
of the DEF doser heater connector and pin 16 of the ACM2 120-pin connector.

206.3 SPN 4358/FMI 5

207SPN 4360 (ACM2) (EPA10)
Section Page
207.1 SPN 4360/FMI 3 ....................................................................................... 207- 3

207.2 SPN 4360/FMI 4 ....................................................................................... 207- 5
207.3 SPN 4360/FMI 20 ..................................................................................... 207- 6
Figure 207-1 SCR Inlet Temperature sensor Circuit

207.1 SPN 4360/FMI 3
This diagnostic is typically SCR Inlet Temperature sensor Circuit Failed High.
1. Disconnect the SCR Inlet Temperature sensor connector.

3. SCR Inlet Temperature Test - Measure the resistance between pin 1 and 2 of the SCR Inlet
Temperature sensor connector (refer to chart for resistance values).
[a] If the resistances are out of range, replace the SCR Inlet Temperature sensor.
Refer to section .
5. Measure the voltage between pin 2 on the harness side of the SCR Inlet Temperature
[a] If the voltage is greater than 3 volts, repair the short to power between pin 2 on
the harness side of the SCR Inlet Temperature sensor connector and pin 76 of the
of the SCR Inlet Temperature sensor connector and pin 76 of the ACM 120-pin
connector.

207.1 SPN 4360/FMI 3
6. Measure the voltage between pin 1 on the harness side of the SCR Inlet Temperature
sensor and ground.
SCR Inlet Temperature sensor connector and pin 75 of the ACM 120-pin connector.
[b] If no voltage is present, repair the open between pin 1 on the harness side of the SCR
Inlet Temperature sensor connector and pin 75 of the ACM 120-pin connector.

207.2 SPN 4360/FMI 4
This diagnostic is typically SCR Inlet Temperature sensor Circuit Failed Low.
2. Disconnect the SCR Inlet Temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the SCR Inlet Temperature
[a] If the resistance is less than 1K ohms, repair the wire between pin 2 of the SCR Inlet
[b] If the resistance is greater than 1K ohms, replace the SCR Inlet Temperature sensor.
Refer to section .

207.3 SPN 4360/FMI 20
207.3 SPN 4360/FMI 20
This diagnostic is typically SCR Inlet Temperature sensor Drift High in Range.
Check as follows:
1. Disconnect the SCR Inlet Temperature sensor.
2. Inspect the SCR Inlet Temperature sensor harness connector for bent, spread or corroded
pins.
[b] If no pin damage is found replace the SCR Inlet Temperature sensor. Refer to section .

208SPN 4363 (ACM2) (EPA10)
Section Page
208.1 SPN 4363/FMI 0 ....................................................................................... 208- 3

208.2 SPN 4363/FMI 3 ....................................................................................... 208- 4
208.3 SPN 4363/FMI 4 ....................................................................................... 208- 6
208.4 SPN 4363/FMI 20 ..................................................................................... 208- 7
Figure 208-1 SCR Outlet Temperature sensor Circuit

208.1 SPN 4363/FMI 0
This diagnostic is typically SCR Outlet Temperature High.

Check as follows:
2. Is SPN 3246 FMI 15 (DPF Outlet over Temperature) also present?
[a] Yes, refer to SPN 3246/FMI 15 for diagnostics.
3. Monitor parameter AS096 SCR Outlet Temperature Voltage, while flexing (wiggle test)
the harness. Are any sudden voltage changes detected?
[a] Yes, repair harness as necessary.
4. Disconnect the SCR Outlet Temperature sensor
5. Inspect the SCR Outlet Temperature sensor harness connector for bent, spread or corroded
pins.
[b] If no pin damage is found, replace the SCR Outlet Temperature sensor.
Refer to section .

208.2 SPN 4363/FMI 3
208.2 SPN 4363/FMI 3
This diagnostic is typically SCR Outlet Temperature sensor Circuit Failed High.
Check as follows:
1. Disconnect the SCR Outlet Temperature sensor connector.
3. SCR Outlet Temperature Test - Measure the resistance between pin 1 and 2 of the SCR
[a] If the resistances are out of range, replace the SCR Outlet Temperature sensor.
Refer to section .
5. Measure the voltage between pin 2 on the harness side of the SCR Outlet Temperature
harness side of the SCR Outlet Temperature sensor connector and pin 78 of the
ACM2 120-pin connector. Verify Repairs 219.1.
[b] If the voltage is less than 2.75 volts, repair the wire between pin 2 on the harness side
of the SCR Outlet Temperature sensor connector and pin 78 of the ACM2 120-pin
connector.
[c] If the voltage is between 2.75 and 3 volts, go to step 6.

6. Measure the voltage between pin 1 on the harness side of the SCR Outlet Temperature
sensor and ground.
[a] If voltage is present, repair the short to power between pin 1 on the harness side of
the SCR Outlet Temperature sensor connector and pin 77 of the ACM2 120-pin
[b] If no voltage is present, repair the open between pin 1 on the harness side of the SCR
Outlet Temperature sensor connector and pin 77 of the ACM2 120-pin connector.

208.3 SPN 4363/FMI 4
208.3 SPN 4363/FMI 4
This diagnostic is typically SCR Outlet Temperature sensor Circuit Failed Low.
Check as follows:
2. Disconnect the SCR Outlet Temperature sensor harness connector.
5. Measure the resistance between pin 2 on the harness side of the SCR Outlet Temperature
[a] If the resistance is less than 1K ohms, repair the wire between pin 2 of the SCR
Outlet Temperature sensor connector and pin 78 of the ACM2 120-pin connector.
[b] If the resistance is greater than 1K ohms, replace the SCR Outlet Temperature sensor.
Refer to section .

208.4 SPN 4363/FMI 20
This diagnostic is typically SCR Outlet Temperature sensor Drift High in Range.
Check as follows:
1. Disconnect the SCR Outlet Temperature sensor.
2. Inspect the SCR Outlet Temperature sensor harness connector for bent, spread or corroded
pins.
[b] If no pin damage is found replace the SCR Outlet Temperature sensor. Refer to section
.

208.4 SPN 4363/FMI 20

209SPN 4364 (ACM2) (EPA10)
Section Page
209.1 SPN 4364/FMI 1 ....................................................................................... 209- 3

209.2 SPN 4364/FMI 18 ..................................................................................... 209- 5
209.1 SPN 4364/FMI 1
This diagnostic is typically SCR NOX Conversion Efficiency Very Low.

2. If SPN 3364 FMI any (Improper DEF Quality) is also present, repair SPN 3364 first.
go to step 12.
[b] No; replace the DEF Pressure sensor, refer to section then go to step 7.
disconnects).
ASL102 Engine Speed

209.1 SPN 4364/FMI 1


209.2 SPN 4364/FMI 18
This diagnostic is typically SCR NOX Conversion Efficiency Low.

2. If SPN 3364 FMI any (Improper DEF Quality) is also present, repair SPN 3364 first.
go to step 12.
[b] No; replace the DEF Pressure sensor, refer to section , go to step 7.
disconnects).
Remove DEF Nozzle from the ATD box. Refer to section .
ASL102 Engine Speed

209.2 SPN 4364/FMI 18


210SPN 4375 (ACM2) (EPA10)
Section Page
210.1 SPN 4375/FMI 3 ....................................................................................... 210- 3

210.2 SPN 4375/FMI 4 ....................................................................................... 210- 4
210.3 SPN 4375/FMI 5 ....................................................................................... 210- 5
210.4 SPN 4375/FMI 6 ....................................................................................... 210- 6
210.1 SPN 4375/FMI 3
This diagnostic is typically DEF Pump Circuit Failed High.

Check as follows:
3. Perform SCR Air Pressure System Check for 60 second duration.
5. Repeat SCR Air Pressure System Check 3 times (60 second duration). The ignition must
be cycled between each test. Does the fault become active?
[b] No, clear the fault and release the vehicle
6. Disconnect the DEF Pump harness connector
pin 2of the DEF Pump harness connector and pin 20 of the ACM2 120-pin connector.

210.2 SPN 4375/FMI 4
210.2 SPN 4375/FMI 4
This diagnostic is typically DEF Pump Circuit Failed Low.

Check as follows:
2. Disconnect the DEF Pump harness connector.
5. Measure the resistance between pin 2 on the harness side of the DEF Pump connector
and ground.
[a] If the resistance is less than 1K ohms repair wire between pin 2 of the DEF Pump
connector and pin 20 of the ACM2 120-pin connector. Verify Repairs 219.1.
[b] If the resistance is greater than 1K ohms, replace the DEF Pump. Refer to section .

210.3 SPN 4375/FMI 5
This diagnostic is typically DEF Pump Circuit Failed Open.

Check as follows:
4. Measure the voltage between pin 1 on the harness side of the DEF Pump connector and
ground.
side of the DEF Pump connector and pin 1 of the ACM2 120-pin connector.
5. Measure the voltage between pin 2 of the DEF Pump harness connector and ground.
[a] If the voltage is between 2.25 and 2.50 volts, replace the DEF Pump.
[b] If the voltage is not between 2.25 and 2.50 volts, repair the wire between pin 2
of the DEF Pump harness connector and pin 20 of the ACM2 120-pin connector.

210.4 SPN 4375/FMI 6
210.4 SPN 4375/FMI 6
This diagnostic is typically Diesel Exhaust Fluid (DEF) Pump Supply Current High.
Check as follows:
3. Is the DEF tank temperature above 25F?
4. Perform SCR Air Pressure Test service routine (30 seconds), after completion of test graph
ACM parameter AS027 DEF Pump Current. Does the DEF Pump Current rise and stay
above 900mA for greater than 5 seconds?

[b] No, repeat test 2 times if current does not rise and stay 900mA for more than 5
seconds, clear faults and release vehicle.
7. Inspect the DEF Pump harness connector for corroded, bent, spread or damaged pins.
[a] If pin damage is found, repair as necessary

[a] If the voltage is less than 11.5 volts, inspect/repair between pin 1 of the DEF Pump
harness connector and pin 1 of the ACM 120 pin connector.
[b] If voltage is greater than 11.5 volts, go to step 10.
[a] If the voltage is less than 2.25 volts, inspect/repair between pin 2 of the DEF Pump
harness connector and pin 20 of the ACM 120 pin connector.
[b] If the voltage is between 2.25 and 2.6 volts, replace the DEF pump. Refer to section .

210.4 SPN 4375/FMI 6

211SPN 4752 (MCM)
Section Page
211.1 SPN 4752/FMI 0 ....................................................................................... 211- 3

211.2 SPN 4752/FMI 31 ..................................................................................... 211- 4
211.1 SPN 4752/FMI 0
This diagnostic is typically EGR Cooler Low Efficiency.

3. Monitor the intake manifold temperature; is the intake manifold temperature reading
greater than 200 F (93C)?
[a] Yes, replace the intake manifold temperature sensor. Refer to section 3.4.1.
5. Disconnect the intake manifold temperature sensor harness connector.
6. Inspect the intake manifold temperature sensor harness connector for bent, spread or
corroded pins.
[a] If pin damage is found replace the intake manifold temperature sensor harness
connector and intake manifold temperature sensor
[b] If no external leakage is found go to step 8.
8. Remove the EGR hot pipe refer to section , EGR crossover tube refer to section and mixer
pipe refer to section and inspect for excessive build up or blockage.
[b] If there is no excessive buildup or blockage, obtain log file of active fault code and
contact the Detroit Diesel Customer Support Center at 313-592-5800. for further
instruction.

211.2 SPN 4752/FMI 31
211.2 SPN 4752/FMI 31
This diagnostic is typically EGR Cooler Performance Monitor.

1. Is there any cooling system or fan operation concerns?
[a] Yes, repair those failures clear codes and release vehicle.
4. Monitor the intake manifold temperature; is the intake manifold temperature reading
greater than 200 F (93C)?
[a] Yes, replace the intake manifold temperature sensor. Refer to section 3.4.1.
6. Disconnect the intake manifold temperature sensor harness connector.
7. Inspect the intake manifold temperature sensor harness connector for bent, spread or
corroded pins.
[a] If pin damage is found replace the intake manifold temperature sensor harness
connector and intake manifold temperature sensor. Refer to section 3.4.1.
[b] If no external leakage is found go to step 9.
9. Remove the EGR hot pipe refer to section , EGR crossover tube refer to section and mixer
pipe refer to section and inspect for excessive build up or blockage.
[b] If there is no excessive buildup or blockage, obtain log file of active fault code and
contact the Detroit Diesel Customer Support Center at 313-592-5800. for further
instruction.

212SPN 5016 (EPA10)
Section Page
212.1 SPN 5016/FMI 3 (ACM) ........................................................................... 212- 3

212.2 SPN 5016/FMI 4 (ACM) ........................................................................... 212- 4
212.1 SPN 5016/FMI 3 (ACM)
This diagnostic is typically Coolant Valve Supply Voltage Failed High.

1. Disconnect the Coolant Valve (disregard the additional faults set with components
disconnected).
[b] No, repair harness short to battery between ACM pin 19 and pin 2 of the Coolant
Valve harness connector.

212.2 SPN 5016/FMI 4 (ACM)
212.2 SPN 5016/FMI 4 (ACM)
This diagnostic is typically Coolant Valve Supply Voltage Failed Low

1. Disconnect the DEF Coolant Valve (disregard the additional faults set with components
disconnected).
[b] No, repair harness short to ground between ACM pin 19 and pin 2 of the DEF
Coolant Valve connector.

213SPN 5298 (ACM) (EPA10)
Section Page
213.1 SPN 5298/FMI 14 ..................................................................................... 213- 3

213.1 SPN 5298/FMI 14
This diagnostic is typically SCR abnormal temperature rise.

2. If SPN 3364 FMI any (Improper DEF Quality) or any DOC or DPF Temperature faults
present repair those faults first.
3. Using refractometer from DEF Test Kit W060589001900, measure DEF percentage.
Is DEF percentage between 28 and 36%?
[a] Yes, go to step4
[b] No, refer to appropriate manual for DEF tank cleaning/flushing procedure.
4. Using DEF test strip A0005850202 to check for diesel fuel or oil contamination of the
DEF fluid. Do the test strips indicate contamination?
[a] Yes, refer to appropriate manual for DEF tank cleaning/flushing procedure.
[b] No, go to step5.
5. Disconnect the SCR Outlet and Inlet Temperature sensor connectors.
6. Inspect the sensor harnesses for bent, spread, or corroded pins.
[b] If connectors show no signs of damage, go to step7.

213.1 SPN 5298/FMI 14
7. SCR Temperature sensor Test - Measure the resistance between pin 1 and 2 of the SCR
Temperature sensor connectors (refer to chart for resistance values).
[a] If the resistances are out of range, replace the suspect temperature sensor.
[b] If the resistances are in range reconnect sensors, perform a Parked Regeneration retain
log file and contact the Detroit Diesel Customer Support Center at 3135925800.

214SPN 5397 ACM (EPA10)
Section Page
214.1 SPN 5397/FMI 31 ..................................................................................... 214- 3

214.1 SPN 5397/FMI 31
This diagnostic is typically a regen frequency error.
NOTE:
Regeneration must be completed with DDDL/DDRS, dash switch initiated regen will
not clear this fault.

2. Perform a Parked Regeneration., clear faults, and release vehicle.

214.1 SPN 5397/FMI 31

215SPN 5444 (MCM)
Section Page
215.1 SPN 5444/FMI 1 ....................................................................................... 215- 3

215.1 SPN 5444/FMI 1
This diagnostic is typically CCV Speed Sensor RPM too Low.

1. Inspect for crankcase oil separator vent for oil leakage.
[a] If oil leakage is present replace the crankcase oil separator.
[b] If no oil leakage is present, go to step 2.
2. Disconnect the crankcase ventilator speed sensor harness connector and inspect bent,
[b] If no pin damage is found, go to step 3
3. Remove the CCV speed sensor from the oil separator and clean any debris or
contamination from the sensor and mounting cavity.
5. Measure the voltage between pins 1 and 3 of the crankcase ventilator speed sensor harness
connector. Is the voltage between 4.5 and 5.0 volts.
6. Measure the voltage between pin 1 of the crankcase ventilator speed sensor harness
connector and ground. Is the voltage between 4.5 and 5.0 volts.
[a] Yes, repair wire between pin 3 of the crankcase ventilator speed sensor harness
connector and pin 102 of the MCM 120 pin connector.
[b] No, repair wire between pin 1 of the crankcase ventilator speed sensor harness
8. Disconnect the MCM 120 pin connector.
9. Measure the resistance between pin 2 of the crankcase ventilator speed sensor harness
connector and pin 49 of the MCM 120 pin connector. Is the resistance less than 3 ohms?
[b] No, repair wire between pin 2 of the crankcase ventilator speed sensor harness

215.1 SPN 5444/FMI 1
10. Measure the resistance between pin 2 of the crankcase ventilator speed sensor harness
connector and ground. Is the resistance less than 1K ohms?
[a] Yes, replace the crankcase ventilator speed sensor reconnect harness, go to step 11.
[b] No, repair short to ground between pin 2 of the crankcase ventilator speed sensor
harness connector and pin 49 of the MCM 120 pin connector.
11. Start engine, and monitor Crankcase Oil Separator speed, increase engine speed to 1500
rpm. Does the Crankcase Oil Separator speed rise above 5000 rpm?
[a] Yes, clear fault and release vehicle.
[b] No, retain log file showing CCV speed and contact the Detroit Diesel Customer
Support Center at 3135925800.

216SPN 520231 (EPA10)
Section Page
216.1 SPN 520231/FMI 13 ................................................................................. 216- 3

216.1 SPN 520231/FMI 13
This diagnostic condition is typically Fuel Mass Signal Not Available via CAN.

216.1 SPN 520231/FMI 13

217SPN 520232 (EPA10)
Section Page
217.1 SPN 520232/FMI 9 ................................................................................... 217- 3

217.1 SPN 520232/FMI 9
This diagnostic is typically NOx Mass Signal Not Available via CAN.

217.1 SPN 520232/FMI 9

218SPN 520249 (EPA10)
Section Page
218.1 SPN 520249/FMI 4 ................................................................................... 218- 3

218.1 SPN 520249/FMI 4
This diagnostic is typically SCR Inlet Temperature Too High.

2. Is SPN 3246 FMI 15 (DPF Outlet over Temperature) also present?
[a] Yes, refer to SPN 3246 FMI 15 for diagnostics.
3. Monitor parameter AS095 SCR Inlet Temperature Voltage, while flexing (wiggle test)
the harness. Are any sudden voltage changes detected?
[a] Yes, repair harness as necessary.
4. Disconnect the SCR Inlet Temperature sensor.
5. Inspect the SCR Inlet Temperature sensor harness connector for bent, spread or corroded
pins.
[b] If no pin damage is found, replace the SCR Inlet Temperature sensor.

218.1 SPN 520249/FMI 4

219VERIFY REPAIRS
Section Page
219.1 VERIFY REPAIRS .................................................................................... 219- 3

219.1 VERIFY REPAIRS
Verify repairs as follows:

2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.X.
ENGINE EXHAUST
exhaust is toxic.
4. Start and bring engine up to operating temperature (coolant temperature over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel


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EPA07/10 DETROIT DIESEL ELECTRONICS AND TROUBLESHOOTING MANUAL

Consider the following before servicing engines:

All information subject to change without notice.

A LETTER TO THE TECHNICIANS

All information subject to change without notice.

All information subject to change without notice.

All information subject to change without notice.

All information subject to change without notice.

3.23 VSS ANTI-TAMPER ................................................................................. 3-40

All information subject to change without notice.

12 POOR ENGINE BRAKE PERFORMANCE

All information subject to change without notice.

All information subject to change without notice.

31.3 SPN 168/FMI 14 (CPC) ............................................................................ 31- 6

All information subject to change without notice.

43 SPN 411 (MCM2) (EPA10)

All information subject to change without notice.

55.5 SPN 615/FMI 14 ....................................................................................... 55- 7

All information subject to change without notice.

All information subject to change without notice.

84 SPN 713 (CPC)

All information subject to change without notice.

All information subject to change without notice.

107 SPN 1636

All information subject to change without notice.

119 SPN 2791

All information subject to change without notice.

130.3 SPN 3226/FMI 4 ....................................................................................... 130- 5

All information subject to change without notice.

138 SPN 3251 (EPA07)

All information subject to change without notice.

147.2 SPN 3509/FMI 4 ....................................................................................... 147- 4

All information subject to change without notice.

163.2 SPN 3599/FMI 4 (MCM) (ACM) ............................................................... 163- 4

All information subject to change without notice.

177 SPN 3663 (EPA07)

All information subject to change without notice.

192.2 SPN 4077/FMI 1 ....................................................................................... 192- 5

All information subject to change without notice.

202 SPN 4353 (ACM2) (EPA10)

All information subject to change without notice.

212.2 SPN 5016/FMI 4 (ACM) ........................................................................... 212- 4

All information subject to change without notice.

1.1 INTRODUCTION ...................................................................................... 1- 3

All information subject to change without notice.

1.2 SCOPE AND USE OF THIS GUIDE

1.2.1 Mechanical Troubleshooting

1.2.2 Electronic Troubleshooting

All information subject to change without notice.

All information subject to change without notice.

1.3 SAFETY PRECAUTIONS

All information subject to change without notice.

1.3.1 Ether Start

FIRE AND TOXICITY

FIRE AND TOXICITY

All information subject to change without notice.

1.3.2 Exhaust (Start/Run Engine)

All information subject to change without notice.

All information subject to change without notice.

All information subject to change without notice.

1.3.5 Pressurized Fluids

All information subject to change without notice.

All information subject to change without notice.